technotrans asia-pacific    delta.spray / gamma.spray / replacement1
technotrans spray dampening                                                              Content    Why spray dampening te...
Why spray dampening technology?                                        Challenges of Today’s Printers (1/4)    Maintain co...
Why spray dampening technology?                                       Superior application features (2/4)    Design is sim...
Why spray dampening technology?                                        Superior application features          (3/4)    Sta...
Why spray dampening technology?                                     Quality – Waste – Maintenance (4/4)    Precision Water...
Why spray dampening technology?                                                          technotrans USP    technotrans US...
Why spray dampening technology?                                                    ROI hard facts (1/3)    Spray dampening...
Why spray dampening technology?    ROI    Example for ROI Analysis (2/3)9                        Customer: Chicago Tribune
Why spray dampening technology?     R.O.I.ROI Analysis questionnaire (3/3)            Calculator10
Spray Dampening System                                                                     Overview (1/2)     A spray damp...
Spray Dampening System                                           Overview-Schematic (2/2)     gamma.sd or   Supply / circu...
Dampening solution circulator                                                             gamma.sd - overview     gamma.sd...
Dampening solution circulator          gamma.sd – standard + options14
Dampening solution circulator            gamma.sd – model selection                                   kW15
Dampening solution circulator                                                Cooling concepts –L / -W / -PW     - L = air-...
Dampening solution circulator                                                        fluidos - additive dosing     fluidos...
Dampening solution circulator                                                     conductivity measurement     Conductivit...
Dampening solution circulator                                                                  pH measurement     pH      ...
Dampening solution circulator                                                    delta.sd / delta.sdf     delta.sd dampeni...
Spray Dampening systems                                                        Product overview (1/2)     technotrans offe...
Spray bar                                                        General description     Customized modular design with no...
Spray Dampening systems     application & configuration matrix23
Spray bar system                                                                    delta.spray     delta.spray offers all...
Spray bar system                                                              delta.spray     A pivot mechanism allows the...
Spray bar system            delta.spray26
Spray bar system                                                                  gamma.spray     gamma.spray is the entry...
Spray bar system                     gamma.spray design details     Same pivot mechanism for fast change of nozzle rail   ...
Spray bar system         gamma.spray29
Spray bar                                                    technotrans replacement kit     Reasons to replace with techn...
technotrans replacement kit                                                 e.g. Baldwin Lithospray World     Drip tray   ...
Spray bar     nozzle arrangement             4-nozzle spray bar             8-nozzle spray bar            12-nozzle spray ...
Spray Dampening System                                                 technotrans Bowman valve     High dosing accuracy d...
System description                                                 Venturi cap for Bowman valve     Optional for delta.spr...
System description                                                   Venturi cap for Bowman valve     Nozzle cleaning is o...
Spray Dampening Control System                                                   technotrans dampControl     Saving and lo...
Spray Dampening Control System                                                                  TUC10 / ISC16     TUC10 (T...
Spray Dampening Control System                                                                                       Proce...
technotrans spray dampening system                References / OEM + Region             Benefit from more the            e...
technotrans spray dampening system                        North America Spray Bar Market market                           ...
technotrans spray dampening systems                                              References / customer statement     Hartf...
Spray Dampening System                                                  Supporting equipment     delta.f                  ...
