ATENA ROTOGRAVURE MACHINE WITH RDC10 ROTARY DIE CUTTER

Description

Year: 2007 (December)
Machine designed for: PRODUCTION OF CIGARETTES PACKAGING, PAPER LABELS AND CARDBOARD PACKAGING
Number of impressions: 12.136.991 m
NUMBER OF PRINTING UNITS: 7
Serial number of the machine: 13347


TECHNICAL SPECIFICATIONS OF THE MACHINE

SUBSTRATE PAPER/CARDBOARD
SUBSTRATE WEIGHT 60-300 gsm

MAXIMUM REEL DIAMETER 1800 mm
MAXIMUM WEB WIDTH 660 mm
MAXIMUM PRINTING WIDTH 640 mm
MAXIMUM PRINTING REPEAT 760 mm
MINIMUM PRINTING REPEAT 360 mm
MAXIMUM ROTARY DIE CUTTING WIDTH 660 mm
MAXIMUM ROTARY DIE CUTTING REPEAT 800 mm
MINIMUM ROTARY DIE CUTTING REPEAT 535 mm

AIR VOLUME 7000 m3/h
AIR VELOCITY 40 m/s

REGISTER ACCURACY
PRINT TO PRINT +/- 0.10 mm
PRINT TO CUT +/- 0.15 mm

ELECTRICAL SPECIFICATIONS 400 V, 3 phases, 50 Hz
PRODUCTION SPEED up to 200 m/min

3 stage rotary die cutting unit RDC10 in-line - embossing, creasing and cutting/stripping cassettes
Production: roll to roll, roll to sheet, roll to die-cut product

Drying: thermo-oil instalation
Register control: DGC 650 from Eltromat

Additional equipment included in price

– 67 printing cylinders (13 steel base only and 54 copper covered)

– 3 sets of cutting + creasing tools (buyer can’t use the whole tool, only original ATN cassettes in which the tools are packed)



DETAILED DESCRIPTION OF THE MACHINE





One ATN 0-speed splicing festoon type both direction unwind unit operating without speed reduction



The unit is of the automatic type, capable of accepting reels of a maximum outside diameter of 1800 mm. Unwinding is made under constant tension. The print can be on either side of the unwinding reel.



It is composed of the following:



Two reels are centred by means of pneumatic expanding chucks for cardboard cores with inside diameter of 300 mm. Both stations are controlled in order to deliver a constant unwind tension on infeed unit fills the festoon with a 4Q DC drive slaved to a constant tension in the festoon.

The festoon is fitted out with a number of idle rollers allowing web splicing up to 200m/min. The web festoon is filled up when the machine is running and unloads itself during the 0-speed splicing.



After the 0-speed splicing, the reel acceleration is controlled by a 4Q DC drive which ensures the filling up of the festoon and maintains the filled up festoon during running at a stable position and at a constant tension. The speed synchronisation is obtained from the main machine by a 0-10 V analogical signal.



The splicing device is mounted on a robust fixed frame. Two independent sliding rules allow the easy-on-both-side pasting preparation.

The two tapes are applied simultaneously on both sides in order to make a good and very precise butt splicing. The automatic splicing cycle with oblique cut is released by push buttons, or automatically, as follows:

1. Quick stop of the finishing reel.

2. Locking the web entering the festoon.

3. Locking on the finishing and the new webs by suction boxes.

4. Oblique cut by symmetrical guillotine knives.

5. Evacuation of the tips.

6. Simultaneous application of the two tapes by means of oscillating arms.

7. Unlocking of the web by releasing the nip rollers and the suction.

8. Acceleration of the reel to fill up the festoon.

9. Tension control at the production speed thanks to a loaded air piston and the 4Q DC drive.



One web cleaning unit with anti-static bars



This unit eliminates dust or foreign particles on the web.

It is composed of the following:



- One vacuum head made of aluminium,

- Two electrodes for ionisation ensuring elimination of static charges,

- One set of static brushes,

- One dust recuperation bag positioned on the machine drive side.



The antistatic bars are composed of an ionisation blade enclosed in a tube with Teflon protection. They are connected to a high voltage generator situated above the travelling web. They eliminate static, thus improving print adherence.



One automatic lateral web guide mechanism



This unit includes the following:



- One power unit

- Two head detectors

- A set of parallel rollers over which the web passes



One positive infeed unit



The positive infeed unit with constant tension is composed of a pulling cylinder and of a dancing roller.



The dancing roller is loaded by membrane air piston electronically controlled. It is friction free, ensuring the correct infeed of the substrate precisely at the preset tension.

The adjustable constant tension is remote controlled from the main operator panel.



1 space for further installation of a supplementary printing unit



Seven Atena rotogravure units



The main characteristics of gravure printing unit are the following:



The printing system



The impression cylinder is made of conical fiber sleeve covered with rubber (usually 90 degrees shore hardness) and is quickly dismountable on the operator side from its metallic base.

The pressure roller with frictionless membrane pistons with vertical guiding and low friction pivot is achieved by a self adjusting impression mechanism with automatic pressure balance and a precise remote control setting

The ink sprayer placed at the opposite side of the blade is with a large tank behind for a better ink coverage of the cylinder on the entire surface.

2 electrostatic assistance units from Eltex for a better inking are included



The doctor blade



The doctor blade is arranged with three knuckles.

It allows, regardless the printing repeat, an angle adjustment from 30° to 60° at the desired doctoring point which can be very close to the nip.

It is locked rigidly by reciprocating pins on each side and can be easily removed from its holder.

The doctor blade pressure is controlled by air cylinder which pressure can be pneumatically adjusted from the unit panel.

