KBA Metal Decorating
MetalStar 3
The new peak performance class in metal decorating
GB
MetalStar 3
Feeder / Sheet Registration
High-performance
DriveTronic feeder
Combining functionality and performance
 Stepless, continuous pile lift ensures a
constant height for sheet feeding
 Automatic feeder head height
compensation
 Double-sheet detectors both on the
feeder and at the infeed
 Suction-belt feed table with multichamber vacuum system
 Special sheet separating facility on the
suction-belt feed table
 Simple adaptation for scroll or
rectangular sheets
Prepared for 0.100 mm technology
The new peak performance class in metal decorating
The MetalStar 3 already incorporates the following equipment in its basic version
 DriveTronic high-performance feeder,
specially designed to handle scroll and
rectangular sheets
 Further improved high-precision
KunziMatic registration system
 Semi-automatic plate changers – plate
change in 60 seconds per unit
 New ErgoTronic console with
touchscreen functionality
 Lateral, circumferential and diagonal
register controlled from the console
2 | KBA MetalStar 3
 Unused inking units can be disengaged
 Internet-based remote diagnosis and
maintenance
 Plasma-coated blanket and impression
cylinders specifically for metal
decorating
 Fully automatic format setting
 Cloth-based blanket washing system
 Two-stage impression switching (plate/
blanket – blanket/impression cylinder)
Designed for high production speeds
 Specially designed guide elements for
scratch-free sheet transport
 Unit substructures cast in one piece for
minimum vibration
 Sheet travel sensors in each printing
unit
 Precision cylinder bearings, preloaded
for play-free running
 Specially developed gripper system to
avoid the risk of damage to the sheets
High-precision
KunziMatic
registration system
 Precise sheet alignment thanks to
the modified KunziMatic registration
system
 Intelligent feeding of the sheets from
the infeed to the first impression
cylinder by way of the VariSpeed drum
KBA MetalStar 3 | 3
Inking and Dampening
Make Ready
New inking unit
CleanTronic washing systems
 Even faster reaction thanks to the
shorter ink trains
 Unused inking units can be disengaged
 Ink-run up programs
 Differential drive of the dampening
forme roller to prevent hickeys; can be
switched during production from the
console
 Lateral oscillation
 Remote setting of the vibrator cycle
 Remote-controlled oscillation timing
adjustment
 Dampening duct roller speed follows
press speed on the basis of characteristic curves
 Automatic pre-dampening program
 Oscillating bridge roller running on the
dampening forme roller
 Ink train separation in case of press
stoppage
New intelligent washing systems for
significantly faster makeready
 Blanket washing with the fixed beam
of the standard CleanTronic system
(feeder side)
 Blanket or impression cylinder washing
with the swing-action beam of the
optional CleanTronic system
(delivery side)
 Simultaneous blanket and impression
cylinder washing with CleanTronic
Synchro (feeder and delivery side)
 Blanket washing from both sides with
CleanTronic Synchro
CleanTronic
CleanTronic
CleanTronic Synchro
- One fixed washing beam
- One swing-action
washing beam
- Two independent
washing beams
CleanTronic washing beams
DriveTronic SRW
(Simultaneous Roller Wash)
Modern multi-roller inking unit
Separate drive enables separate washing
of the ink rollers, also during
 Parallel blanket or impression cylinder
washing
Inking unit temperature control
4 | KBA MetalStar 3
Separate inking unit drive
KBA MetalStar 3 | 5
Plate Change
Coater
Plate change with
DriveTronic SPC
Anilox coater
Chamber blade system with laserengraved anilox roller. Remote
setting of both the printing
pressure and the lateral, circumferential and diagonal register
from the ErgoTronic console.
The pneumatic coating forme
clamping and tensioning is
accomplished without tools
at the press of a button.
Direct drives for the individual plate
cylinders replace the gears driven by
the press and enable parallel makeready
processes which were previously not
possible.
The makeready processes in the towers
and unit substructures can be treated
separately and started simultaneously.
Plate changes can be performed parallel
to blanket and/or impression cylinder
washing.
DriveTronic SPC, standing for
Simultaneous Plate Change, enables
parallel makeready processes as the
basis for ultra-fast makeready.
Available plate change systems
 SAPC
Semi-Automatic Plate Change
 FAPC
Fully Automatic Plate Change
 DriveTronic SPC
Simultaneous Plate Change
6 | KBA MetalStar 3
Changing times
 SAPC
60 seconds per unit
 FAPC
All printing units in 3:00 minutes
 DriveTronic SPC
All printing units in 1:15 minutes
The new Hi Flow
blade chamber
The chamber volume of the new Hi Flow
blade chamber has been reduced by
approx. 70%. The increased flow rate of
the coating serves to eliminate coating
starvation and reduces foaming.
KBA MetalStar 3 | 7
Integrated Systems
MetalStar 3
Triple box stacking unit
VacStack
SMS
Sheet Management
System
Automatic plate
change device
UV final cure
Ink agitator
DriveTronic
feeder
ErgoTronic
console
DensiTronic
UV interdeck dryer
CleanTronic
KunziMatic
registering system
Peak performance class
in metal decorating
8 | KBA MetalStar 3
KBA MetalStar 3 | 9
ErgoTronic Console
Quality Control
CIP3 interface
 Interface to transmit prepress data
to the press for presetting of the ink
profiles
 Order and system administration,
repro data for repeat jobs
DensiTronic Professional – colour quality control
DensiTronic Professional is a modern
measuring system for the online control
of the print quality. It can measure not
only colour densities in control strips but
also spectral and colormetric values in
the image. The DensiTronic Professional
system sensor combines a spectrometer
and a densitometer in one measuring
head. The colour corrections are calculated automatically and transferred to
the printing units.
