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FLEXO Magazine : August 2010
Technologies & Techniques chambers that utilize automatic force loading systems will greatly extend the life of blades and end seals. In addi- tion, low blade detection systems will warn operators when to change these components preventing leaking and cleanup caused by over worn compo- nents. The design of the chamber itself can also significantly aid in reducing ink consumption. Having a low profile chamber with a large wet gap opening will provide ample time for the anilox cells to fill, allowing for higher density print while using as much as 20 percent less ink through the use of lower volume anilox screens. This is achieved by laying down a more consistent, thinner layer of ink, which, in turn, provides a higher measured and perceived color density. In addition, wash up ink con- sumption can be reduced to two gallons or less per deck wash by combining solvent saving systems and a high pres- sure reversing action on the pump. Power saving can also come in creative yet simple ways. Replacing standard on/off type devices with speed- compensated components will allow for significantly lower power consumption. Having an all electric, variable speed dryer system that ramps up in speed and temperature creates a truly efficient, low power usage system that consumes more than 30 percent less power. In addition, heat generated by motors can be reclaimed and ducted into the dryer system to conserve even more power. An Investment In UptIme Keeping your equipment running and productive is the key to staying profit- able. What is the use in reducing power consumption or waste if it is not ulti- mately affecting profitability in a positive way? The keyword here is “sustainable. ” Machine maintenance plays a large role in remaining profitable and sustain- able and an indirect role in power and waste reduction. The more time and effort spent on maintaining equipment, the more resources it consumes and the more it cuts into productivity. Like some of the topics covered above, what seems like trivial numbers can add up to signifi- cant savings. Presses that utilizes frameless motors and direct drive technology eliminate the need for couplings, gears, and belts, which eventually wear out and need replacement. Ink wash-up systems using peristaltic pumps only requires a simple tool-less hose replacement versus expensive and time consuming diaphragm pump rebuilds. Additionally, the power and maintenance require- ments for compressed air to run a diaphragm pump ink system far exceed that needed on a peristaltic system. Considering a press with an integrat- ed automatic drum wash-up system is another tremendous maintenance time saver. Having the ability to fully wash the surface of the drum with a push of a button, and in no more time than it takes to wash up the deck ink system, adds up to very significant times savings. In addi- tion, it eliminates an unsafe practice that operators go through quite frequently. RetURn on YoUR Investment When choosing to focus on being a more sustainable printer, there are many benefits new technology can offer you. Reducing total press power con- sumption by more than 30 percent from day one, and setting full press impres- sion and registration without any web moving, will add up to huge savings. When combined with low maintenance designs in the ink system and deck components and automatic features like drum wash-up and solvent savers, the return on investment for new equipment makes it hard to look the other way. For example, let’s estimate it takes no more than 45 minutes to do a manual cleaning, versus a typical 8 minute auto-wash. With only one wash-up per day, if we assume 350 days of operation per year, then manual cleaning would require 263 hours annually. Compare that to only 47 hours for an auto-wash system. That’s a difference of 216 hours! The major advantage to modern equipment that has saving features built-in is no programs or initiatives are required to realize the savings. The machine does it for you. All the features described above can easily add up to over $250,000 in savings per year over existing equipment or new equipment without these capabilities. n ABOUT THE AUTHOR: Jason Manders is product line application leader for Paper Converting Machine Co. (PCMC), Green Bay, WI. All the features and per- formance capabilities mentioned above are available on the new Fusion press offered by PCMC. www.flexography.org august 2010 FLeXO 37 FTA/FFTA is looking for industry professionals to serve at the highest level of leadership! The FTA Board of Directors & FFTA Board of Trustees are the chief elected bodies of the Association & Foundation. The Boards represent the members’ interest in the organization and hold ownership of the organizations on behalf of the membership. The Boards are the guardian of the organization’s assets, its policy setting body and advisor to the President. In general, it is the responsibility of the two Boards to: • Plan for the future of the organization • Write policies to set limits and define how the organization will operate • Monitor and evaluate outcomes of the business plan, organizational performance, Board policies, financial stability and outcomes of programs and services • Act as advocate for the organization and the programs and services offered If you’ve been an active member of FTA/FFTA committees, meetings programs, industry councils or project teams, why not consider stepping up to the next level of service...as a member of the governing boards of the FTA/FFTA. You’re sure to find the experience personally rewarding and professionally self-fulfilling! Interested? Contact Mark Cisternino email@example.com August2010_mech.indd 37 8/13/10 1:23 PM
Sustainable Summer 2010