metalcoat 470 - kba: kba metalprint - blechdruck ... precision cross or longitudinal stenciling and...

MetalCoat 470High performance coating

GB

KBA Metal Decorating

100 years of experience in metal decorating KBA-MetalPrint is the technology leader

in metal decorating Benefit from 100 years of experience in

metal decorating We manufacture high quality, German

designed printing machines, coating machines, ovens, air purification sys-tems as well as sheet handling devices for metal decorating customers around the world

Continuous improvements of our prod-ucts according to new requirements of the metal print and can making industry

Technical benefits Designed for TFS, tinplates as well as

aluminium sheets (optional) Large sheet format up to

1 000 x 1 200 mm (39.37” x 47.24”) Accurate film weight and low lacquer

consumption High precision cross or longitudinal

stenciling and spot coating Robust design with low maintenance Electronic synchronisation to other

line components like KBA-MetalPrint printing presses and ovens

The MetalCoat 470 is available as a free-standing coating machine with fully automatic sheet feeder for internal and exterior coating applications, or as an 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 (on request) as well as UV materials.

The MetalCoat 470 can be supplied with a VacuMatic front register infeed table for high precision cross or longitudinal stenciling and spot coating or with a belt infeed table for solid coating.

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.

High performance coating

2 | KBA MetalCoat 470 KBA MetalCoat 470 | 3

Highlights Highlights

High performance single sheet feeder type 780 Designed for high speed and large sheet

format Suitable for TFS, tinplates as well as

aluminium sheets (optional) Remote feeding start from main control

panel Clearly arranged operating console Fast lifting and lowering of pile frame

Permanent control of pile height during sheet feeding

Lifting frame stops automatically after last sheet has been removed, avoiding feeding any non-metal material

Double sheet ejection system Permanent magnets and blowing

nozzles to separate sheets Reduced noise level by new developed

blowing nozzles

Free adjustable magnets at side guides for sheet separation

Format setting and pile centering by handwheel

Adjustable sheet arrival while machine is operating for optimised sheet conveying to the infeed-table

Oil-free compressor and vacuum pump for low maintenance

Further available options Automated pallet changer for reducing

the pile change time to 20 – 30 seconds Motorised roller conveyor sections Pallet side feeding and unloading

system Customised conveyor solutions for

flexible pallet logistics Stop & Turn device with turn table for

faster pile alignment and less damages Laser assisted pile centering Motorised side adjustment of lifting

frame instead of manual adjustment Special sheet guiding systems for scroll

sheets Overhead magnet bars with rollers for

scroll sheets Air blowing nozzles at side guides to

separate aluminum sheets Continuous pile lifting during

production Anti-flecking system for flame

treatment of the sheets Sheet straightening device

Stop & Turn with laser assisted pile centering

Laser assisted pile centering Motorised side adjustment of lifting frame

Feeder type 780 Optional features


Feeder Feeder

High performance coater type MetalCoat 470 Designed for high speed and large sheet

format Suitable for TFS, tinplates as well as

aluminium sheets (optional) Coater is available with belt infeed table

and front-lays for solid coating or with VacuMatic front register infeed table and gripper drum for high precision cross or longitudinal stenciling and spot coating

Accurate film weight and low lacquer con sumption with three-roller coating head

Easy setting of film thickness by wheels with scales

Pneumatically controlled scraper blade system for impression cylinder

Quick tool-free format change by hand-wheel and digital readouts

Good access for washing, operator can stand in upright position

Fast roll-out for coating cylinder change Delivery with round belts for fast and

tool free format change Robust design with low maintenance

Electronic synchronisation between coater and other line components

Further available options Vacuum system for gripper drum to

operate with aluminum sheets Automatic sheet size setting instead of

quick manual format change by digital readouts

Flexo Scraping System instead of standard 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

Lacquer heater Quick Change Kit for fast lacquer

changes and final cleaning of lacquer carrying parts outside of the machine

Special device for longitudinal scraping with scraper bar and scrapers (for short runs only)

Anti-ghosting roller to avoid ghosting effects

Scraper blade grinding machine

Quality control devices Inline viscosity measuring device Inline wet film weight measuring device Inline sheet position control device –

misregistered sheets will be removed manually in the cooling zone of the wicket oven

Control panel MetalCoat 470

MetalCoat 470 with infeed table for solid coating

MetalCoat 470 Optional features


High Performance Coating High Performance Coating

Complete systems for printing, coating and drying

Steps ahead in Metal Decorating

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

C 6-colour MetalStar 3 printing line with inline coater MetalCoat, 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

DensiTronic

HighEcon drying oven

Inline pile turner type 93 M

High performance LTG drying oven

Double box stacker VacStack

Wicket preheating

High performance cooling zone

Cooling zone

Single box stacker VacStack

Triple box stacker VacStack

UV final dryerFlow out conveyor

UV backside dryer MetalCoat

SMS Sheet Management System

ErgoTronic console B

C

A

UV precoat

SMS Sheet Management System

Mailänder 280

MetalCoat

Feeder type 780

Fresh air heat exchanger

Exhaust air cabin

Eco incinerator

Feeder type 780

MetalStar 3 with fully automatic plate change

High performance stream feeder


Integrated Systems

Flexo Scraping System Fast scraper blade change in about 2 minutes Short run-in time (approx. 1 minute) Uniformly distributed force across the width No need for a secondary scraper with solvent Best scraping performance Longer blade lifetime Minimises washing time by special shape of the coating pan

