H-UV Expert Session

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Komori H-UV
An Eco-friendly application taking
process to new levels of efficiency

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Komori H-UV
1. The origins of H-UV.
2. Why we developed H-UV.
3. What is H-UV?

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The origins of H-UV

Seven years ago we were
evaluating curing systems.
Benefits but many
negatives.
Maintain the benefits and
get rid of the negatives.
Develop with partners a
new way of drying and
new type of inks.

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The Origins of H-UV

Many hours in
development and testing.
Ensuring the recipe
worked time after time.
The Return on investment
ROI had a solid platform.
Why? Many false
applications in the past

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WHY WE DEVELOPED H-UV

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Why we developed H-UV.

A constant drive for
process efficiency.
Constant battle to maintain
competitive edge.
Manufacturing requires
innovation to progress.
Komori has a 30 year
history of innovation.

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Press room efficiency

People
Process

Technology

Each leg is important independently but each is

reliant on the strong support from the other two
legs

Why we developed H-UV.

Compete with digital
High cost of materials.
Printing on difficult
substrates.
Print On demand
requirements.
A constant battle to
maintain a status quo!

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WHAT IS H-UV

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What is H-UV
Development of a
unique lamp with
unique wavelength.
Ink with specially
developed photo
initiators.
Combination of tested
and certified products.

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What is H-UV ?
H-UV is a combination of
NEW Technology and
utilizing tested and
selected products
Developed by KOMORI
and only available from
KOMORI
H-UV is Unique!

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Conventional offset printing.

The ink emulsion dilutes
into substrate.
Difficult to print on
absorbent substrates.
Requires a combination of
methods to speed up
manufacturing.
Spray powder.
Water based varnish,
IR/Hot air.
Standing time.
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The Future!
Speed up the
manufacturing process.
Reduce production cost.
Broaden your market
possibilities.
Improve margins.

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H-UV printing.
The ink dries on the
surface.
Very little absorbency
Higher gloss levels
especially on low grade
papers.
No dry back therefore
uses less ink.
Allows immediate
finishing.
Allows immediate reverse
printing.
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H-UV printing

Reduced initial cost

Low Heat generation
Ozone free production
Environmentally friendly
Carton board printing
possible
Plastic printing possiblel

A system which can cure ink quickly using

just one ozone-free UV lamp
Yellow Magenta Cyan

One H-UV lamp

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Black

H-UV benefits
A real alternative to
conventional printing.
An application that
increases your product
quality, productivity
and truly benefits your
business.

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H-UV ink
Advantages for conventional and
UV printers

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18

hubergroup H-UV inks

Advantages for conventional and UV printers

Printology H-UV
Reto Andres
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Drying mechanism
Conventional drying

Evaporation
Resins
Oils

Resins
Oils

Penetration

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Dry ink film

Problems with oilbased conventional inks

1 uncoated offset papers
=> very slow drying, low piles
=> depending of water-/oil absorption of substrates
2 non-absorbent substrates
=> very slow drying, low piles
=> Usage of spray powder

3 coated offset papers

=> more and more rub, carbonating issues
=> varnishing necessary
=> Usage of spray powder

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Advantages UV offset

Fast curing
Inline finishing
High chemical, mechanical resistances
Highest gloss levels (OPV)
Non absorbing substrates
No spray powder

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Drying mechanism
UV curing

UV

oligomers
monomers
photoinitiator

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dry ink film

Electromagnetic spectrum

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Spectrum mercury UV H-UV lamp

Depth curing
Adhesion
Opaque white

Depth curing
Adhesion
Pigmented inks

Surface curing
UV varnishes
100. 0

Heat
formation

Ozone
formation

90.0

80.0

70.0

Inks and varnishes must be adjusted to the lamp spectrum !

60.0

50.0

40.0

30.0

20.0

10.0

0.0
200

260

320

Wave length [nm]

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380

440

Is H-UV able to improve conventional and UV offset printing?

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Drying
Carbonating
Need of varnishing
Other benefits ?
Areas of usage ?

Drying / Curing differences

Standard UV ink

H-UV ink

No dependency on different substrates (water/oil absorption)

No spray powder needed !

