KBA C16

KBA-Digital & Web Solutions

The best of 16pp web offset technology

2 | KBA C16

Competition among publication printers in high-volume markets today is fiercer than in any other sector.Fast job changes, flexibility in production, a minimum of start-up waste, a high yet stable output, trouble-free integration in the workflow and an optimum print quality on different substrates are indemand as never before – along with easy handling, energy efficiency and minimum maintenance. Ournew 16pp KBA C16 web offset press was engineered to meet these specifications. Incorporating anadvanced level of automation, it is available with a maximum rated output of 55,000 or 65,000cph.

KBA C16Performance and flexibility for a tough market

Winning features

KBA C16 | 3

The C16 combines the proven technologyof our popular Compacta 215 and thesophisticated innovation of our high-endCompacta 217. The result is an exceptionallyversatile, cost-effective press with an arrayof new modules.

Intelligent automation, ergonomic operation,low-maintenance technology from thereelstand to the folder and a raft of practical details make the C16 a highlycompetitive tool capable of withstandingthe challenges of a pressroom environment.

Winning features in brief:• Automatic or semi-automatic plate

change• KBA RollerTronic patented automatic

roller bearings1

• Flying imprint capability• Automatically convertible folder with

just one quarterfold up to 65,000cph

• Unique, patented copy control2 in folder• Ergonomic operation• Automatic press preset via

KBA LogoTronic• Optional JDF process integration via

KBA LogoTronic• Job management via KBA LogoTronic

4 | KBA C16

Safeguarding a disruption-free supply of paper to the reelstand is key to maintaining a high net output.With our proven combination of Patras reel logistics and Pastoline or Pastomat C reelstand we offer aone-stop, integrated system for efficient paper logistics.

Integrated paper logisticsJust-in-time reel supply

KBA PatrasOur modular Patras reel transport andlogistics system is robust yet flexible,requires a minimum of maintenance andis compatible with all customary reel-loading systems. Configurations rangefrom manually assisted to fully automated,with retrofit automation and upgradespossible at any time.

Ecology and economy right from the startKBA Pastomat COur proven Pastomat C automatic reelstandwith integrated infeed unit is engineeredfor reel weights up to 3 tonnes (3.3 UStons) and a maximum reel diameter of1270mm (50in). Clearly laid out datascreens at the reelstand and subsequentunits to the folder aid the press crew byfurnishing data on the current operatingstatus. The Pastomat CL is available as anoption for reel diameters up to 1524mm(60in).

KBA PastolineEngineered for a maximum web speed of13mps (2,560fpm), the Pastoline acceptsreels weighing up to 1.6t (1.76 US tons)and with a maximum diameter of 1270mm(50in). Controls are the same as for thePastomat C and CL.

The infeed unit integrated in both typesof reelstand is extremely compact andmaintenance-friendly yet has all the components necessary for precise webalignment.

When it comes to ease of operation andcost efficiency, KBA reelstands are wayahead of the field. On top of this, theirunique regenerative braking system withenergy feedback reduces running costs.

KBA C16 | 5

Reel handling

6 | KBA C16

Printing unit

KBA C16 | 7

12

3

45

6 78

910

11 12

13KBA C16 printing couple

1 Ink duct

2 Duct roller

3 Film roller

4 Ink distributor

5 Bridge roller

6 Ink transfer roller

7 Ink distributor

8 Ink transfer roller

9 Ink distributor

10 Ink distributor

11 Ink forme roller, oscillating

12 Ink forme roller

13 Ink forme roller

A superb print quality, fast changeover times, ergonomic operation, good stability, low maintenance and optimum flexibility: the printing units for the C16 were designed to deliver on every point. Their robust construction, practical automation level(plate change, roller bearings etc.) and ingenious details (settings for paper thickness) make the C16 the perfect tool for round-the-clock production of short, medium and long print runs alike.

Quality and stabilityPerformance in print

The C16’s film inking unit and dampeningunit can handle even the most problematicand challenging images, delivering a highquality in every type of production and at any speed. Four forme rollers, someoscillating, ensure that the ink/water balance is achieved in a minimum of timeduring start-up. Large-diameter rollersguarantee uniformity and rich solidsthroughout the production run. They alsoreduce ink spray and mist. This is wherethe C16 scores over its rivals. And it isideal for environmentally responsible alcohol-free printing.

