Reduce wastage and save cost with technotrans\' proven spray dampening technology. Uplift your press room and improve productivity by retrofiting technotrans spray dampening system on to your existing web press
2. technotrans spray dampening
Content
Why spray dampening technology (challenges, application)
technotrans USPs
ROI analysis
Spray Dampening System Overview
Dampening Circulator (gamma/delta)
Technotrans product range of spray dampening systems
delta.spray, gamma.spray and replacement kits
Bowman valve technology
Electronic concept
References for spray dampening systems world wide
Supporting Equipment for spray dampening
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3. Why spray dampening technology?
Challenges of Today’s Printers (1/4)
Maintain consistently high quality level
Create larger window of press operation
Reduce the following:
Operating costs (life of the product)
Maintenance
Press down time
Enviorenmental impact
The solution:
Order spray dampening technology with new presses
or
Upgrade to spray bars now
3
4. Why spray dampening technology?
Superior application features (2/4)
Design is simple for operation and maintenance
One system fits all: Suitable for all inks (heat set, cold set, UV)
Electronics are adjustable to fit all printing conditions (variable on ON time,
water curves and press speed following)
All spray bar parts are interchangeable throughout the press
Less waste. During any start-up of the press, the plates will clean up much
faster.
Excellent long term consistancy
More flexibility with zone control: the different zones (individual nozzles) will
give the ability to make water adjustments in the spots where needed
Less maintenance: only general cleaning of the nozzles required. No wear
on brushes, no cleaning of complicated water systems
Safer and easier: if any component fails, it can be fixed or replaced within
minutes.
4 Faster & faster: faster make-ready / faster maintenance / faster repairs
5. Why spray dampening technology?
Superior application features (3/4)
Standardization of spray bars and development of electronics and valve
technology have made spray bars the most favorable dampening system.
Spray bars do not influence the dampening solution supply as they are
contact free dampening units
Dampening water quality controlled for peak performance (filtration and
temperature)
The dampening solution circulates in a closed loop and thus is separated
from the environment
no contamination
less cooling capacity required = lower energy consumption
lower risk of germination
5
6. Why spray dampening technology?
Quality – Waste – Maintenance (4/4)
Precision Water Preset Q
Consistent Water Output Q
(speed related across the plate cylinder)
Achieve Optimal Ink/Water Balance Q&W
½ Page Zone Control Q&W
Tailor for Various Consumables Q&W
Fine Water Droplets Q&W
Redundant Fail Safe System W
Low Startup Waste W
One Time Bar Distance Setting M
Stainless Steel Construction M
Water Proof Electrical Compartment M
Q = QUALITY
6 W = WASTE
M = MAINTENANCE
7. Why spray dampening technology?
technotrans USP
technotrans USPs ….
technotrans Bowman valve can be easily dismantled for maintenance.
Individual parts are available as spare part.
All stainless steel valve body. No adjustment necessary, precise and stable
volume output across valves.
Special coated (valve) plunger for longest live cycle and reliable functionality
No choking of the valves due to ink misting or ink sling
Shortest ON time and highest frequency ensures precise and even water
distribution.
Precise electronic valve control
Robust design: Only high quality and durable materials, such as all stainless
steel housing, are in use.
Only for delta.spray
Comfortable in-press service position, e.g. to check caps or nozzles
Options such as side shutter and internal circulation are available
7 If necessary, maintenance of the bar can be done from the front end
8. Why spray dampening technology?
ROI hard facts (1/3)
Spray dampening systems have a great “Return on Investment” (ROI)
based on the cost justification analysis for:
News Print savings (paper start- up waste)
Ink consumption
Electricity
Fountain solution
Maintenance labor
Spare parts costs
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9. Why spray dampening technology?