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Carbonating differences

coated paper

=> Lowest carbonating with H-UV

=> No varnish needed !

conventional
Non UV ink

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Standard
UV ink

H-UV ink

Print quality on uncoated offset paper

H-UV
=> More contrast
=> Brighter colours
=> Bigger gammut

=> Less ink consumption

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oilbased

Possible applications / Benefits of H-UV inks

On uncoated substrates:
More contrast
Brighter colours
Bigger gammut
Less ink consumption (up to 30%)
General:
Better drying/curing
No need of spray powder
No varnishing needed
Less temperature impact (plastics)
Inline effects / finishing
Less energy consumption

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Commercial

Packaging

Available ink series for H-UV

NewV set KHS (high sensitive)
Uncoated, Coated papers / boards

NewV poly KHS (high sensitive)

Metallised papers/boards, Plastic films

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Consumables
Ink EUR/kg
Dispersion varnish EUR/kg
Varnish H-UV EUR/kg
Spray powder EUR/kg
Energy cost EUR/kWh
Replacement HUV bulb EUR/piece

Conventional
8.00
1.50
7.00
0.14

HUV
15.00
16.00
0.14
600.00

Consumables consumption
Ink kg/year
Dispersion varnish kg/year
Varnish H-UV kg/year
Spray powder kg/year
Energy kW/h
Energy consumption per year
Lifetime H-UV bulb

Conventional
1'800.00
5'500.00
360.00
58.00
189'312.00
-

HUV
1'620.00
0.00
20.00
65'280.00
750.00

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Working times
Daily working time (2 shift) in h
Working days per year
=> h per year
Cost per working hour

Conventional
13.60
240.00
3'264.00
290.00

HUV
13.60
240.00
3'264.00
290.00

Annual cost calculation

Inks
Dispersion varnish
Varnish H-UV
Spray powder
Energy
Replacement H-UV bulbs
Total costs

Conventional
14'400.00
8'250.00
2'520.00
26'503.68
51'673.68

HUV
24'300.00
0.00
10'053.12
2'611.20
36'964.32

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H-UV drying

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34

H-UV Drying
Printing & Drying
Drying technology

H-UV Technology
Power Consumption
Efficiency
Going Green

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35

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Sheetfed dryers - options

PRINTING & DRYING

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Best technology available

Ink only

Sealer /
Coating

conventional

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Special
Substrates

(Application vs. technology)

High Gloss
Coating

UV Offset

Drying principles / options

Absorption

Evaporation

Curing

Slow process

Accelerated drying

Kick-started chain reaction

No Dryer

IR & HA Dryer

1 day

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79kW

UV Dryer EOP + 1

>90kW

Where does H-UV fit?

Ink only

Sealer /
Coating

Special
Substrates

conventional
H-UV

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High Gloss
Coating

UV Offset

Example: 5Colour + Coater

Conventional + wb coating

UV offset + UV coating

H-UV + H-UV coating

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Lets have a look behind it

DRYER - TECHNOLOGY

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Example: 5Colour + Coater

Conventional + wb coating

UV offset + UV coating

H-UV + H-UV coating

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IR/HA Power Consumption

What for:
Effect:
Costs:

IR lamps boosting temperature of paper and water

evaporation of water born materials
52kW

What for:
Effect:
Costs:

Hot Air for boosting ambient temperature in press

Creating environment to absorb water vapour
18kW

What for:
Effect:
Costs:

Exhaust enabling Air exchange

Removing hot, damp air to keep process going
9kW

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Example: 5Colour + Coater

Conventional + wb coating

UV offset + UV coating

H-UV + H-UV coating

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UV Power Consumption
What for:
Effect:
Costs:

UV lamp creating radiation

broad exposure of radiation to the sheet
71kW

What for:
Effect:
Costs:

Exhaust to atmosphere
Removing ozone contaminated air to atmosphere
7kW

What for:
Effect:
Costs:

Water Cooling
Cooling of dryer parts in press to protect from overheating
12kW

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Example: 5Colour + Coater

Conventional + wb coating

UV offset + UV coating

H-UV + H-UV coating

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Lets step back and explain in detail

