technotrans technology in trouble-free operation at the "Saarbrücker Zeitung" for six years

By using peripherals, web printers increase not only the printing quality but also the machines' efficiency – the "Saarbrücker Zeitung" group is the proof. Since the media company switched in September 2006 from the old KBA Express 60 to two Colorman presses, it has used "deltaspray" spray dampening machines supplied by technotrans AG for the past six years. This technology has worked trouble-free since then.

The print specialists at the "Saarbrücker Zeitung" knew perfectly well that it would be more challenging to remain a member of the renowned International Newspaper Color Quality Club than it was to become one in the first place. After the company had reached this lofty level for the years between 2006 and 2008, they intended to raise the bar even further. A new "Colorman" was purchased from manroland which fully replaced the KB Express 60 when it was put into operation in September 2006. However, "Saarbrücker Zeitung" wanted more than an "off-the-shelf" system. Based on their positive experience with peripheral machines offered by system providers from the graphical industry sector, they decided for a technology supplied by technotrans AG. The spray dampening systems created in Sassenberg, Germany, would prove to be essential for high printing quality. From 2008 on, the media group continues to play in the "Champions League" of international printing companies – and will remain unchallenged until 2016. In the past year, the "Saarbrücker Zeitung" was accepted into the WAN-IFRA's Star Club.

No nozzle failure in more than five years of production
Still more important for the "Saarbrücker Zeitung" and technotrans: More than five years after commissioning of the "deltaspray" unit, the dampening system operates close to maintenance-free – despite the fact that the printers are not "permitted" to clean valves and nozzles. Before signing the agreement, the printers agreed to an endurance test which specifies that technotrans services the machine only once per year. "Our expectations have been exceeded," says Hans-Peter Hammes. At the "Saarbrücker Zeitung", Mr. Hammes is the driving force behind innovations in the print shop and continually looks for improvement potential to increase productivity. "Thanks to the utilisation of the technotrans technology, we have gained not only in matters of printing quality, but the machine also returns very little set-up spoilage, reliable technology and consistent printing quality at highly stable processes." They printed 370 million cylinder rotations in approximately 10,800 operating hours in less than six years – without failure of either nozzles or valves. The nozzle caps have been cleaned after 36 months for the first time, and the nozzles themselves one year later. "The spray dampening unit is completely reliable. Maintenance is extremely low-level and can be scheduled flexibly," says Hammes.

"Saarbrücker Zeitung" uses a total of four technotrans peripheral components with the two Colorman machines. In addition to the "deltaspray.line" spray dampening units, the ink pumps (the same pump type for all four inks), a damping water cooling unit and a cross-flow filtration were supplied by the company in Sassenberg. The functionality of the spray dampening units is the heart of the overall system. With the field trial in Saarbrücken, the printers were mostly impressed by the ultra-fine application of the dampening solution and the simple and accurate control of the spray bars.

The entire set-up of the system aims at boosting productivity. Due to their individually-controlled nozzles, the modular and symmetrically-designed spray dampening units ensure a precise dosage of the dampening agent. The exact dampening solution application improves the quality of the printed product to a considerable extent. The nozzles are designed with anti-twist protection that ensures the specified positional angles are maintained. They also feature a bayonet lock enabling quick and tool-free exchange in just a few steps. As a result, maintenance tasks can be completed easily in just a few minutes.

Thanks to the technotrans technology, the "Saarbrücker Zeitung" does not need expensive external compressed air. The caps ensure that the nozzles clean themselves. Special structures in the cap of the nozzle produce the so-called Venturi effect, i.e., the generation of negative pressure. Clean air from inside the housing is drawn in and flows around the nozzles. As a result, outside dirt and ink particles cannot clog the nozzle. "The saved maintenance and cleaning costs significantly increase the efficiency of existing systems," states Klaus Wiedemann, Key Account Manager with technotrans AG. In the more than five years since the solution has been installed, no production was lost due to clogged nozzles. Neither has the media company experienced any valve failure. Until now, none of the nozzles had to be replaced by a new one. At the "delta.f" filter unit, not even the ceramic membrane had to be replaced.

Cleanliness and production reliability
The "Saarbrücker Zeitung" also paid great attention to the cleanliness of the individual machine components. Before the switch to technotrans, paper dust and ink mists had been the main reason for machine clogging. The concept of reducing ink mists by using a more viscous ink was realised with the installation of a new ink pump. Clogging was significantly reduced.

Contaminated water is returned from the drip pans of the spray dampening units to the dampening agent unit after it has passed through the "delta.sd" filtration system. The contaminated dampening agent is caught in a stainless steel tank and fed in batches through the ceramic membrane filters. The filtered dampening agent which is a mixture of RO water, hardening agent and dampening medium additive is then optimally prepared for re-entering the cycle. The typical putrid odour of the dampening water treatment area is eliminated in Saarbrücken. By eliminating any filter material, except for a filter cartridge for safety purposes, and any other consumables, the print shop saves additional maintenance expenses. Up until today, approximately one million litres of filtered dampening solution have been reintroduced into the process.

"Thanks to the right partners, we have been able to get that bit more printing quality from the machine," says Hammes. He believes that the high level of expertise is proven by the fact that technotrans looks at the end-to-end printing process with its technology. "The days when personnel at the control centre used their gut feeling to ensure sufficient quality are over. All factors must be taken into consideration in modern production, from the properties of the dampening solution to the ink and the cleanliness inside the machine, and the interaction between these factors in particular must be understood," says Hammes.