The ink ducts adopted from Rapida high-performance sheetfed presses have integrated electronics and operate with atotal absence of bleed in the ink zones.Inking and reproductive accuracy are uniformly stable even during long printruns.

In keeping with the widespread shifttowards greener production the dampeningunit in the C16 is also engineered foralcohol-free operation, and allows bothdirect and indirect dampening with remoteconversion from the console. The drivesystem supports optimum metering fordifferent types of substrate.

Each printing couple has its own dedicatedAC drive (i.e. two per unit) for the fast,precise setting of the circumferentialregister with a minimum of mechanical

input. Electric motors control settingmechanisms with much greater precisionthan mechanical systems.

Because there are two motors for eachprinting unit, less braking and acceleratingforce is generated than with the single-motor systems more common today. This reduces mechanical abrasion on components, which means less maintenanceand greater reliability. The printing unitsare water-cooled to promote operationalconsistency even during long productionruns.

Dispensing with bearer rings eliminatesneedless wear and tear and also allowsthe nip between the blanket cylinders tobe set to the relevant stock thicknesswith absolute precision. The gap betweenthe side frames is much smaller, whichimproves stability and vibration resistance,and there is less load on the journals.Finally, the absence of bearer rings andthe forces they generate reduces energyconsumption and prolongs the service lifeof all the drive components.

8 | KBA C16

Plate change

KBA C16 | 9

KBA

Competitor A

Competitor B

Plate-changing time in seconds

There is an ongoing shift away from long print runs and towards personalisation. For many printers, fast job changes have become a question of survival. Our C16 features operator-friendly semi-automatic platechanging as a standard, while both the 55,000 and 65,000cph versions can be configured with optionalautomatic plate changers that are the fastest on the market. They can change the plates in a single couple or the entire press line in less than sixty seconds.

Semi- or fully automaticFast and easy plate change

With KBA automatic plate changers, jobsof fewer than 10,000 copies – which werepreviously the preserve of sheetfed – cannow be printed cost-effectively on a webpress. In tandem with an optional imprinterthey support additional production capabilities such as edition changes ortext imprints.

Variable imprinterexpands the optionsIn commercial printing, long runs withflying imprint changes are becomingincreasingly popular for direct mail. KBAhas taken a new approach made possibleby dedicated drives.

With conventional imprinters a flyingimprint change can only be carried out on one side of the web, for example toinsert different addresses or prices. Withdedicated drives it is possible to changeimprints simultaneously on both sides ofthe web and at maximum press speed byengaging and disengaging two printingcouples alternately. So the different language versions of a brochure, say, can now be printed in a single run.

20 40 60 80 100 120 140 160 180

1

2

3

4

5

10 | KBA C16

6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108

RollerTronic

Conventional

Recoating frequency in months

100 200 300 400 500 600 700 800 900 1000

RollerTronic

Conventional

Automatically adjustable roller bearing

1 Pressure chamber for roller throw-off

2 Pressure chamber for setting roller relative

to ink distributor

3 Blocking mechanism (after automatic setting)

4 Pressure chamber for setting roller relative

to plate cylinder

5 Module for controlling setting direction and pressure

In today’s commercial market the focus is on process optimisation and cost efficiency. Our uniqueRollerTronic patented1) automatic roller bearings make a key contribution. This is reflected in the fact that so far over 50,000 have been fitted in newspaper and commercial web presses.

Innovative and effectiveRollerTronic – the printer-friendly roller bearing

When actuated by push-button from theconsole panel, RollerTronic automaticallysets and adjusts all the inking rollers inless than two minutes. Irksome time- andcost-intensive manual roller setting, andthe hours of down time associated withit, are history.

Rollers set with optimum precision ensurethat ink is transferred uniformly acrossthe entire width. RollerTronic dramaticallyreduces roller abrasion and thus the frequency with which rubber coatingsmust be replaced, thereby delivering further cost savings. It obviates unevenwear and tear arising from the incorrectpositioning of the rollers relative to eachother.