Secondary scraper device for more flexible production Simple operation and adjustment since the solvent blade is

thrown on pneumatically

Solvent scraping device

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

Inline coating machines can be supplied with our FlexoCoat System with Anilox roller for precise film weights with minimal adjustments

Precise film weights, low lacquer consumption

High accurate spot coating VacuMatic infeed table for perfect register, damage-free sheet

transportation and reduced maintenance Gripper drum with magnets and optional vacuum system in

the infeed table of the coater ensures perfect registration of the sheets

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

Grinding unit Dressing unit Pneumatic sledge

Scraper blade grinding device

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 (optional)

Fast coating cylinder change

Fast format change Quick manual format change with assistance of digital

readouts Alternatively automatic sheet size setting

Infeed table with manual format setting and digital readouts

Cost and production efficiency


Economic Production Economic Production

2727

8989

4545

1041041001001201101009080706050403020100

Gas c

onsu

mpt

ion

% HighEconDrying oven with EcoTNVDrying oven without TNVDrying oven with RTODrying oven with

integrated TNV

6 000 operating hours/year20 % set-up time80 % productionTNV 10 000 Nm3/h

Speed 7 000 sheets/hAverage solvent load 60 kg/hFresh air heat exchangerAverage sheet weight 1.2 kg

Comparison gas consumption

HighEcon LTG drying oven (Innovation award METPACK 2014)

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

KBA-MetalPrint has developed a new generation of drying ovens which guarantees even greater energy savings and efficiency. Key features of the new HighEcon drying oven concept are the automatically controlled exhaust air volume, a reduction of up to 70 % in gas consumption compared to an oven without air purification, modified air flows within the oven, and the use of frequency controllers for all fans. Together, these features enable the handling of extremely thin metal sheets down to a thickness of just 0.100 mm.

EcoTNVThe EcoTNV system possesses a flexible, high-performance heat exchanger. The heat recovery coefficient of the heat ex changer is set automatically to the maxi mum at-tainable value for the current production conditions. The exhaust air volume remains constant. The EcoTNV sys-tem is especially suitable as a retrofit package for existing lines or for new decorating/coating or coat-ing lines for lower outputs.

The HighEcon and EcoTNV systems are by far the most economical air purification systems for use on coating lines for metal packaging. Even when compared to installations with no air pollution control equipment, both systems achieve a dramatic reduction in gas consumption under normal production conditions with typical changeover patterns. This means that, in addition to purification of the solvent-laden air, they also contribute to reduced CO2 emissions and lower operating costs.

HighEcon TNVThe HighEcon air purification and drying oven system is based on an enlarged fresh-air heat exchanger and a main heat exchanger with maximum heat recovery coefficient of 60 % which remains fixed. Variations in the production conditions are taken into account by way of the auto-matic exhaust air volume con trol. The ex-haust air volume is adjusted auto matically and steplessly between its minimum and maximum settings.The HighEcon system is especially suitable for new installations and high perfor-mance coating lines.

Gas savings HighEcon / EcoTNV

Scheme of the HighEcon TNV with enlarged main heat exchanger, the

centerpiece of the HighEcon drying ovenHighEcon flow diagram

KBA-MetalPrint coating line solutions with LTG continuous drying ovens

HighEcon / EcoTNV – Air purification with payback


Drying Oven Drying Oven

a b c

min

200 ˚C

100

0

Impact-free stackingOur stackers equipped with overhead dynamic sheet control technology allow the slow-down of sheets from full produc-tion speed to an impact-free stacking. The sheet falls vertically onto the stillage, which avoids scratching and jams.

Low spoilage rates, less stoppages, higher productivity 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

Optimised air circulation and temperature control Perfect temperature curves are achieved by a special injection nozzle system.Once the drying temperature is reached, the metal sheets are consistently baked at temperatures within +/-1,5 %.

Optimised solution for your product

Your benefits Save time – external and internal

coating in one pass Save energy with HighEcon technology

Save money – lower investment and

operation costs Great flexibility – thanks to single-

mode operation

Tandem coating line

Your benefits Save time – two internal coatings in

one pass Save energy with HighEcon

technology

Save money – lower investment and

operation costs

Double coating line

Air circulation within the ovenMetal temperature curve

LTG continuous drying ovens


Drying Oven Coating Line

SpecificationsWidth of sheet 710 – 1 200 mm 27.95” – 47.24”

Length of sheet 510 – 1 000 mm 20.08” – 39.37”

Thickness of sheet 0.12 – 0.50 mm 0.0047” – 0.0197”

Cylinder diameter spot coating Ø 328.7 mm Ø 12.94”

Cylinder diameter plain coating Ø 324 – 339 mm Ø 12.76” – 13.35”

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

conditions and ingoing material quality)

Maximum weight of feeder pile 3 500 kg

Connected load (depending on accessories)

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

Compressed air, 6 bar/80 psi 4 m³/h

MetalCoat 470At a glance

DimensionsHeight of machine (A) 1 489 mm 58.62”

Width of machine 2 400 mm 94.49”

Length of machine (B)* 3 750 mm 147.64”

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

A

B

© KBA-MetalPrint GmbH, Stuttgart. Texts and illustrations refer in part to special features not included in the basic price. No parts of this publication may be reproduced in any way without the manufacturer’s permission. The manufacturer reserves the right to carry out modifications without prior notice.60

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

Technical Data

metalcoat 470 - kba: kba metalprint - blechdruck ... precision cross or longitudinal stenciling and...

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