8/10/2019 Nip Control 2011 6

1/31

A Sensor Development Company

NIPS

Are we measuring

the right thing

2011:6

Most innovative offset product!

Nip Control is moving the industry from external

estimates to objective measurements inside the

nip - where the offset process takes place

8/10/2019 Nip Control 2011 6

2/31

Outline

1. General on nips

2. Cylinder nips

3. Roller nips

4. Testimonials

5. Applications

8/10/2019 Nip Control 2011 6

3/31

Pressure Indicator

320 Newton/cm2

nip pressure

Plate / BlanketBlanket / Impression

Blanket / Blanket

Pressure Range

60 - 750 Newton/cm2

Roller Nip Indicator

3.5 mm

nip width

Rollers

Measuring Range

1.5 - 20 mm nip width

8/10/2019 Nip Control 2011 6

4/31

What is a process nip?

The meeting point of rollers, ink, fountain solution,plate, blanket and finally the paper

The nip is a combination of materials, chemicalsand pressure

Printing unit

Ink rollersDampening rollers

Plate to blanketBlanket to impressionBlanket to blanket

General Nips

8/10/2019 Nip Control 2011 6

5/31

1. Mix, create and move ink andwater between the rollers

2. Transfer ink & water to the

plate3. Transfer the ink emulsion and

water from the plate to theblanket and then the paper

4. Transporting the paper in weboffset presses

Why process nips?

General Nips

8/10/2019 Nip Control 2011 6

6/31

CYLINDER NIPS

8/10/2019 Nip Control 2011 6

7/31

End-user introductionof Pressure Indicatorat IPEX 2010 incooperation withContinental / ContiTech

Cylinder Nips

8/10/2019 Nip Control 2011 6

8/31

Many Blanket Constructions

Blankets from different manufacturers

Blankets of the

samethickness.

Can they all

give the same

pressure?

Cylinder Nips

8/10/2019 Nip Control 2011 6

9/31

Whatsmeasured in the

cylinder nip today

Cylinder Nips (mm)

Thickness of the plate or blanket &

underpacking in relation to the bearer

Press manuals discuss pressure load, but

we do not measure pressure but millimeters

The compressibility of the blanket, or the

softness or hardness of the underpacking,is not considered

Cylinder Nips

8/10/2019 Nip Control 2011 6

10/31

Pressure Indicator

320 Newton/cm2nip pressure

Cylinder Nips

8/10/2019 Nip Control 2011 6

11/31

By entering the sensor blade into the nip, the instrumentmeasures the pressure load inside the nip (Newton/cm2)

Shows the highest pressure load in the display

Measurement range between 60 - 750 N/cm2

plate and blanket blanket to impression blanket to blanket

Instrument repeatability +/- 10 N/cm2

What does the instrument do?Pressure Indicator

Cylinder Nips

8/10/2019 Nip Control 2011 6

12/31

What do we want to measure?

Peak pressure moves

the dot from one

substrate to another

-plate to the blanket-blanket to the paper

Cylinder Nips

8/10/2019 Nip Control 2011 6

13/31

How does the instrument work?Pressure Indicator

Measures and registers

thousands of times as the

pressure sensitive area of

the sensor blade moves

through the nip.

Ex: 4 500 times in a 10mm nip

Pressure range:

200 - 750 N/cm2

60 - 750 N/cm2 with Low

Pressure Kit

Instrument repeatability:

+/- 10 N/cm2(typical deviation)

Peak value staysin display

Cylinder Nips

8/10/2019 Nip Control 2011 6

14/31

Blanket properties influencing nip pressure

Surface hardness Surface structure

HeightTightening of

blanket

Type of surface rubber

Compressibility

Underpacking

Fabric properties

Fabric properties

Blanket height+Compressibility+ Surface rubber+Fabric properties+Tightening

+Underpackings

= Nip pressure thattransfers the dot

Blanket height

Thickness Peak Pressure

Cylinder Nips

8/10/2019 Nip Control 2011 6

15/31

AdvantagesDigital instrument Cylinder Nips

1. Measures the process critical point of the nip Print quality & print consistency

2. Easy to check process status when a problem occurs(poor ink transfer / ink build-up / plate wear / web wander or breaks)

Parallel pressure level along the nip (operatorcenter - drive side)