Correct roller settings reduce maintenancecosts and energy consumption while promoting optimum production conditions.

Benefits of RollerTronic:• Much lower maintenance costs• Less frequent renewal of rubber coating• Better energy efficiency• Greater process stability• Optimum printing conditions

Roller setting time in minutes

KBA C16 | 11

Automatic roller bearing

12 | KBA C16

Minigap

KBA C16 | 13

KBA

Other

32

Time in minutes required to change blankets in each printing couple

54.543.52.51.510.5

The blanket cylinders in the C16 incorporate the minigaps first developed by KBA in the 1990s and subsequently adopted by other manufacturers. With minigaps, the image-free margin is less than 6mm (0.2in). This reduces both vibration and plate abrasion. And there is no need for bearer rings.

An eye for detailMinigap and printing pressure

Minigap cylinders are typically fitted with metal-backed blanket plates that can be changed much faster than eitherconventional rubber blankets or morecostly sleeves, and without the aid oftools. Retightening is no longer necessaryand the trailing edge of the blanket platecan dip into the cylinder gap duringimpression to compensate for heat-induced elongation. This is not the casewith sleeves.

Another benefit is the tool-free adjustmentof printing pressure to paper thickness viaa setting screw. Adjustment is thereforemuch quicker and easier than on othermakes of press involving lengthy changesof blankets and blanket packing (see comparison below).

Benefits of minigaps:• Tool-free blanket change in around

3 mins• No retightening necessary• Reduced storage costs for metal blankets• Cheaper than sleeves• No elongation during impression• No bearer rings, i.e.

- less strain on cylinder bearings- less energy consumption- longer service life of all drive

components

KBA

Other

6040

Time in minutes required to set paper thickness or change blanket packing

807050302010

14 | KBA C16

Bespoke configurationsFor individual production scenarios

Single-web superstructure for straight-on production Single-web superstructure with turner bars

Double-web superstructure for duplex operation Double-web superstructure Double-web superstructure with all modules

SuperstructureThe superstructure on the C16 is configuredfor straight-on production, but can be fitted with optional turner bars. All theweb guide elements are easily accessible,even the former and slitter. A modulardesign and dedicated drives throughoutallow the superstructure to be customisedfor specific production scenarios.

Superstructure and configurations

KBA C16 | 15

Duplex press with cross lead

4 + 4 printing units with two webs and all modules approx. 38m

appr

ox. 5

.7m

Typical straight-on press approx. 35m

appr

ox. 1

2map

prox

. 7.8

m

The microporous patented turner bars are one of the many proven features thatare unique to KBA. They no longer need to be set for different ribbon widths, and operate reliably with a minimal air cushionand superior ribbon guides.

A next-generation slitter with motorisedlower knife slits and trims cleanly withvery little paper dust. Cutting and perforating modules can be included inthe original build or added at a laterdate.

The former can be angled in the directionof or counter to web travel and is laterallyadjustable from the console. Oblong holesallow air to escape. The perforating knifedirectly in the former, with quick and easyadjustment from the console, promotesprecision folding. Waste-intensive webshifts and the manual adjustment of theperforating line are a thing of the past.The web is fed in by the chain to thecentre of the former in less than threeminutes.

Chill roller standThe KBA chill roller stand is locatedbetween the hot-air dryer and the superstructure. Configured with three orfour rollers (depending on press output)and multiple cooling circuits, it is engineered for maximum impact and energy efficiency. A heatset dryer withbuilt-in chill roller stand is available asan option.

ConfigurationsThe C16’s clever modular design3 not onlyallows press lines to be custom-configured,it also shortens and facilitates projectplanning. The heavy-duty printing unitswith cast-on, ready-wired subframes cuton-site installation and commissioningtimes.

The choice of configurations ranges froma basic straight-on version with four tosix printing units and standard folder totwo-web versions erected in one line oron two levels, and duplex installationswith ten printing units, four turner bars,a cross lead and a folder.