ROI Example for ROI Analysis (2/3)
9
Customer: Chicago Tribune
11. Spray Dampening System
Overview (1/2)
A spray dampening system consist of the following components:
dampening solution circulator (gamma or delta.sd)
(mixing, cooling and supply of dampening solution)
spray bar system
(nozzle ray, shielding, drip tray and bracket)
installation material
(pipes, fittings and electrical connection)
control system
- touch screen + PC with dampControl software
- unit controller (TUC-10)
- integrated spraybar controller (ISC-16)
- speed reference module
- Ethernet switch
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12. Spray Dampening System
Overview-Schematic (2/2)
gamma.sd or Supply / circulation pipe work
delta.sd
Spay dampening system for
each printing unit
Position for Control PC / Screen
with dampControl software
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13. Dampening solution circulator
gamma.sd - overview
gamma.sd dampening solution circulator
Powerful high pressure pump
Constant feed pressure via pressure control valve
direct refrigeration via coil evaporator inside the tank
CFC / HCFC free refrigerant R407C
Filter in the feed line as a standard
Digital temperature display
Full equipment range in measuring and dosing
Service-friendly design
Available in 2, 4, 8, 12 and 16 kW
different cooling concepts (-L / -W / -PW)
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16. Dampening solution circulator
Cooling concepts –L / -W / -PW
- L = air-cooled condenser
- W = with water cooled condensor
for chill water supply of 10-27 °C
- PW = with chill water / dampening solution heat
exchanger for chill water supply for chill water supply 8°C
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17. Dampening solution circulator
fluidos - additive dosing
fluidos
works with water pressure only, without electrical supply
amount of mixed additive is always proportional to amount of water
dosing range 1 - 5 Vol.%
fresh water supply pressure sensor for function control
also available for dosing ranges 0,5 – 2,5 and 2 – 12 Vol.%
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18. Dampening solution circulator
conductivity measurement
Conductivitiy
Conductivity measurement by means of an inductive probe
Measuring range: 0 - 5000 µS/cm --> accuracy +/- 50µS/cm
Integrated temperature compensation
Calibration-free and reliable
Temperature and chemistry resistant
Virtually maintenance-free (simple cleaning approx. 1 - 3 times /a
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19. Dampening solution circulator
pH measurement
pH
pH measurement by means of a glass sensor in the tank
Limited use only as a quality parameter, as the dampening
solution additives usually contain pH buffers
Frequent cleaning and calibration is necessary
A pH value deviation or variation can be an indicator for:
- wrong additive formulation
- incorrect dampening solution mixing
- influences from the printing process (paper / ink)
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20. Dampening solution circulator
delta.sd / delta.sdf
delta.sd dampening solution circulator
in addition / different to gamma.sd …
cabinet design
recommended for double or triple width presses delta.f
Recycling by filtration
softflow filtration system
multi.com control touch screen
available in 8, 120, 160, 250, 400 kW
delta.sdf dampening solution circulator
in addition to delta.sd …
delta.sd tion
ing solu ulation
integrated filtration system delta.f dampen ring and circ
onito
tion, m
prepara
recycling of reflex water of spray dampening
available in 80, 120, 160, 250 kW
20
21. Spray Dampening systems
Product overview (1/2)
technotrans offers 3 different spray dampening systems:
delta.spray
gamma.spray
spray bar replacement for existing systems
The systems differentiate in
design
options / features
However, there is no compromise in application quality and
functionality, as all systems use the unique technotrans spray nozzle
and valve technology.
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22. Spray bar
General description
Customized modular design with nozzle rail and spray chamber
Compact, low-weight nozzle rail
Rigid stainless steel construction
High performance valves and nozzles
Proven plunger – valve technology
Excellent long term consistency
Tool-less exchange of valve inserts and nozzle
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24. Spray bar system
delta.spray
delta.spray offers all features and options you can imagine for a spray
dampening system
delta.spray is dedicated for customers demanding highest flexibility in
application and operation
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25. Spray bar system
delta.spray
A pivot mechanism allows the spray bar to be turned into the “service
position”
Contaminated nozzles can simply be exchanged in the machine when in
the service position
In the same way the whole spray bar can be exchanged quickly and
easily
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27. Spray bar system
gamma.spray
gamma.spray is the entry level system to offer customers the full range of
advantages of spray dampening technology
gamma.spray is optimized to replace brush dampening systems on a very
price competitive level.
Beside the cost competitiveness, gamma.spray guarantees the same
application performance, reliability and quality as delta.spray, e.g. by using
same control electronic and valve technology.
gamma.spray is 100% compatible with delta.spray with respect to
mechanical, hydraulic and electronic integration
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28. Spray bar system
gamma.spray design details
Same pivot mechanism for fast change of nozzle rail
New, highly qualified hydraulic
couplings. Same hose dimension as
delta.spray
Same electrical connector as in
28 delta.spray.
30. Spray bar
technotrans replacement kit
Reasons to replace with technotrans spray bar / dampening technology?
