metalcoat 470 480 brochure en

GB

MetalCoat 480 MetalCoat 470You have the choice – high performance coating

KBA Metal Decorating

Free standing coater type 480

Your benefits Gain back valuable production time with

25% reduction in change over time Be one step ahead by using ultra-

light tin plate with thickness down to 0,100 mm (0.00394 inch)

Excellent coating results with individual drive technology

Perfect sheet registration with VacuMatic infeed table and gripper drum

Large sheet format up to

1 000 mm x 1 220 mm (39,37” x 48,03 ”) Maximum mechanical speed up to

9 000 sheets per hour Designed for TFS, tin plates as well as

aluminum sheets Photopolymer plate or rubber line

coating cylinder for UV application

Flexo Scraping System for long blade

lifetime and fast setup Fast electronic synchronisation

between feeder type 780, coater and other line components

Intuitive operation and user guidance Prepared for closed loop film weight

control

The MetalCoat 480 is available as free-standing coating machine with fully automatic sheet feeder for internal and exterior coating applications and as inline coater for clear varnish after printing.

An intermediate feeder can be supplied between KBA-MetalPrint printing presses and inline coaters for further production flexibility.

The MetalCoat 480 is compatible with conventional solvent or water-based lacquers and UV materials.

The MetalCoat 480 is equipped with VacuMatic front register infeed table for high precision cross, longitudinal stenciling and spot coating or with a plain belt infeed table for solid coating.

Inline coater type 480 in a 6-colour MetalStar printing line

The MetalCoat 480 is the newest generation of coating machines from KBA-MetalPrint and is the result of continuous improvements of our metal decorating equipment.

2 | KBA MetalCoat 480 / MetalCoat 470 KBA MetalCoat 480 / MetalCoat 470 | 3

MetalCoat 480MetalCoat 480

Motorized coating cylinder and lacquer head roller setting

Laser-assisted rapid zero setting of the coating cylinder

for lacquer head rollers, coating cylinder and counter pressure cylinder for fast and precise set up.

Individual roller drive technology

New developed operating philosophy implemented, using the touch panel with flat menu structure, allows intuitive operation and user guidance. Visual representation with memory function of the actual job settings. Means repeatable quality, easy operation and reduced set up times.Comfortable machine operation from one side.Electrical synchronisation between feeder, coater and other line components.

Touch & Control operation

Fast manual format setting with digital readouts or Automatic format setting from the control panel

Pneumatic clutch for coating cylinder change within only 2 minutes

Fast roll out on rails Coating cylinder lifting device integrated in the LTG Oven

exhaust air cabin

Fast format setting

Fast coating cylinder change in upright position

Further features to reduce the changeover time

Flexo scraping system for fast scraper blade change, short run in time and long blade lifetime.

Solvent scraper system as secondary scraper device for more flexible production.

Quick change kit for fast lacquer changes and final cleaning of lacquer contaminated parts outside of the machine.

All settings can be memorized in the PLC system.

for fast set up of high precision cross coating jobs.

High Performance Coating – more than 25% reduction in changeover time, achieved by:


High Performance CoatingHigh Performance Coating

2-roller coating head

Individual drive technology for coating cylinder, counter pressure cylinder and the lacquer head rollers.

Gripper drum with magnets and vacuum sucking system ensures perfect registration of the sheets

The VacuMatic infeed table with vacuum belts replaces the chain system

Precise film weights, low lacquer consumption, easy repeatability

Use of photopolymer plates

High accurate spot coating

Sheet thickness reduction down to 0.100 mm (0.00394 inch)Savings in material costs and further improvement of sustainability in can production will be achieved through the use of ultra-light tin plate of 0.100 mm. The MetalCoat 480 and other KBA-MetalPrint equipment like our LTG oven, sheet handling devices and printing presses have been further developed for production with 0.100 mm sheet material.

The MetalCoat 480 is designed for application of solvent based, water based or UV lacquers. Traditional rubber lined cylinders or photo polymer plates for the coating cylinders can be used for UV varnish.