The superstructure can be retrofitted withfurther modules as the need arises. Externalsubassemblies such as the dryer, blanket-washing unit, length gluer, silicone unit,dampening circulation system etc. are allfully embedded in the console controls.

16 | KBA C16

Intelligent folder technology Flexibility is keyA high level of press performance and production flexibility, rapid conversionand precision folding, yet low maintenance, total reliability and ergonomic operation are the properties demanded of today’s commercial folders.

The P3 pin folder’s compact design andease of access reflect its advanced technology.

Our new P3 folder can produce over 30different folds in a range of formats. Notonly this, it is easy to operate via a

swivelling touch screen directly at thefolder delivery.

We offer the benefit of a remotelyadjustable first and second cross fold, anda quarterfold unit comprising a singlemodule. This supports a wide choice of

folds while dramatically shortening conversion times. The strike length anddepth of circumferential and lateral perforation can be adjusted on the fly so as to adapt perforation and foldingaccuracy to stock type and productionconditions with a minimum of waste.

Folder

KBA C16 | 17

Benefits of the P3 folder:• Touch-screen operation at folder

delivery• Touch screen doubles as full console• Just one quarterfold for output levels

up to 65,000cph• Intelligent copy control• Pneumatic belt tension with holding

brake• Maintenance- and user-friendly

For outputs up to 65,000cph the P3 folderrequires just one quarterfold. This isbecause the belt paths are short andbroad, ensuring smooth copy transport.Intelligent, patented copy control in thequarterfold makes for a trouble-free foldingsequence. It is user-friendly and requiresno manual intervention. Production conditions are therefore always consistentirrespective of operator skill.

Copies are slowed effectively and with aminimum of abrasion, and aligned in thedirection of fold during deceleration. Ournew, automatic copy control system is self-adjusting and exceptionally reliableregardless of production speed and copythickness. As a result folding is consistently accurate, even duringchanges in press speed.

The pneumatic belt system maintains aconstant tension yet effectively preventsstretching. This reduces abrasion and thusmaintenance input. Belt tension can alsobe adjusted on the fly.

18 | KBA C16

a II

I

II

I

II

I

II

I

II

I

e

b

c

d

Folding optionsPerfect copies in every format

W1/3

1/4 C

W1/3

W1/2

1/4

Auxiliary equipment

1/6

Auxiliary equipment

W1/2

1/4

W1/2

1/4 W

1/2 C

1/4 W 1/4 W 1/4 C1/4 W

1/6 W 1/4 C

1/4 W

1/2 C

1/8 W

1/2 C

1/4 W

1/2 C

1/3 W

1/2 C

Auxiliary equipment

W2/3

1/3

W1/3

W1/1

1/2 1/2 W

1/2 C

Auxiliary equipment

2 x 8 pages A41/2 C = 3101/4 W = 250 max./165 min.

Circumference C = 620 mm Web width W = 1,000 mm (max.)

420 mm (min.)

W1/3

W1/2

32 pages A51/4 C = 1551/4 W = 250 max./165 min.

16 pages A41/2 C = 3101/4 W = 250 max./165 min.

32 pages1/2 C = 3101/8 W = 125 max./105 min.

24 pages1/2 C = 3101/6 W = 166 max./165 min.

1/6 W

1/2 C

1/4 W

1/2 W 1/4 C

1/6 W

1/2 C

1/3 W 1/4 C

Former foldFormer fold First cross fold Former fold1 First cross fold 2 Quarter fold 3 Double parallel fold

48 pages1/4 C = 1551/6 W = 166 max./165 min.

2 x 16 pages A51/4 C = 1551/4 W = 250 max./165 min.

Standard8 pages A31/2 C = 3101/2 W = 500 max./210 min.

16 pages A41/2 C = 3101/4 W = 250 max./105 min.

32 (2 x 16) pages A5 (two-up) 1/4 C = 1551/2 W = 500 max./210 min.

24 pages1/4 C = 1551/3 W = 333 max./165 min.

12 pages1/2 C = 3101/3 W = 333 max./165 min.

24 pages1/2 C = 3101/6 W = 166 max./105 min.