H-UV TECHNOLOGY

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Radiation

H-UV

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H-UV Dryer
H-UV lamp head
Ozone free lamp
Higher efficiency
Less heat
Built in Active Power Control (APC)

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Efficiency

Electrical
Control

H-UV Lamp

Matching of
Components

less energy, MORE Curepower

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Sounds magical

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H-U Lamps (K-Supply )

UV lamp manufacturing
Design
Manufacturing
In house with equipment manufacturing unit

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Magic? Science!
Original H-UV
represents most advance technology

STANDARD
QUARTZ

Special metal halide doping

QUARTZ
used for H-UV bulbs

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H-UV bulb

Special lamp with tuned output:

=> Reducing Energy requirement by 66%

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H-UV Power Consumption

What for:
Effect:
Costs:

Lamp creating H-UV radiation

High intensity H-UV output
16kW

What for:
Effect:
Costs:

Lamp control
Keeping H-UV bulb and output stable
3kW

What for:
Effect:
Costs:

Water Cooling
Cooling of lamp head and heat sink
4kW

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Lithrone GL40 H-UV

GL 40 H-UV
One lamp H-UV dryer in the delivery

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Line Current

42 A/~

Power

(actual)

27 kW

Power

(apparent)

29 kVA

Printing technology
Focus
Ink Only

Conventional

UV Offset

H-UV

Very good

Fair

Very good

Protection

Fair

Good

Good

High Gloss
Special substrates

Poor

Very good

Very good

Poor

Very good

Very good

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Gloss
Technology

Gloss Points

Oilbased print Varnish

approx. 60

Waterbased Coating

approx. 70

Primer + UV

approx. 80

UV inks & coating (inline)

approx. 90

H-UV inks & coating

(inline)

up to
95

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Green Printing

Going green without worries

IPA free Print

Min. power consumption
Preserving the touch of paper
Safe for immediate post press handling

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Thank you for your attention!

Uli Sause Baldwin Technology

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An Eco-friendly application taking process to

new levels of efficiency.

Printology H-UV

Tony Carter
www.komori.eu

www.komori.eu

H-UV
Sheet-fed sales
68 sheet-fed presses

2 2

1
2

4
2 7

27

1
2

8
1
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Market segments
H-UV is adaptable and
flexible.
Packaging Market

On demand
Printing

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Added Value
Market

H-UV proving that it can

benefit all types of print
markets.

On demand market
Efficient production
requirements.
High quality control,
standards.
H-UV reduces material
cost and increases
available production
time.

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Added value market

Special substrates
Creative papers,
Cardboards, plastics .

High quality image

Very heavy ink coverage
High quality varnish
Creative Drip off
Ambitious creative
prints

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Packaging market
Huge reduction of
energy consumption.
Easier image match
with other prints
processes.
Higher flexibility.
Easier treatment of heat
sensitive substrates.
Higher Quality of
Images.
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WHAT ARE THE REAL

BENEFITS TO YOU.

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Improvements in productivity
Immediate back side
printing (shorter total
turnaround time)
Immediate drying, ready
for finishing.
Prints on heat sensitive
stocks
Reduction of work in
progress space.
Smaller press footprint.
Heavy ink coverage
benefits.
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Overhaul Quality improvement!

No changes in gloss or
colour after drying.
Quality of heavy images.
Quality of the printed dot
Reduction of marking
risks
Improved quality due to
powderless operation
Print on difficult paper
(difficult to dry) :
Muncken, Chromolux
You can feel the paper!
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Benefits to the environment!

Reduction of paper waste
No powder pollution
No ozone emission (waste
of energy)
No heat emission (waste
of energy)
Reduced compared to UV
or IR drying electrical
consumption
Valuable factory space
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Production comparison

Komori LS 840P conventional

vs

Komori GL 840 H-UV

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CUSTOMER PROFILE
Commercial Printer
Equipment:
LS 529 HC H-UV (2012) 2,2
shifts/ week on yearly base.
GL 540 HC H-UV (2012) 2,5
shifts/ week on yearly base.