The DensiTronic Professional saves time
in adjusting the printing press and is an
efficient tool for quality control.
DensiTronic Professional
measuring table
Windows®-based ErgoTronic console
 Touchscreen for ergonomic access to all
press functions
 Ink profile display on the console
 Integrated remote maintenance module
with Internet connection for remote
maintenance and software updates
Wallscreen
10 | KBA MetalStar 3
Console functions
 Job-based saving of all relevant press
parameters for repeat jobs
 Remote register adjustment
 Control of peripheral systems
 Job changeover program
 Maintenance display and printing of
maintenance checklists
 Generation and printing of pile dockets
 Display of CIP3 preview images
ErgoTronic ACR
(Automatic Camera Register)
 Special register marks and measuring
system with handheld measuring head
 Measurement by way of the printed register marks, processing of the measured
values, and calculation of the necessary
corrections for lateral, circumferential
and diagonal register settings
KBA MetalStar 3 | 11
Remote Maintenance
Boundless and convincing
A remote maintenance module is installed in the ErgoTronic console as
standard and provides a direct line to KBA-MetalPrint. Online diagnosis and
fault rectification gets your press back into production without delay.
Data security? No worries, as a remote maintenance link must always be
activated by the press user.
UV Dryers
Designed by KBA – manufactured by KBA –
service from KBA
UV final dryer
 Lamp output 160 W/cm
(option: 200W/cm)
 New reflector geometry reduces
energy consumption
Maintenance manager and spare parts catalogue
UV interdeck dryer
The maintenance manager integrated into the ErgoTronic console helps you to plan
necessary maintenance tasks and thus to ensure that your press is always in optimum
condition for production.
 Lamp output 160 W/cm
(option: 200 W/cm)
 Minimised distance between dryer
and substrate
 Blanket and impression cylinder
washing in standby mode
(CleanTronic UV)
An electronic spare parts catalogue is similarly implemented on the ErgoTronic console
and saves you time-consuming searches for the correct spare part.
12 | KBA MetalStar 3
 Full dryer control via the ErgoTronic
console
 Stepless adjustment of the lamp output
 Plug-in system for cooling water and
electrical connections
KBA MetalStar 3 | 13
Sheet Management System
Modular Stacker
SMS – Sheet Management System
Modular stacking concept
Modular sheet handling system
with facilities for
 Sheet inspection
 Reinsertion of sheets
 Waste sheet ejection
SMS Sheet Management System
Waste management and sheet inspection during job makeready and production
 Reliable and simple realisation of
damage-free waste sheet ejection
(aluminium or tinplate)
 The number of sheets to be ejected can
be programmed. The undamaged waste
sheets can be stacked separately for
later re-use.
14 | KBA MetalStar 3
 Damage-free ejection and reinsertion
of inspection sheets also at maximum
production speed
 Ejected good sheets can be removed
safely from the SMS
 Single-, double- or triple-box stacking
 Triple-box stacking: Box 1 for waste,
Boxes 2 and 3 for non-stop production
 Consequently, high productivity
 Automatic switching according to
production mode
 Automatic stack removal
 MagStack – magnetic overhead
transport system for the damage-free
stacking of tinplate and TFS sheets
VacStack – vacuum overhead transport
system for the damage-free stacking of
tinplate, TFS and aluminium sheets
 Automatic format setting (option)
 Extended roller conveyor as a storage
buffer (option)
 Roller conveyors with chain drive for
smooth, jerk-free transport (option)
This dynamic concept not only prevents damage at maximum production speeds, but also
achieves a drastic reduction in makeready times.
KBA MetalStar 3 | 15
Technical Data
MetalStar 3
At a glance
Maximum sheet size
1 000 x 1 200 mm
39.37” x 47.24”
510 x 710 mm
20.08” x 27.95”
0.12 – 0.40 mm
0.0047” x 0.0157”
1 095 x 1 220 x 0.4 mm
43.11” x 48.03” x 0.0157”
995 x 1 200 mm
39.17” x 47.24”
0.3 – 0.4 mm
0.0118” – 0.0158”
1 220 x 1 275 mm
48.03” x 50.20”
3 mm
0.118”
5 mm from edge of sheet
0.197” from edge of sheet
10 000 sheets/h
167 spm
Minimum sheet size standard
Sheet thickness standard
Size of printing plate
Maximum printing area
Plate thickness
Size of pre-bar blanket
Gripper margin
Print start
Maximum mechanical speed
(maximum printing speed depending upon print
shop conditions and ingoing material quality)
Standard power supply
400 V / 50 Hz, 3 phase
Maximum weight of feeder pile
3 500 kg
The listed data
applies to the
basic version of
the MetalStar 3
2-Colour
MetalStar 3
3-Colour
MetalStar 3
4-Colour
MetalStar 3
5-Colour
MetalStar 3
6-Colour
MetalStar 3
7-Colour
MetalStar 3
8-Colour
MetalStar 3
Machine length
without roller
conveyor
10 417 mm
410.1 ”
12 060 mm
474.8 ”
13 702 mm
539.4 ”
15 438 mm
607.8 ”
16 987 mm
668.8 ”
18 630 mm
733.5 ”
20 273 mm
798.1 ”
Total connected
load of machine
without dryers
99 KVA
116 KVA
132 KVA
150 KVA
166 KVA
183 KVA
199 KVA
601-45 (1114)
KBA-MetalPrint GmbH
Wernerstr. 119-129
70435 Stuttgart, Germany
Phone +49 711 699 71-0
Fax +49 711 699 71-670
[email protected]
www.kba-metalprint.com
© KBA-MetalPrint GmbH, Stuttgart. Some of the features and functions described in this brochure are options and can be added to
the basic design to provide customer-specific configurations. We reserve the right to modify design features and technical data.