Spray Dampening System43
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Spray Dampening System

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Reduce wastage and save cost with technotrans\' proven spray dampening technology. Uplift your press room and improve productivity by retrofiting technotrans spray dampening system on to your existing web press

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Spray Dampening System

  1. 1. technotrans asia-pacific delta.spray / gamma.spray / replacement1
  2. 2. technotrans spray dampening Content Why spray dampening technology (challenges, application) technotrans USPs ROI analysis Spray Dampening System Overview Dampening Circulator (gamma/delta) Technotrans product range of spray dampening systems delta.spray, gamma.spray and replacement kits Bowman valve technology Electronic concept References for spray dampening systems world wide Supporting Equipment for spray dampening2
  3. 3. Why spray dampening technology? Challenges of Today’s Printers (1/4) Maintain consistently high quality level Create larger window of press operation Reduce the following: Operating costs (life of the product) Maintenance Press down time Enviorenmental impact The solution: Order spray dampening technology with new presses or Upgrade to spray bars now3
  4. 4. Why spray dampening technology? Superior application features (2/4) Design is simple for operation and maintenance One system fits all: Suitable for all inks (heat set, cold set, UV) Electronics are adjustable to fit all printing conditions (variable on ON time, water curves and press speed following) All spray bar parts are interchangeable throughout the press Less waste. During any start-up of the press, the plates will clean up much faster. Excellent long term consistancy More flexibility with zone control: the different zones (individual nozzles) will give the ability to make water adjustments in the spots where needed Less maintenance: only general cleaning of the nozzles required. No wear on brushes, no cleaning of complicated water systems Safer and easier: if any component fails, it can be fixed or replaced within minutes.4 Faster & faster: faster make-ready / faster maintenance / faster repairs
  5. 5. Why spray dampening technology? Superior application features (3/4) Standardization of spray bars and development of electronics and valve technology have made spray bars the most favorable dampening system. Spray bars do not influence the dampening solution supply as they are contact free dampening units Dampening water quality controlled for peak performance (filtration and temperature) The dampening solution circulates in a closed loop and thus is separated from the environment no contamination less cooling capacity required = lower energy consumption lower risk of germination5
  6. 6. Why spray dampening technology? Quality – Waste – Maintenance (4/4) Precision Water Preset Q Consistent Water Output Q (speed related across the plate cylinder) Achieve Optimal Ink/Water Balance Q&W ½ Page Zone Control Q&W Tailor for Various Consumables Q&W Fine Water Droplets Q&W Redundant Fail Safe System W Low Startup Waste W One Time Bar Distance Setting M Stainless Steel Construction M Water Proof Electrical Compartment M Q = QUALITY6 W = WASTE M = MAINTENANCE
  7. 7. Why spray dampening technology? technotrans USP technotrans USPs …. technotrans Bowman valve can be easily dismantled for maintenance. Individual parts are available as spare part. All stainless steel valve body. No adjustment necessary, precise and stable volume output across valves. Special coated (valve) plunger for longest live cycle and reliable functionality No choking of the valves due to ink misting or ink sling Shortest ON time and highest frequency ensures precise and even water distribution. Precise electronic valve control Robust design: Only high quality and durable materials, such as all stainless steel housing, are in use. Only for delta.spray Comfortable in-press service position, e.g. to check caps or nozzles Options such as side shutter and internal circulation are available7 If necessary, maintenance of the bar can be done from the front end
  8. 8. Why spray dampening technology? ROI hard facts (1/3) Spray dampening systems have a great “Return on Investment” (ROI) based on the cost justification analysis for: News Print savings (paper start- up waste) Ink consumption Electricity Fountain solution Maintenance labor Spare parts costs8
  9. 9. Why spray dampening technology? ROI Example for ROI Analysis (2/3)9 Customer: Chicago Tribune
  10. 10. Why spray dampening technology? R.O.I.ROI Analysis questionnaire (3/3) Calculator10
  11. 11. Spray Dampening System Overview (1/2) A spray dampening system consist of the following components: dampening solution circulator (gamma or delta.sd) (mixing, cooling and supply of dampening solution) spray bar system (nozzle ray, shielding, drip tray and bracket) installation material (pipes, fittings and electrical connection) control system - touch screen + PC with dampControl software - unit controller (TUC-10) - integrated spraybar controller (ISC-16) - speed reference module - Ethernet switch11