Your benefits Uniform coating application achieves the optimum of quality

for your products and reduces the lacquer consumption Easy repeatability through storage of the job-related settings

in the PLC

Integrated solvent extraction system for high efficient exhaust ventilation and minimisation of the exhaust air with low solvent concentration

Part of the heat recovery system of KBA-MetalPrint Eco incineration systems

Solvent extraction

Features


Features Features

Steps ahead in Metal Decorating

A Coating line with HighEcon drying oven and integrated air purification system

B

C

C 6-colour MetalStar 3 printing line with inline coater MetalCoat 480, UV drying system and triple box stacking unit with test sheet box

B 2-colour Mailänder 280 printing line with LTG thermal drying oven, stacker and inline pile turner

A

UV precoat

SMS Sheet Management System

DensiTronic

Mailänder 280

MetalCoat 480

Feeder type 780

HighEcon drying oven

Inline pile turner type 93 M

High performance LTG drying oven

Fresh air heat exchanger

Double box stacker VacStack

Wicket preheating

Exhaust air cabin

High performance cooling zone

Eco incinerator

Feeder type 780

Cooling zone

Single box stacker VacStack

Triple box stacker VacStack

UV final dryerFlow out conveyor

UV backside dryer MetalCoat 480

SMS Sheet Management System

ErgoTronic console

MetalStar 3 with fully automatic plate change

High performance stream feeder

Complete systems for printing, coating and drying


Integrated Systems

The MetalCoat 470 is available as free-standing coating machine with fully automatic sheet feeder for internal and exterior coating applications and as inline coater for clear varnish after printing. An intermediate feeder can be supplied between KBA-MetalPrint printing presses and inline coaters for further production flexibility.The MetalCoat 470 is compatible with conventional solvent and water-based lacquers as well as UV materials. The MetalCoat 470 is equipped with VacuMatic front register infeed table for high precision cross, longitudinal stenciling and spot coating or with a plain belt infeed table for solid coating.

Your benefits Maximum mechanical speed up to

8 000 sheets per hour Large sheet format up to

1 000 mm x 1 220 mm (39,37” x 48,03 ”) Designed for TFS, tin plates as well as

aluminium sheets Accurate film weight and low lacquer

consumption with three-roller coating head

VacuMatic infeed table instead of chain register system for low maintenance and shorter changeover times

Gripper drum with strong magnets

and vacuum sucking system produces perfect registration

Automatic sheet size setting or quick manual format change by digital readouts

Flexo Scraping System for fast scraper blade change, short run-in time and long blade lifetime

Quick change kit for fast lacquer changes

Solvent Scraper System as secondary

scraper device for more flexible production

Robust design with low maintenance Electronic synchronisation between

coater and other line components

The MetalCoat 470 has been designed to match the increasing demand for higher speed and larger sheet size combined with the need for faster changeover.


MetalCoat 470MetalCoat 470

Scheme of an EcoTNV with integrated bypass

LTG oven loading machine with dynamic sheet control

KBA-MetalPrint coating lines with LTG thermal drying ovens ensure high production output combined with excellent quality and cost effective operations.

High accurate spot coating VacuMatic infeed table with vacuum belts instead of chain and

pusher system for perfect register coating work, reduction of maintenance and reduction of set up time

Gripper drum with magnets and vacuum sucking system in the infeed table of the coater ensures perfect registration of the sheets

Additional scraper bar for longitudinal reserve coating, recommended for small run lengths only

Our 3-roller coating head ensures precise film weights and short adjustment times

Alternatively the coating machines can be supplied with our FlexoCoat System for precise film weights with minimal adjustments

Precise film weights, low lacquer consumption

Fast roll out of the coating cylinder on rails

Cylinder change in upright position

Coating cylinder lifting device integrated in the LTG oven exhaust air cabin

Fast coating cylinder change

Smooth sheet transport through the complete line Special conveyor and air distribution control device in the thermal oven designed for

operation with lightweight sheets Vacuum dynamic sheet speed control devices for loader and unloader of the thermal

oven for damage-free sheet transport, higher line efficiency and reduced spoilage Our stackers equipped with overhead dynamic sheet control technology allow the

slow-down of sheets from full production speed to an impact-free stacking. The sheet falls vertically onto the stillage, which avoids scratching and jams.

A high reduction in the gas consumption of the thermal oven is achieved by means of our Eco incineration system (up to 65% reduction in the annual gas consumption for coating lines has been achieved), air flow management and HighEcon energy saving modules.

Grinding unit Dressing unit Pneumatic sledge

Scraper blade grinding device

Fast scraper blade change in less than 2 minutes Short run-in time in about 1 minute only Uniformly distributed force across the width No need for a secondary scraper with solvent Best scraping performance Up to 10 times longer blade life time Minimizes washing time by special shape of the coating pan

KBA-MetalPrint coating line solutions

Low spoilage rates, less stoppages, higher productivity

Air purification with pay back

Flexo scraping system


Cost EfficiencyCost Efficiency

Semi-automatic pallet changer at the feeder of a coating line

VacStack

Inspection of sheets during set up and production.The SMS is used to eject sheets for inspection in high speed lines

Double box stacker Nonstop, continuous production Creates high productivity Individual sheet counter per box Additional total sheet counter Automatic lowering of full stack when

box change is activated Automatic conveyor starting and stack

transportation to the exit Stack discharge storage function via

automatic stack conveyor control

Overhead dynamic sheet control device in VacStack or MagStack versionsThis revolutionary option provides a completely soft and controlled method of slowing down the sheet from full production speed to zero for impact-free stacking. Thanks to the unique deceleration process, the sheet falls vertically onto the stillage thus eliminating scratches completely.The overhead dynamic sheet control not only avoids damage of the sheet at highest speed, it also drastically reduces the make ready time.

