Quick pressroom retrofit of Grapho Metronic IDC system

Closed loop color controls added to Kala Jyothi’s Komori heatset

InkZone Inline IDSm 1280x1191

In 2006, Kala Jyothi installed a new Komori System 38S heatset press at its web offset plant in Kondapur near Hitec city in Hyderabad for printing magazines and newspaper supplements. The press has been running well with excellent service on the whole over the years. From the outset, it had a KHS-AI (Advanced Interface) preset system for shortened makeready, which remembers ink and dampening preset and corrections from previous runs and incorporates these in current runs.

However, when Kala Jyothi’s KHS-AI system stopped working about 5 or 6 years after the press was commissioned, Komori was unable to fix it although the request was well within 10 years of the press installation. The company spoke of the requirement for a new software purchase at considerable cost and was also unable to put in a modern closed loop color at a cost-effective price or convincing time frame saying that the solution had to be redeveloped for what it described as an older generation press.

However, the German press manroland web systems together with a Swiss interface supplier was ready to retrofit and upgrade Kala Jyothi’s Komori System 38S press with a Swiss interface and a manroland web systems Grapho Metronic Inline Density Control system – a closed loop color density and control system. Kala Jyothi director Kartik Alapati says, “They said they were ready to make it work, and we said if you can make it work you can have the order. Remarkably the manroland web and Swiss interface combination didn’t even ask us for an advance although it was the first time they had done this interface on a Komori System 38S. They were quite confident and we were very pleased to see a German company that is ready to provide not just a new press but every type of accessory and upgrade together with engineering service in case you need just another unit or some modification or let’s say an improvement in your quarter folder. This was super interesting.”

“We understand that life is competitive nowadays,” says Kala Jyothi director Ramnath Alapati, adding, “Others such as QuadTek and QI were also interested in the competitive estimate and time frame that we received from the Swiss team, which were a fraction of the cost and the whole process took just 45 days. The actual machine was down for a few hours only on two days for the retrofit work. After shifting to the Grapho Metronic system, it took us another few days to create the new curves. We are even looking at a similar solution for our Goss heatset press, which is a year younger than the Komori 38S.”
The Grapho Metronic inline density control (IDC) measuring system features quick measuring and response cycles with high resolving capacity cameras, LED flash illumination and a design that is claimed to have no moving parts, and thus no wear. With the parallel arrangement of the cameras, the measuring strip can be covered across the full width of the paper in one measuring. The high measuring frequency means that with the dynamic fast-reaction controls, process fluctuations can often be compensated for even before the tolerance limits are exceeded. The control process includes the zonal shift elements and also the ink fountain roller thus covering the entire ink flow effectively, using the linked fountain-key opening actuators and fountain-roller speed.u
This article has inputs from manroland web systems.

The Covid-19 pandemic led to the country-wide lockdown on 25 March 2020. It will be two years tomorrow as I write this. What have we learned in this time? Maybe the meaning of resilience since small companies like us have had to rely on our resources and the forbearance of our employees as we have struggled to produce our trade platforms.

The print and packaging industries have been fortunate, although the commercial printing industry is still to recover. We have learned more about the digital transformation that affects commercial printing and packaging. Ultimately digital will help print grow in a country where we are still far behind in our paper and print consumption and where digital is a leapfrog technology that will only increase the demand for print in the foreseeable future.

Web analytics show that we now have readership in North America and Europe amongst the 90 countries where our five platforms reach. Our traffic which more than doubled in 2020, has at times gone up by another 50% in 2021. And advertising which had fallen to pieces in 2020 and 2021, has started its return since January 2022.

As the economy approaches real growth with unevenness and shortages a given, we are looking forward to the PrintPack India exhibition in Greater Noida. We are again appointed to produce the Show Daily on all five days of the show from 26 to 30 May 2022.

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