Double-width, Double-circumferential, Shaftless Offset Press "Color Top 8200CD":
Built as a similar model press as the Shaftless Offset Press, Color Top 7000CD, the 85,000 cph Shaftless Offset Press, Color Top 8200CD, was developed incorporating a new concept which has the reelstand unit, not below the floor, but on the same floor level. In the 1999 JANPS exhibit, a unit drive, double-wide, double-circumference, shaftless tower offset press, Color Top 7000UD, was displayed and actual printing was demonstrated at a maximum speed of 85,000 cph.

The layout at that time consisted of a full sheet right angle turner bar between the press unit and reelstand, all on the same floor, however, this time, based on the experience at JANPS, from the standpoint of such factors as print image quality, stable running, and paper waste, the full sheet right angle turner bar was placed just as the running web came out of the printing unit. In this Color Top 8200CD, the plating side of the printing unit was turned to face the operating side and the reelstand was placed next to its side, which is an arrangement that would have been very complicated in the old linked (main shaft) system. With the shaftless system utilizing computer controlled synchronous linkage, it is not necessary to go through the complicated linkage of gears and shafts, and presses can be laid out freely to suit the building resulting in efficient use of space. Also, by having all units on the same floor, it becomes easy to keep track of each section and workflow is enhanced, contributing to an efficient work environment.

The Color Top 8200CD is made up of three 4/4 couple drive color units, two 2/1 units, one 600 Model folding unit, and five reelstand units that handle 50" paper rolls. This is a shaftless offset press for precisely registered and high quality printing. Through the use of high performance cylinder bearings, stability during high speed printing is assured resulting in a very dependable automatic register correction system at ultra fast speeds using the TKS Shell Cylinder and Super Register Device (SRD). With the use of a high speed Digital Ink Pump (DIP) device for the inking system, consistent top quality image reproduction is realized from low to high speeds. In the folding unit, by incorporating an Indirect Catch Carrier (IDCC) device, high speed delivery to output products at accurate pitches from slim to thick pages is possible and furthermore, tension stability is maintained through the use of 70░ formers and double trolley devices.

Because the web path becomes longer due to the rail frame being on the same floor, drag rollers are positioned at appropriate locations making it easy to make adjustments in tension. For the reelstands that are also on the same floor, a fixed three-arm reelstand capable of handling AGVs, and with a rotating round brush system is used.

Main Features of the Color Top 8200CD:

  • For the main drive systems on the printing and folder units, super efficient ECO DRIVE motors that feature ultra-strength permanent magnets are used and because of improvements in transmission efficiency brought about by vastly reducing shafts, gears, clutches and bearings and through regenerative braking, savings on electric power consumption by 15% to 20% are realized. Further, on a full color unit, it is possible to stop the printing units on the levels where multiple color printing is not done.
  • Unlike before when overload clutches and shear keys were used, this is a system whereby if a torque goes over the overload torque limit actually set in the motor, it is quickly and precisely detected and stops the motor itself, therefore, if the reason for the overload is corrected it can be restarted immediately. Also, when there is a power outage, the induced voltage proportionate to the ECO Drive Motor's revolution is made use of by supplying this energy to other motors while coming to a controlled, full stop. Furthermore, as the ECO Drive Motor is mounted on each plate cylinder, work such as putting on or taking off plates and changing blankets can be carried out for each cylinder at multiple locations.
  • The Super Register Device (SRD), which has a resolution accuracy of 7Ám, is used to control the lengthwise register and folder precision for excellent printing and folding quality. There are individual motors for each Roller Top of Former allowing for fine adjustments on the pull-in force. The infeed roller controls the position of the dancer roller maintaining optimum tension control regardless of speed reduction/increase or emergency stop.
  • The press ramp up speed from start to 85,000 cph is 90 seconds and 17 seconds to come to a full emergency stop, and it is possible to hold waste paper below 120 copies at start time for a 40-page full color product. Furthermore, during plate change or when webbing paper through a different unit, waste paper is kept to a minimal level.
  • By cutting down on drive-related mechanical parts, and utilizing highly efficient and long-lasting electrical components, maintenance time and costs have been reduced. Furthermore, for maintenance of electrical parts and components, a remote maintenance system using telephone lines was developed and delivered. Through the use of this system, there has been a dramatic impact on speedy recovery after a breakdown, on preventive maintenance through periodic history checks, on parts restocking, and on making periodic backups of files and data.
  • As there are few lubrication points, there is less worry about oil leakage. Also, there is less noise and vibration due to usage of smaller cooling fans made possible by reductions in the main shaft gears and lowering of motor heat generation.
  • As there is no need to link the main shaft, press layout can be done freely to suit the building, and spaces can be efficiently utilized. Construction time can be reduced for plant extensions.

The Color Top 8200CD was actually built, erected and test run at our Tamagawa Factory on August 31st, 2001. To be noted is the fact that, at the Shikoku Newspaper Production Center, where this press was delivered to, all operations from reception of plate data transmission, platemaking, paper storage and delivery, printing to mailroom are all done on the same floor--an ideal functional layout.