High maintenance costs of existing spray bar (e.g. valve / valve parts)
Spare parts are not available anymore (e.g. old Baldwin spray bars)
Spray pattern not good enough
Technotrans Replacement Kit
Always needed is the technotrans bi-stable converter board and unit cable
For the spray bar replacement there are different options
Bowman valve assembly (installed in existing housing + spray chamber)
New nozzle rail (use only existing spray chamber)
Complete new spray bar (only electronic control is the same)
30 …furhter configurations possible depending on existing spray bar set-up
32. Spray bar
nozzle arrangement
4-nozzle spray bar
8-nozzle spray bar
12-nozzle spray bar
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33. Spray Dampening System
technotrans Bowman valve
High dosing accuracy due to very short ON-time and high spray frequency
of ~50Hz
Long service live due to special coating of plunger
Nozzle can be exchanged from outside by cap replacement (no need to
dismantle the entire valve for cleaning or replacement)
No special tools requirement in case of valve maintenance
Proven pilot valve technology (further development of the Ryco technology,
which has been well-tried in many extreme applications)
Very high resistance to chemicals for dampening solution additive and
solvent residue
Very low maintenance effort (one annual service interval recommended)
Optional nozzle cleaning with Venturi cap
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34. System description
Venturi cap for Bowman valve
Optional for delta.spray: Nozzle Cleaning
Patent applied, system “without external energy”
Little installation work (no compressed air or electric connections)
Permanent active principle of contamination control
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35. System description
Venturi cap for Bowman valve
Nozzle cleaning is optionally available and can be retrofitted to all delta.spray
systems
Longer nozzle service life of approx. 4 times longer than normal
Simple handling / very service-friendly
Minimal installation work
No negative influence on the spray image
Nozzle after 4 weeks operation Nozzle after 25 weeks operation
without cap (cleaning required) with „Venturi“ cap
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36. Spray Dampening Control System
technotrans dampControl
Saving and loading of jobs
Make trim adjustments during press run
Defining up to 30 water curves
One flood per water curve for fast start up
Defining up to 10 start up sequences
Presetting water values
Easy system configuration backup and
restore on USB stick
Automatic configuration backup and restore to
networked PC’s
Easy software and firmware update
Interface to 3rd party controls through
Ethernet and RS-485
Comfortable + practical user interface
36 Remote access to system service and support
37. Spray Dampening Control System
TUC10 / ISC16
TUC10 (Technotrans Unit Controller):
Calculate the nozzle timings for the ISC16
Independent frequency calculations for each nozzle
Web based diagnostics
ISC16 (Integrated Spray bar Controller):
Patented driver technology
Delivers the smallest packet of water possible at the highest possible
frequency
Better nozzle distribution
Smaller droplet size
Zero configuration necessary (“plug &play”)
Optional connection to press control system (e.g. Profi bus)
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38. Spray Dampening Control System
Process Chart
Control System per 4Hi tower
Unit cable;
Signals
(Speed signal / folder select
/ startup sequence)
Press Speed Signal PC + Touch Screen
Signal (Enable)
Ethernet
Ethernet
Switch X - Tower
TUC10 Tower 1 TUC10 Tower 2
RS-485
RS-485
RS-485 RS-485
ISC16 ISC16 ISC16 ISC16
spraybar spraybar spraybar spraybar
spraybar spraybar spraybar spraybar
spraybar spraybar spraybar spraybar
spraybar spraybar spraybar spraybar
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39. technotrans spray dampening system
References / OEM + Region
Benefit from more the
experience of more than
25.000 units installed
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40. technotrans spray dampening system
North America Spray Bar Market market
References / US
Of the Top 100 Web newspaper customers in the USA…..
…74 have spray bars
thereof:
technotrans 85% (46% are second purchases)
Smith 12%
Baldwin 1.5%
Goss 1.5%
…6 use the MAN Turbo
…20 use FLEXO or Brush systems
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41. technotrans spray dampening systems
References / customer statement
Hartford Courant hits the right spot with spray system
By Marcelo Duran
Associate Editor
You can teach old iron new tricks.
Thanks to an upgrade of its press control, inking and spray dampening systems, The
Hartford (Conn.) Courant expects to trim waste, improve the quality of first papers off
and, most important, take advantage of virtually hands-free printing on a decades-old
pressline, said Press Manager Ken Coates, who spearheaded the project.
The upgrade, using technology from Rockwell Automation, Goss International Corp.
and technotrans, respectively, was expected to conclude last month. But early tests
and implementation of the first three components of the four-phase upgrade resulted
in a 40 percent drop in start-up and printed waste, Coates said.
Ken Coates, pressroom manager at The Hartford (Conn.) Courant, orchestrated a systems upgrade
that will help the newspaper reduce waste and boost print quality.
Photo: Matt Massagli
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42. Spray Dampening System
Supporting equipment
delta.f Reverse Osmosis (RO)
…recycling of reflex water …water preparation system
delta.r 120 with alpha.r 60 with
1000 l tank 500 l tank
(e.g. 6x4H) (e.g. 3x4Hi)
Reduce waste by filtering reflex Controlled water conditions as
water and return to dampening one key for reproducible high
circulator printing quality.
Reduce disposal costs RO capacity adjusted to press
and production requirements
Safe fountain solution / chemicals
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