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It incorporates new main drive system, mechanical PIVs has been replaced by shaftless drives, updated safety system and a new machine and quality control system.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

2023 promises an interesting ride for print in India

Indian Printer and Publisher founded in 1979 is the oldest B2B trade publication in the multi-platform and multi-channel IPPGroup. While the print and packaging industries have been resilient in the past 33 months since the pandemic lockdown of 25 March 2020, the commercial printing and newspaper industries have yet to recover their pre-Covid trajectory.

The fragmented commercial printing industry faces substantial challenges as does the newspaper industry. While digital short-run printing and the signage industry seem to be recovering a bit faster, ultimately their growth will also be moderated by the progress of the overall economy. On the other hand book printing exports are doing well but they too face several supply-chain and logistics challenges.

The price of publication papers including newsprint has been high in the past year while availability is diminished by several mills shutting down their publication paper and newsprint machines in the past four years. Indian paper mills are also exporting many types of paper and have raised prices for Indian printers. To some extent, this has helped in the recovery of the digital printing industry with its on-demand short-run and low-wastage paradigm.

Ultimately digital print and other digital channels 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. For instance, there is no alternative to a rise in textbook consumption but this segment will only reach normality in the next financial year beginning on 1 April 2023.

Thus while the new normal is a moving target and many commercial printers look to diversification, we believe that our target audiences may shift and change. Like them, we will also have to adapt with agility to keep up with their business and technical information needs.

Our 2023 media kit is ready, and it is the right time to take stock and reconnect with your potential markets and customers. Print is the glue for the growth of liberal education, new industry, and an emerging economy. We seek your participation in what promises to be an interesting ride.

– Naresh Khanna

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