Advantages of the modular design: Wide belt conveyors for perfect

sheet guidance Horizontal sheet transport through

the stacker Available as single or double box

stacker for nonstop operation Upgrade from single to double box

stacker Motorised roller conveyor User friendly operation

Optional features for single and double box stacker Vacuum dynamic sheet control device for

single box stacker MagStack, overhead electro-magnetic

dynamic sheet control device for impact- free stacking of tinplate and TFS sheets at lowest noise level

VacStack, overhead vacuum dynamic sheet control device for impact-free stacking of tinplate, TFS and aluminium sheets

Automatic format setting Additional roller conveyor modules to

facilitate automatic stack storage Sprocket-driven roller conveyor instead

of the standard chain drive for smooth conveying of the full stacks

Stacker in modular design

Pallet changer

Semi-automatic pallet changer for pallet change in a few seconds

STOP and TURN, automatic pile alignment with turn table

Double sheet ejection system

Electrical synchronisation with coater type 480

Designed for high speed and large sheet format

Reduced noise level by newly developed blowing nozzles

Free adjustable magnets at side guides for sheet separation of scroll sheets

Overhead magnet bars with rollers for scroll sheets

Continuous pile lifting (after every sheet)

Anti Flecking System for flame treatment of the sheets

Sheet straightening device

Feeder Type 780

Reducing the pallet changeover stop to only a few seconds means higher production efficiency on lines running long jobs. Full pallet and pallet fork hold

in the waiting position until the hoist changing level is achieved

When the pallet is empty, the suckers stop working and the fork automatically moves the empty pallet out of the feeder area

The suckers then resume operation feeding sheets off the new pallet

Reinsertion of inspected sheets at high speed

Eject at high speed – damage-free Safe and simple operation Conveyor table in design with round

belts available

Sheet handling SMS – Sheet Management System


Sheet HandlingSheet Handling

601-

43 (0

414)

KBA-MetalPrint GmbH Wernerstr. 119-129 70435 Stuttgart, GermanyPhone +49 711 699 71-0 Fax +49 711 699 [email protected] www.kba-metalprint.com

© KBA-MetalPrint GmbH, Stuttgart. Some of the features and functions described in this brochure are options and can be added to the basic design to provide customer-specific configurations. We reserve the right to modify design features and technical data.

MetalCoat 480 / MetalCoat 470At a glance

Specifications MetalCoat 480 MetalCoat 470

Width of sheet 710 – 1 220 mm 28.0” – 48.0” 710 – 1 220 mm 28.0” – 48.0”

Length of sheet 510 – 1 000 mm 20.0” – 39.4” 510 – 1 000 mm 20.0” – 39.4”

Thickness of sheet0,12 – 0,50 mm

(0,100 mm on request)0.005” – 0.020”

(0.004” on request)0,12 – 0,50 mm

0.005” – 0.020”

Cylinder diameter spot coating Ø 328,7 mm Ø 12.9” Ø 328,7 mm Ø 12.9”

Cylinder diameter plain coating Ø 324 – 339 mm Ø 12.8” – 13.4” Ø 324 – 339 mm Ø 12.8” – 13.4”

Maximum mechanical speed up to 9 000 sheets/h up to 150 spm up to 8 000 sheets/h up to 133 spm(maximum coating speed depending upon print shop

conditions and ingoing material quality)(maximum coating speed depending upon print shop

conditions and ingoing material quality)

Weight (without feeder) ≈ 4 000 kg ≈ 3 600 kg

Connected load (depending on accessories)

20 – 30 kW without feeder 33 – 43 kW with feeder

15 – 25 kW without feeder 27 – 40 kW with feeder

Compressed air, 6 bar/80 psi 4 m³/h 4 m³/h

Dimensions MetalCoat 480 MetalCoat 470

Height of machine (A) 1 675 mm 65.9” 1 489 mm 59.0”

Width of machine 3 020 mm 118.9” 2 400 mm 94.5”

Lenght of machine (B)* 3 750 mm 147.6” 3 750 mm 147.6”

*) the additional length of the corresponding feeder is approx. 2 475 mm

A

B

A

B

Technical Data

metalcoat 470 480 brochure en

Documents