The lateral movement of the doctor blade holder is driven by motor.



The trolley



The very rigid trolley integrates a carriage arrangement made of stainless steel which supports the engraving, the ink weir and the ink tray as well as the ink reservoir including chilling unit and the pump.

Viscosity control equipment with solvent reservoir enables to measure and adjust viscosity of solvent inks (Opticolor Junior)



3 supplementary trolleys are included



The dryer



The low temperature high efficiency dryer insure an air circulation and heating. The circulating air in the dryer has a velocity of 40 m/s with an adjustable fan and blower 7000 m3/hour and heated by thermo-oil installation and with temperature regulation.

Very precisely controlled air recirculation allows an efficient dryer at a low temperature, saving thus energy and substrate quality.



A chill roll



Electronic drives

Length registers:

A stepping motor, acting on compensating bars covering the repeat range, ensures the print to print register.

A second stepping motor controls the sidelay print to print register.



Longitudinal sidelay register control



Type DGC 650 from Eltromat

All deviations from the exact register lead to correction commands to the corresponding register motors.

All register errors occurring are clearly visualized at a glance on the graphical colour monitor and the fast adjustment can be observed.

The system includes the following:

A main cabinet integrating all the components

A control unit for the detection and storage of all regulating parameters and the control behaviour

Plug-in modules for length and side register control

A graphical colour monitor

A clearly arranged touch control panel, adapted to industrial requirements, for the input of parameters as well as for the adjustment of the control behaviour

A fiber optic sensing head to secure detection of register marks.

A digitalizer for synchronizing the register control.

A set of plug-in cablings.



Turning bars



This unit includes the following:

- One set of turning bars with air blower

- One automatic edge guide with:

- One power unit

- Two head detectors

- A set of parallel rollers over which the web passes

- 1 video camera type BST Handyscan



One rotary decurler



This rotary decurler has a double action front/reverse and is also electrically controlled with an external calibrated indicator from the receptacle area.



One pull through with automatic repeat length adjustment



This unit, placed on the frame of the rotary die cutter, pulls the web material under constant tension through a dancing roller from the printing units. The pulling is automatically adjusted to the printing repeat with an automatic insetting mechanism scanning a printing mark.



One 3 stage rotary die cutter RDC 10



The cutting unit is designed to accommodate patented ATN cassettes with rotary dies, respectively embossing, creasing and cutting/stripping cassettes. These cassettes can be easily moved in and out of the rotary die cutter thanks to the three integrated hoists positioned above and across the embossing/creasing/cutting unit.

The ”Cassette”, a world wide covered ATN patent holds the rotary dies in an ON-OFF pressure position when stored outside the rotary die cutter stations, the cylinders do not need resetting when remounted in the rotary die cutter. Pressure on the cylinders is hydraulically controlled and is an integral part of the system. The cassettes carrying the cylinders are moved IN and OUT of the rotary die cutter by means of a hoist positioned above and across the embossing, the creasing and the cutting sections.

Wastes are stripped and then removed by means of transporting belt.



One spreading unit



After the cartons are stripped, they are introduced through a series of transfer belts and received on an endless belt delivery on which they are received shingled.



One electrical equipment



The machine is operated by monitor and central computer.

It is delivered completely pre-wired. Electrical, electronic and pneumatic equipment makes part of the whole machine; cable trunks included which are placed four metres away from the machine.



The machine is also equipped with one voltage stabilizer



One universal sheeting tool



It is composed of 2 cassettes placed in the rotary die cutter in place of the rotary tools.

They are driven by brushless motors allowing a variable cutting length between 500 and 1000 mm without changing the tools.

In this case, the speed of the machine is limited to 140 m/mn

- The pulling cassette is installed like a creasing tool on the RDC second stage.

The pulling cassette consists of a pull roller gripping the web with 2 nip rollers. The web will then keep the same tension and accurate positioning during and between the cuts.



- One slitting unit with 2 scissor knives (for the 2 trims) placed on the pull-through unit.

The width of the strips is assured by precisely adjusted spacers designed for an easy change over.

The upper knives are pneumatically operated in two directions :

- vertical in order to bring the knives in a crossing position

- horizontal in order to bring the knives in contact for cutting.

The lateral pressure of the upper knives is precisely adjusted by means of a gearing mechanism.



- One trim exhauster with pipes and suction pump placed closed to the machine



- The cutting cassette is installed like a cutting tool on the RDC third stage.

The cutting cassette consists of an upper male cylinder with 1 disposable knife that can be easily dismounted and set by the operator.



One high pile receptacle



The high pile receptacle is designed to stack sheets on pallets.

The pallet change over can be made at any time without any machine stoppage.

Samples can be picked up during a run.

This unit is placed just after the main machine conveyor belt.

It is mounted on wheels in order to easy its handling; Moreover, the operator just have to plug 2 sockets on the main machine to make it work..

The high pile receptacle consists of:

- Kicker rollers device for the sheets’ infeed.

- Joggers on the sides and on the conveyor belt side.

- Automatic going down stacking device.

- Horn and light alarms for pallet change over.

- Device for samples pick up.



One single shaft rewinder RHS



This rewind is foreseen for reels up to 1300 mm diameter. It will be installed in line with the ATENA rotogravure press after the RDC rotary die cutter.

One gantry will overpass the rotary cutter section.



It is equipped with:

- One automatic edge guide

- One single pneumatic expanding shaft for cores inner diameter 76 mm.

- One motor.

- Lift of the reel from the floor
  • Astrographic
    Croatia
  • Manufacturer:
  • Atena
  • Model:
  • RCD10
  • Year:
  • 2007
  • Impressions:
  • 12 mio.
  • Stations:
  • 7

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