  12. 12. Spray Dampening System Overview-Schematic (2/2) gamma.sd or Supply / circulation pipe work delta.sd Spay dampening system for each printing unit Position for Control PC / Screen with dampControl software12
  13. 13. Dampening solution circulator gamma.sd - overview gamma.sd dampening solution circulator Powerful high pressure pump Constant feed pressure via pressure control valve direct refrigeration via coil evaporator inside the tank CFC / HCFC free refrigerant R407C Filter in the feed line as a standard Digital temperature display Full equipment range in measuring and dosing Service-friendly design Available in 2, 4, 8, 12 and 16 kW different cooling concepts (-L / -W / -PW)13
  14. 14. Dampening solution circulator gamma.sd – standard + options14
  15. 15. Dampening solution circulator gamma.sd – model selection kW15
  16. 16. Dampening solution circulator Cooling concepts –L / -W / -PW - L = air-cooled condenser - W = with water cooled condensor for chill water supply of 10-27 °C - PW = with chill water / dampening solution heat exchanger for chill water supply for chill water supply 8°C16
  17. 17. Dampening solution circulator fluidos - additive dosing fluidos works with water pressure only, without electrical supply amount of mixed additive is always proportional to amount of water dosing range 1 - 5 Vol.% fresh water supply pressure sensor for function control also available for dosing ranges 0,5 – 2,5 and 2 – 12 Vol.%17
  18. 18. Dampening solution circulator conductivity measurement Conductivitiy Conductivity measurement by means of an inductive probe Measuring range: 0 - 5000 µS/cm --> accuracy +/- 50µS/cm Integrated temperature compensation Calibration-free and reliable Temperature and chemistry resistant Virtually maintenance-free (simple cleaning approx. 1 - 3 times /a18
  19. 19. Dampening solution circulator pH measurement pH pH measurement by means of a glass sensor in the tank Limited use only as a quality parameter, as the dampening solution additives usually contain pH buffers Frequent cleaning and calibration is necessary A pH value deviation or variation can be an indicator for: - wrong additive formulation - incorrect dampening solution mixing - influences from the printing process (paper / ink)19
  20. 20. Dampening solution circulator delta.sd / delta.sdf delta.sd dampening solution circulator in addition / different to gamma.sd … cabinet design recommended for double or triple width presses delta.f Recycling by filtration softflow filtration system multi.com control touch screen available in 8, 120, 160, 250, 400 kW delta.sdf dampening solution circulator in addition to delta.sd … delta.sd tion ing solu ulation integrated filtration system delta.f dampen ring and circ onito tion, m prepara recycling of reflex water of spray dampening available in 80, 120, 160, 250 kW20
  21. 21. Spray Dampening systems Product overview (1/2) technotrans offers 3 different spray dampening systems: delta.spray gamma.spray spray bar replacement for existing systems The systems differentiate in design options / features However, there is no compromise in application quality and functionality, as all systems use the unique technotrans spray nozzle and valve technology.21
  22. 22. Spray bar General description Customized modular design with nozzle rail and spray chamber Compact, low-weight nozzle rail Rigid stainless steel construction High performance valves and nozzles Proven plunger – valve technology Excellent long term consistency Tool-less exchange of valve inserts and nozzle22
  23. 23. Spray Dampening systems application & configuration matrix23
  24. 24. Spray bar system delta.spray delta.spray offers all features and options you can imagine for a spray dampening system delta.spray is dedicated for customers demanding highest flexibility in application and operation24
  25. 25. Spray bar system delta.spray A pivot mechanism allows the spray bar to be turned into the “service position” Contaminated nozzles can simply be exchanged in the machine when in the service position In the same way the whole spray bar can be exchanged quickly and easily25
  26. 26. Spray bar system delta.spray26
  27. 27. Spray bar system gamma.spray gamma.spray is the entry level system to offer customers the full range of advantages of spray dampening technology gamma.spray is optimized to replace brush dampening systems on a very price competitive level. Beside the cost competitiveness, gamma.spray guarantees the same application performance, reliability and quality as delta.spray, e.g. by using same control electronic and valve technology. gamma.spray is 100% compatible with delta.spray with respect to mechanical, hydraulic and electronic integration27
  28. 28. Spray bar system gamma.spray design details Same pivot mechanism for fast change of nozzle rail New, highly qualified hydraulic couplings. Same hose dimension as delta.spray Same electrical connector as in28 delta.spray.