Differences in pressure between printing units

Absolute pressure level

3. Improved Productivity

Process corridor defined Trend analysis software hansson nips to

support process control

Cylinder Nips

Pressure Indicator

8/10/2019 Nip Control 2011 6

16/31

Instrument, Sensor blade,

Calibration tool & Low Pressure Labels

It is the small 5 x 5 mm square in top of

the sensor blade that is the pressuresensitive area and which measures

Quick & easy to useJust let the top of the sensor blade

go through the nip, and you will see

the pressure in Newton/cm2Calibration Tool

Low Pressure Labels forpressure loads between

approx. 60 - 200 N/cm2

Cylinder Nips

8/10/2019 Nip Control 2011 6

17/31

ROLLER NIPS

8/10/2019 Nip Control 2011 6

18/31

Roller setting make a differenceDensity variations - Newspaper printing

Density

Density

Bad settings of ink rollers cause large

density variations

Comparison of two printed editions and 30 sequencial copies

30 printed signatures in a sequence

30 printed signatures in a sequence

When ink rollers settings were adjusted,the density variations also were reduced

Roller Nips

8/10/2019 Nip Control 2011 6

19/31

Whatsmeasured in theroller nip today

Roller Nips

Roller Nip mm)

Contact strip between two static

rollers meeting

Changes in Shore A hardness isnot considered

Plastic strips occationally used to

try to feel the nip pressure

Bulge withunclear edge

8/10/2019 Nip Control 2011 6

20/31

Roller nipsthe shear forces get the job done!

Source: Bttcher Rollers

1. The shear forces are created when two

surfaces are moving with differentsurface speed

2. The emulsion is created, processedand transported by

shear forces

adhesion of ink to rollers

surface roughness

3. No contact between the rollers during

production as a very thin liquid film of

ink and water is between the rollers

4. Ifthe pressure between the rollers isincorrect, the shear forces and the

temperature are affected negatively

late cylinder or

hardest roller

Roller Nips

8/10/2019 Nip Control 2011 6

21/31

Roller Nip Indicator

3.5 mm nip width

Roller Nips

8/10/2019 Nip Control 2011 6

22/31

How does the instrument work?

Black curve = New, flexible roller

A = Aging roller

B = The oldest and also the hardest roller

A

B

Contact widthInked stripe

Digital

measurement

Pressure width

1. All roller nips have apressure curve and, thispressure curve mirrors theshear forces

2. The pressure curve changesas rubber hardens with age

3. When rubber gets harder,the pressman increasespressure to achieve originalnip width in mm

4. He achieves the nip width hewants but also higher nippressure / pressure width

The instrument measures

the distance (mm) when

the pressure is above apre-defined level

Roller Nips

Roller Nip Indicator

8/10/2019 Nip Control 2011 6

23/31

Rollers-process consequences

Increased

roller nip

pressure

Increased

friction.

Shear

forces are

affected

Increased electricity consumption

Lower ink

viscosity

Ink

absorbes

more water

Pressman

compensates

Ink & water

consumption

increases

Lower print

quality

Breaks

down

rubberss

dynamic

properties

Increased

heat

generation

Shrinkage

develops &less rubber

flexibility

Shorter roller

life

Roller Nips

http://upload.wikimedia.org/wikipedia/commons/d/dc/500_Euro.Recto.png

8/10/2019 Nip Control 2011 6

24/31

A Real Life ExperimentBttcher Rollers

1. Two months of printing at typical roller settings (2-color press)

2. Optimized pressure settings for two months

Results

59% savings on energy

27 % savings on ink

15% savings on fountain solution

and better print quality!

www.bottcher.com/FAQ; section setting rollers

Roller Nips

http://www.bottcher.com/FAQhttp://www.bottcher.com/FAQ

8/10/2019 Nip Control 2011 6

25/31

AdvantagesDigital Instrument Roller Nips

1. Measures where the offset process takes place - inside the nip

Optimized print quality

Despite swelling, shrinkage or hardening of rollers correct nip pressure can be achieved

2. Trouble shooting & process control

Objective, standardized way to check parallel alignment,

shrinkage or swelling regardless of operator

Correct roller setting with or without ink on rollers

3. Save time and increase productivity

Up to 50% time savings when setting rollers Can be used by a single operator

4. Save on consumables

Electricity / Ink / Fountain solution / Rollers

Roller Nips

http://upload.wikimedia.org/wikipedia/commons/d/dc/500_Euro.Recto.pnghttp://upload.wikimedia.org/wikipedia/commons/4/4d/Usdollar100front.jpg

8/10/2019 Nip Control 2011 6

26/31

Simple to use,

sophisticated concept

Static sensor blade concept

1. Insert and position the sensor blade inside the nip

2. If needed, adjust the pressure load so correct digital

value is seen in the display

3. Done

Note:

A digital nip width value isdifferent from the ink stripe

and that is th e benef i t!

6.0 mmdigitalnipwidth

Static sensor

Semi-dynamic sensor blade concept

1. Let the press pull the sensor blade

2. Stopp the press when the two green

lines have passed the nip.

3. Read the nip value

Semi-dynamic sensor

Measurement in DNU

Roller Nips

8/10/2019 Nip Control 2011 6

27/31

Three different sensor blades

to Roller Nip Indicator

SS30002/03 ALL ROUND

DS30001

SS30001

ALL ROUND - STATIC SENSOR BLADE

Roller nips in offset, rotogravure and flexo.