Web leads Standard folds

Possible folds

KBA C16 | 19

1/4 W

1/8 W

1/6 W 1/3 C2 x 6 pages 1/2 C = 3101/3 W = 333 max./185 min.

1/3 W1/2 C

1/2 W 1/3 C

1/4 W 1/3 C1/4 W 1/2 C

1/4 W

1/8 W

1/3 C

1/4 W

1/3 C

64 pages1/4 C = 1551/8 W = 125 max./105 min.

1/4 C

1/4 W

1/3 C

1/4 W 1/4 C

1/6 W

1/4 C

1/6 W1/3 C

1/3 W1/3 C

2 x 8 pages A41/2 C = 3101/4 W = 250 max./185 min.

1/4 W1/2 C

1/2 W

1/2 C

1/4 W

1/2 CFormer fold Former fold Former foldDouble parallel fold Former fold Delta fold First cross fold4 Quarter fold 5 Delta fold 6 Quarter fold 7 Quarter fold 8 Former fold

2 x 8 pages A41/2 C = 3101/4 W = 250 max./105 min.

2 x 4 pages A31/2 C = 3101/2 W = 500 max./210 min.

36 pages1/3 C = 2071/6 W = 166 max./105 min.

18 pages1/3 C = 2071/3 W = 333 max./165 min.

4 x 4 pages A41/2 C = 3101/4 W = 250 max./185 min.

48 pages1/3 C = 2071/8 W = 125 max./105 min.

24 pages1/3 C = 2071/4 W = 250 max./165 min.

36 pages1/3 C = 2071/6 W = 166 max./165 min.

2 x 12 pages1/3 C = 2071/4 W = 250 max./165 min.

32 pages A51/4 C = 1551/4 W = 250 max./105 min.

24 pages1/3 C = 2071/4 W = 250 max./105 min.

12 pages1/3 C = 2071/2 W = 500 max./210 min.

48 pages1/4 C = 1551/6 W = 166 max./105 min.

Extension module8/16pp Cut-off cassette

20 | KBA C16

OPERA

Open Ergonomic Automation System Efficient dialogue with the press

The KBA ErgoTronic console, KBA EasyTronic automatic press presetting system and KBA LogoTronic production management system are the primary components in the C16’s integrated automation concept. Intelligent control technology at subassembly level and concise data screens ensure that the operator at the console has total control of the press at every stage of production. Our module-based OPERA (OPen ERgonomic Automation) system incorporates all the requisite modules for a rapid dialogue between man and machine.

KBA ErgoTronicThe console for the new C16 is a perfectinterplay of functionality and aesthetics.All essential production commands,

including automatic folder conversion, areinitiated at the console. Easy-read datascreens with plain-language displays onthe touch screen facilitate operation.

KBA C16 | 21

KBA SupportOnlineA 24/7 service hotline ensures promptand effective customer support. The computer in the service department cancommunicate with the C16 via a networkor the internet. Any malfunctions thatmay arise are generally detected within a very short space of time, so remedialaction can be initiated without delay.

KBA ColorTronicThe ColorTronic desk is the operator’s primary workstation. It supports optimumcolour setting and incorporates a colour

presetting system as a standard feature.The colour profile is depicted as a broadLED band, allowing prompt correction.

KBA CIPLinkA CIPLink interface for transferring pre-press data is included in LogoTronic. CIP3files are accessed via a local network. A CIP4 capability is available as an option.

KBA EasyTronicOur EasyTronic automatic press presettingsystem, which includes slitter, turner-bar,register-roller and former preset during

job changes, boosts productivity and atthe same time helps to minimise waste,e.g. through rapid web tensioning, run-outwashing (depending on product) anddefined pre-inking. The ability to presetall the components in the superstructureand the folder according to pre-press datais available as an option. Optimised pressstart-up, makeready and run-down areactuated at the touch of a single button.

22 | KBA C16

KBA LogoTronicDigital workflow

Workflow

Among printers today the concept of an integrated workflow from order reception to print production anddistribution is steadily gaining currency. The diversity of equipment and software installed means that shrink-wrapped packages are rarely appropriate, so workflows must be customised using existing kit with the addition of bought-in components where necessary. We offer suitable tools in the form of LogoTronicand LogoTronic Professional, and also work closely with prominent providers of proprietary software. This enables us to offer integrated networks based on JDF (Job Definition Format).