  29. 29. Spray bar system gamma.spray29
  30. 30. Spray bar technotrans replacement kit Reasons to replace with technotrans spray bar / dampening technology? High maintenance costs of existing spray bar (e.g. valve / valve parts) Spare parts are not available anymore (e.g. old Baldwin spray bars) Spray pattern not good enough Technotrans Replacement Kit Always needed is the technotrans bi-stable converter board and unit cable For the spray bar replacement there are different options Bowman valve assembly (installed in existing housing + spray chamber) New nozzle rail (use only existing spray chamber) Complete new spray bar (only electronic control is the same)30 …furhter configurations possible depending on existing spray bar set-up
  31. 31. technotrans replacement kit e.g. Baldwin Lithospray World Drip tray Drain pipe Technotrans nozzle Supply pipe rail (with Baldwin’s Aluminum profile)31
  32. 32. Spray bar nozzle arrangement 4-nozzle spray bar 8-nozzle spray bar 12-nozzle spray bar32
  33. 33. Spray Dampening System technotrans Bowman valve High dosing accuracy due to very short ON-time and high spray frequency of ~50Hz Long service live due to special coating of plunger Nozzle can be exchanged from outside by cap replacement (no need to dismantle the entire valve for cleaning or replacement) No special tools requirement in case of valve maintenance Proven pilot valve technology (further development of the Ryco technology, which has been well-tried in many extreme applications) Very high resistance to chemicals for dampening solution additive and solvent residue Very low maintenance effort (one annual service interval recommended) Optional nozzle cleaning with Venturi cap33
  34. 34. System description Venturi cap for Bowman valve Optional for delta.spray: Nozzle Cleaning Patent applied, system “without external energy” Little installation work (no compressed air or electric connections) Permanent active principle of contamination control34
  35. 35. System description Venturi cap for Bowman valve Nozzle cleaning is optionally available and can be retrofitted to all delta.spray systems Longer nozzle service life of approx. 4 times longer than normal Simple handling / very service-friendly Minimal installation work No negative influence on the spray image Nozzle after 4 weeks operation Nozzle after 25 weeks operation without cap (cleaning required) with „Venturi“ cap35
  36. 36. Spray Dampening Control System technotrans dampControl Saving and loading of jobs Make trim adjustments during press run Defining up to 30 water curves One flood per water curve for fast start up Defining up to 10 start up sequences Presetting water values Easy system configuration backup and restore on USB stick Automatic configuration backup and restore to networked PC’s Easy software and firmware update Interface to 3rd party controls through Ethernet and RS-485 Comfortable + practical user interface36 Remote access to system service and support
  37. 37. Spray Dampening Control System TUC10 / ISC16 TUC10 (Technotrans Unit Controller): Calculate the nozzle timings for the ISC16 Independent frequency calculations for each nozzle Web based diagnostics ISC16 (Integrated Spray bar Controller): Patented driver technology Delivers the smallest packet of water possible at the highest possible frequency Better nozzle distribution Smaller droplet size Zero configuration necessary (“plug &play”) Optional connection to press control system (e.g. Profi bus)37
  38. 38. Spray Dampening Control System Process Chart Control System per 4Hi tower Unit cable; Signals (Speed signal / folder select / startup sequence) Press Speed Signal PC + Touch Screen Signal (Enable) Ethernet Ethernet Switch X - Tower TUC10 Tower 1 TUC10 Tower 2 RS-485 RS-485 RS-485 RS-485 ISC16 ISC16 ISC16 ISC16 spraybar spraybar spraybar spraybar spraybar spraybar spraybar spraybar spraybar spraybar spraybar spraybar spraybar spraybar spraybar spraybar38
  39. 39. technotrans spray dampening system References / OEM + Region Benefit from more the experience of more than 25.000 units installed39
  40. 40. technotrans spray dampening system North America Spray Bar Market market References / US Of the Top 100 Web newspaper customers in the USA….. …74 have spray bars thereof: technotrans 85% (46% are second purchases) Smith 12% Baldwin 1.5% Goss 1.5% …6 use the MAN Turbo …20 use FLEXO or Brush systems40
  41. 41. technotrans spray dampening systems References / customer statement Hartford Courant hits the right spot with spray system By Marcelo Duran Associate Editor You can teach old iron new tricks. Thanks to an upgrade of its press control, inking and spray dampening systems, The Hartford (Conn.) Courant expects to trim waste, improve the quality of first papers off and, most important, take advantage of virtually hands-free printing on a decades-old pressline, said Press Manager Ken Coates, who spearheaded the project. The upgrade, using technology from Rockwell Automation, Goss International Corp. and technotrans, respectively, was expected to conclude last month. But early tests and implementation of the first three components of the four-phase upgrade resulted in a 40 percent drop in start-up and printed waste, Coates said. Ken Coates, pressroom manager at The Hartford (Conn.) Courant, orchestrated a systems upgrade that will help the newspaper reduce waste and boost print quality. Photo: Matt Massagli41
  42. 42. Spray Dampening System Supporting equipment delta.f Reverse Osmosis (RO) …recycling of reflex water …water preparation system delta.r 120 with alpha.r 60 with 1000 l tank 500 l tank (e.g. 6x4H) (e.g. 3x4Hi) Reduce waste by filtering reflex Controlled water conditions as water and return to dampening one key for reproducible high circulator printing quality. Reduce disposal costs RO capacity adjusted to press and production requirements Safe fountain solution / chemicals42
  43. 43. Spray Dampening System43

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