Infeed or draw roller nips within specification

Coating and lamination nips.

Recommended in applications where the

rollers are clamped together (not inched).

Shows nip width in millimeter or inches.

DYNAMIC SENSOR BLADERoller nips in offset, especially newspaper

presses.

Shows nip width in DNU (Dynamic Nip Units).

SS 30001- STATIC SENSOR BLADEConverting nips with very low activation force.

Shows nip width in millimeter or inches.

Maximum pressure load: Static sensor blades 200 N/cm2. Dynamic sensor blade 15 N/cm2.

Roller Nips

8/10/2019 Nip Control 2011 6

28/31

Testimonials

8/10/2019 Nip Control 2011 6

29/31

Daily Print

Daily Print prints over 300.000 newspapers per day. The company has an older press with printingunits from three different suppliers. In 2004 the press was totally rebuilt into as new condition.Daily Print uses both the Roller Nip Indicator and the Pressure Indicator

Thomas Sandstrm, Technical & Production Managersays:

Our problem is and has been to achieve the same printquality in all the printing units.

We therefore purchased one of the first Pressure

Indicatorinstruments from Nip Control for checking of

cylinder nips.

The measuring instrument is of great help when we

control the print settings and explore other print technicalproblems.

We are very satisfied with the tool, and it is easy to

measure inside the printing units without removingblankets and underpackings.

Patrik Jonsson, printer and Anders Brnnstrm,

production leader and responsible for print

technology

Pressure Indicator Roller Nip Indicator

8/10/2019 Nip Control 2011 6

30/31

Nip UniversityIt is in the nip s that the core offset process takes place. This is w here

the rol lers, the ink , the fou ntain so lut ion , the plate, the blanket and f inal lythe paper meet determin ing pr in t qu ali ty and co st

Rolf Hansson, reponsible for printing

technology education at the University of

Dalarna, Sweden and printing consultant

Rolf Hansson Consulting executes full days educational sessions on nips.

The training include:

Theory and discussions

How to control nips

Testing on press

Evaluation and future steps

Peter Johansson. Segment Manager Strlfors AB withbusiness in seven countries and revenue of over500 million:

This introductory training plus support from staffmanagement on how to use the Pressure Indicator in

routine checking of cylinder nips as well as the status of the

blankets has been very positively received. The level of

knowledge has increased and more printers now are engaging

themselves in the steering and control of the printing process

on their own press.

Pressure IndicatorRoller Nip Indicator Nip University

http://www.stralfors.se/http://www.stralfors.se/

8/10/2019 Nip Control 2011 6

31/31

Introduction of measuring instrument Pressure Indicatorat Strlfors in Ljungby, Sweden in September 2010.Strlfors is owned by the Swedish/Danish Postal Services, with business in seven countries and revenues of over500 million.

Peter Johansson: Segment Manager for printing of business communication and the gambling industry states:

A requirement to be able to produce with high predictability and repeatability in a printing company is to ensure correct basic sett ings

of the pr int ing process.

To do so the measurement instruments, the Roller Nip Indicator (RNI) for roller nips and the Pressure Indicator (PI) for

measurements of t he pressure level of cy l inder nips, are of excel lent help.

Since a few years Strlfors Sv enska AB in L jung by uses the Roller Nip Indicator. The equipment in the printing facility mainly

consists of narrow w eb presses for direct mai l and business form s.

The exper ience given from being able to cont ro l ro l ler sett ings with th e RNI were so pos i t ive that we decided i t could be interest ing to

test i f also cyl inder sett ings and b lankets could be c ontro l led in a sim i lar way.

Before implementing the Pressure Indicator in the print shop a full days training was organized with Rolf Hansson Consultin g. The objective

was to ensure that all involved pressmen had sufficient basic knowledge before this new way of calibrating and controlling a printing process was

introduced. The focus was on the key parameters which can be controlled, as well the functionalities of the instrument. It was also important tofind a method of working which all pressmen can agree upon to be able to create a positive exchange of knowledge and experience between the

different shift and press teams.

The first half of the day was given to theory and discussions about the construction of a blanket and its function in the printing nip. A substantialamount of time was dedicated to the fact that blankets are designed differently, and thus will give show different printing properties, additionally

affected by the underpacking. The remainder of the first half of the day focused on the construction of the instrument and its role in superior

process control of the press. To be able to ensure high precision measurements, the instrument can be calibrated, and therefore a hands on

training on how to handle the calibration tool was included. During the afternoon the Pressure Indicator then was tested on press on differentpress types, the results were discussed and evaluated.

This introductory training plus support from staff management on how to use the Pressure Indicator in routine checking of cylinder nips as well

as the status of the blankets has been very positively received. The level of knowledge has increased and more printers now are engaging

themselves in the steering and control of the printing process on their own press.

Full statement

http://www.stralfors.se/