LS 840 P conv. (2009) 3

shifts/ week on yearly base.
K-STATION
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K-STATION DATA

Press

Good copies
/year

Plate changes/year

LS529 plus coater HUV

19,350.000

4,830 plate changes

GL540 plus coater

H-UV

24,100,000

5,520

LS840P
Conventional

27,000,000

3,450

Real data from real

production.

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Description

Production details

LS840P Conventional printing.

Only APC year

3,540

251 Hours

4 mins 15
secs

2,006 Hours

34 mins

973,500 sheets

275 sheets

2,307 Hours

11,700c/hour

Faults due to set off

125,000 sheets

125,000 shts

Maintenance/Year

655 hours

Make Ready/ Year

3,540
Waste sheets/Year
M/R, colour, register
Production/Year
27,000,000 sheets

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Data

Customer request!
H-UV Technology
More productive
Better quality
Less maintenance
Less paper consumption

Less fault percentage

Diversification
Added value
Figures..
Which configuration?

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GL 840P H-UV/ including

A-APC- and PDC-SX
Fact:
185.000 euro more ink
cost a year (H-UV)

Dont panic yet!

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GL 840P H-UV figures:

Plate change A-APC
versus APC
3540 plate changes a year:
APC: 251 hours
A-APC: 59 hours

= Savings 192 hours

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More productivity!
H-UV Make ready versus conventional
Conventional make ready
3540 x 34 min.= 2,006 hours
H-UV make ready
3540 x *20 min.= 1,180 hours
= Savings 826 hours

*Make ready time given by Nord imprim

and DM Print (Both GL 840P HUV users).

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More savings..of course!

Maintenance H-UV vs conventional
Conventional given by K-station
on yearly base: 655 hours
H-UV given by Nord Imp. and DB
print: 351 hours
= Savings 304 hours
Maintenance includes:
Greasing
Cleaning (delivery etc .)
Daily maintenance jobs by
operators.

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Looks better already!

Savings A-APC/H-UV make ready/

Maintenance:

Total savings
1,324hours.

Finished yet?...... of course not!

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Waste sheets!
Conventional make ready sheets 973.500 sheets
Faults due ink set off 125.000 sheets
Total: 1.098.500 sheets

H-UV make ready sheets: 513.300 sheets

(N.I&DB 145 sh)
Savings: 582.200 sheets
Is this the only savings related to paper?
NOT AT ALL!!!
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(data K-station )

PDC-SX and HUV advantage

PDC-SX advantage
Read color bar in the middle
of the sheet.

Paper size 1 cm less in cumfrence!

H-UV advantage
No space needed for suction wheels!

Paper size 2 cm less Lateral

What does that mean in figures or
sheets?
856.000 sheets
68.000 kg. (calculated 115 grs.)

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What about speed!

K-station data LS 840P

conventional 11.739 s/h (
2.307 hours) Normal for a
Komori press

But H-UV can run faster!

Average 12.750 s/h.
27 Mili. Sheets= 2.117 hours
savings 190 hours.

Do you want me to continue?

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Summary of all savings

Plate change

LS840P

GL840P

251hrs

59 hrs
Savings 192 hrs

Make-ready

2,006 hrs

1180 hrs
Savings 826 hrs

Maintenance

655 hrs

350 hrs
Saving 304 hrs

Wasted sheets

1,098,500

513,300 sheets
Savings 582,200 sheets

Speed
Advantage H-UV/PDC-SX

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11,700 sph- 2,037

hrs

12,750 s/hr 2,117 hrs

856,000 sheets
68,000kg

Savings 190 hrs

What is the end result?

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Facts!
Producing the same as a
conventional printer on his LS840P
in a year:
He needs:
1512 hours less (378,000 )
1.438.000 sheets less (68,000 )
TOTAL : 446,000
More cost ink: 180.000
266,000 per annum

BENEFIT

What does that mean in real

production figures?

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Today and tomorrow!

Today-LS840P

Tomorrow-GL840P, AAPC, PDC-SX

Plate changes -3540

Plate changes-5740

Good copies -27 million

Good copies -33.5 million

CONVINCED? Well I am.

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I REST MY CASE!

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KOMORI H-UV today!

H-UV is proven and can
benefit your business.
Just listen to users in
Europe to get an insight
into its success.

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Questions?

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