Basic presetting data in the printing units,superstructure and folder can be storedfor future use, substantially reducing makeready time and waste when printingrepeat jobs. Continuously improved sinceits launch, LogoTronic has a standardised,easy-to-use graphical user interface andcan be embedded in the central console,furnishing the operator with an overviewof all the systems required for fast jobchanges.

LogoTronicA standard feature of all KBA commercialpresses, the basic version of LogoTronicenables essential presetting data to betransferred directly to the press. It includesa CIPLink module for the CIP3-/CIP4-compliant transfer of data for press preset,

with reel- and ink-data capture availableas an option. The workflow is networkedusing the in-house hardware (server). Ink-key, colour and dampening data can betransferred to the press for presetting.

LogoTronic ProfessionalAs an option the console can be configuredwith LogoTronic Professional, an open-architecture production management systemthat supports production monitoring, thedigital flow of job and presetting data,and the systematic evaluation of productiondata. It connects the press to upstreamproduction planning and scheduling systems and commercial IT. This well-proven system translates production andadministrative data into meaningful statistics and makes for greater

transparency by capturing press and operational data.

LogoTronic Professional is a key link inthe communication chain between theKBA press and the printshop’s managementinformation system. New KBA presses canbe embedded at any time in an existingLogoTronic Professional scenario with KBAsheetfed, newspaper and commercial webpresses, delivering synergy gains and creating a uniform platform for all thepresses in the printing plant. The databasecan be accessed either direct or, as anoption, via JDF.

KBA C16 | 23

KBA C16At a glance

Modifications may be made with no prior notice. No part of this publication may be reproduced in any way without the permission of Koenig & Bauer AG. Illustrations maydepict special features not included in the basic press price.

SpecificationsMaximum production speedMaximum web speedCylinder circumferenceWeb widthPrintable stock weightsPlate-changing time**

Webbing-up speed, with chain

Standard equipmentKBA reelstand with integrated infeed unitSpreading rollerPrinting unitsSemi-automatic plate changersMobile operating panelBlanket-washing systemInk-pumping systemDampening systemWeb catcher (Baldwin)Dryer with/without post-incineration

with/without integrated chill roller stand

OperaKBA ErgoTronic consoleRemote adjustment of inking unit, dampening unit and registerKBA DriveTronic shaftless drivesKBA LogoTronic production management systemCIP3 integration

Optional equipmentKBA Patras reel-handling systemWebbing-up unit with chain to formerFlying imprint capabilityAutomatic plate changersDesk lightingHeight-adjustable deskRemoistening unitColour-density controlCross lead for duplex press lines Steel substructure for stacked configurations

Opera (optional extras)KBA LogoTronic Professional production management systemKBA EasyTronic automatic press presetting CIP4 integration

* with sheeter ** with automatic plate change

Technical data

65,000 revs/h11.4 m/s546 – 630 mm / (700 mm)1,000 mm36 – 200* g/m2

approx. 1 min.40 m/min

SuperstructureSilicone unitWeb-centre controlColour-register controlCut-off-register controlLength gluing unitP3 pin folderPlate punchBending machine for plates and metal blankets

Auxiliary formerExpansion module for 2x8 pages Cut-off cassette for 4x4 pagesDie-cutter and perforatorCoater, UV coater and remoist gluerPlough foldSheeterCompressed-air unitChilling stationP3 folder with no delta or double parallel fold

1 patents EP 1628829 B1, EP 1379385 B1, EP 1370417 B1 2 patent EP 1730063 B1 3 patent application EP 2265443 B1

The KBA C16 fromKoenig & Bauer Group

For further information please contact our sales department at:KBA-Digital & Web Solutions AG & Co. KG Postfach 60 6097010 Würzburg, GermanyFriedrich-Koenig-Str. 497080 Würzburg, GermanyTel: (+49) 931 909-0Fax: (+49) 931 909-4101kba-wuerzburg@kba.comwww.kba.com05/2016-e. Printed in Germany

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