Koenig & Bauer partnered with DCOS on Compacta S80 retrofit and upgrade

New feature in DCOS Print Inspection System developed

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Koenig
Koenig & Bauer partnered with DCOS on Compacta S80 retrofit and upgrade

The Koenig & Bauer Compacta S80 short-grain heatset press is said to be known for its robustness, dependability and high print quality. Even though these presses were manufactured decades ago, they are still used and require service-life-extensions and automation upgrades.

Koenig & Bauer partnered with DCOS to develop a retrofit & upgrade solution for these presses and first out is a 1991 vintage Compacta S80 in Germany. Besides a complete drive and control system upgrade the project also includes a fully loaded print inspection system.

DCOS offers a new approach in operation and control systems, operator interfaces, production follow-up and camera-based inspection systems for new and printing press installations, including retrofitting of existing ones. The company has printing press customers across the world and operates a strong service organization based on a network of skilled agents and partners.

The original drive and control systems were facing absolute obsolescence and becoming a liability. DCOS automation platform Printing Framework was customized to fit the needs in a combined engineering effort between Koenig & Bauer and DCOS.

It incorporates new main drive system, mechanical PIVs has been replaced by shaftless drives, updated safety system and a new machine and quality control system.

Mattias Andersson, chief executive officer at DCOS, says: “Customizing a Retrofit on a thirty-year-old press, that was fairly automated for its time, always comes with some engineering challenges. We have enjoyed being part of this project together with Koenig & Bauer and it is rewarding to see the outcome. A modernized & fully automated press with many productive years ahead… and only 30 years old.”

To further increase print quality and waste efficient the project scope also included a full DCOS closed-loop density, colour register and cut-off control system, and softproof system.

A new feature in the DCOS Print Inspection Systems family was developed for this project, a camera-based closed-loop web-guide control system. This feature will serve as a possible upgrade solution for obsolete web-guide control systems.

DCOS Inspection Systems is a range of in-house developed camera-based systems for the printing industry. The systems automate a majority of the traditionally manual quality adjustments made in the printing process. This in turn increases productivity and cost-effectiveness as waste, start-up time, use of consumables and manning can be greatly reduced. At the same time a high and consistent quality is guaranteed.

DCOS Inspection System measures solid ink micro marks. Offline densitometric measurement of ink solid is proven in the industry for decades, it simple and stable. DCOS has reengineered the concept and developed an online high-speed solution adaptable to any press. This technology is claimed to be optimized for best performance, repeatability and effectiveness.

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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