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Home > News/Release (News up till now) > Double-width, Double-circumferential, Shaftless Tower Offset Press "Color Top 7000CD"
Double-width, Double-circumferential,
Shaftless Tower Offset Press "Color Top 7000CD"

An open house where actual printing of the TKS Double-width, Double-circumferential, Shaftless Tower Offset Press "Color Top 7000CD" for delivery to the Nagano Production Center of SHINANO MAINICHI NEWSPAPER was held for two days on August 29 and 30th of 2001 at our TKS Haneda Plant with a total of 450 guests attending the two days. During this public printing, a speed of 85,000 cph with full color on 40 pages was achieved and the actual printed copies were given out to the visitors.

In the development of the exhibited Color Top 7000CD, the first shaftless rotary press was displayed at the JANPS exhibit in 1997 where both a double-wide, double-circumference tower type, color keyless offset press, Color Top 6500, and a single-wide, double-circumference tower type Color Top 3000 were exhibited. Following this, at JANPS 1999, a unit drive shaftless double-wide, double-circumference, tower type offset press, the Color Top 7000UD, was put on display and actual printing at a speed of 85,000 cph was demonstrated at the show. The first couple drive shaftless press, the Color Top 7000CD, was displayed at DRUPA in Dusseldorf, Germany in 2000 where it was not only printing at a top speed of 85,000 but also doing flying plate changes for the duration of the three weeks.
Today, with an upgraded feature consisting of a shell cylinder, the Color Top 7000CD prints 40 pages of full color at a maximum speed of 85,000--the first in the world for a couple drive shaftless offset rotary press to attain this ultra high speed. This Color Top 7000CD consists of five 4 X 4 couple drive color units, one folder unit, and five reelstand units. The folder unit is a combination type with a 2:3:3 jaw folder on the operator side and a 2:2 model 600 rotary folder on the drive side, and below, in the reelroom, are split two-arm reelstands. By use of these equipment (the jaw folder and split arm reelstands are special specifications) stable print quality and precision folding were realized.
On the press unit, shell cylinders were used on the first, second and third levels, and on the 4th level a standard straight across cylinder was used. Through the use of high precision cylinder bearings an ultra-high speed of 85,000 cph was maintained with stability even as shell cylinders and the Super Register Device (SRD) were achieving automatic register control. Additionally, with such systems as a high speed Digital Ink Pump (DIP) inking system and a 3-roller spray dampening system, a very high level of print quality was constantly realized whether at slow speed or high speed. In the folder unit that utilizes a combination folder, the jaw folder produces stable and precise folds during slow or high speeds and is a versatile folding instrument able to handle a wide range of product thicknesses at an ultra high speed of 85,000 cph, which is why they are widely used for newspapers in Europe and Korea. It is possible to make adjustments on the jaw opening (jaw bite), lap, and pin release while running, and on the jaw opening adjustment in particular, as the fixed and moving sides of the jaws open or close in the same amount in reference to the folding blade, even if there is a change in the number of pages there is no need for fine adjustments. Also, as standard equipment, there is a device to adjust the folding cylinder's outer diameter when the press is stopped. On a reelstand unit with a split arm device, any width roll can be put on any arm. For instance, when a full roll is being printed on one arm, a half roll can be put on the other arm. With this feature, the time for changing web widths can be drastically cut. By using an expansion type center collar, the paper roll hold force is improved, which makes it possible to come to an emergency full stop in 17 seconds from a top printing speed of 85,000 cph.

Main Features of the Color Top 7000CD
* Energy Saving Printing Press
  For the main drive systems on the printing and folder units, super efficient ECO DRIVE motors that feature ultra-strength permanent magnets are used and because of improvements in transmission efficiency brought about by vastly reducing shafts, gears, clutches and bearings and through regenerative braking, savings on electric power consumption by 15% to 20% are realized. Further, on a full color unit, it is possible to stop the printing units on the levels where multiple color printing is not done.
* Improved Efficiency
  Unlike before when overload clutches and shear keys were used, this is a system whereby if a torque goes over the overload torque limit actually set in the motor, it is quickly and precisely detected and stops the motor itself, therefore, if the reason for the overload is corrected it can be restarted immediately. Also, when there is a power outage, the induced voltage proportionate to the Eco Drive Motor's revolution is made use of by supplying this energy to other motors while coming to a controlled, full stop. Furthermore, as the Eco Drive Motor is mounted on each plate cylinder, work such as putting on or taking off plates and changing blankets can be carried out for each cylinder at multiple locations.
* High Quality Printing
  The Super Register Device (SRD), which has a resolution accuracy of 7 µm, is used to control the lengthwise register and folder precision for excellent printing and folding quality.
There are individual motors for a group of drag rollers allowing for fine adjustments on the pull-in force. Individual motors are used for each former level Roller Top of Former arrangement.
The infeed roller controls the position of the dancer roller maintaining optimum tension control regardless of speed reduction/increase or emergency stop.
* Reduction of Waste Paper
  The press ramp up speed from start to 85,000 cph is 90 seconds and 17 seconds to come to a full emergency stop, and it is possible to hold waste paper to 120 copies at start time for a 40-page full color product. Furthermore, during plate change or when webbing paper through a different unit, waste paper is kept to a minimal level.
* Less Maintenance
  By cutting down on drive-related mechanical parts, and utilizing highly efficient and long-lasting electrical components, maintenance time and costs have been reduced. Furthermore, for maintenance of electrical parts and components, a remote maintenance system using telephone lines was developed and delivered.
Through the use of this system, there has been a dramatic impact on speedy recovery after a breakdown, on preventive maintenance through periodic history checks, on parts restocking, and on making periodic backups of files and data.
* Enhancement of Work Environment
  As there are few lubrication points, there is less worry about oil leakage. Also, there is less noise and vibration due to usage of smaller cooling fans made possible by reductions in the main shaft gears and lowering of motor heat generation.
* Flexible Press Layout
  As there is no need to link the main shaft, press layout can be done freely to suit the building, and spaces can be efficiently utilized. Construction time can be reduced for plant extensions.

The newspaper delivery system is made up of stackers and delivery equipment that are able to handle high press speeds of 85,000 cph so that, linking with our address labeling online systems, time and manpower savings are realized in the work involved in newspaper delivery. We have just recently developed the following new products: Top Sheet Supply Device, WS-220, and the Paper Band Banding Machine, BM-350. The underlay sheet applicator applies the bottom sheet to the newspaper bundle, and the WS-220 applies the top sheet to this bundle.
After the address label is placed on top, the BM-350 straps the paper band.
These two machines replace the previous polyethylene packaging and the polypropylene band devices. With this use of paper packaging and paper banding, environmental issues are mitigated.
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