Deltabach sets the pace with LED UV retrofit by AMS

The improvement in productivity, which has seen output rise to a current rate of 36 million printed sheets per year, is the result of three key benefits of the AMS LED UV curing technology Deltabach Director, Marc de Jong explains below:

“When we introduced the B1 Heidelberg to replace a B2 press 5 years ago, we specified a standard delivery, but included a coater because it was an important element of our work – though it meant we had to run the press slower when coating. Since then the demand for coating has increased significantly, so we were losing productivity. With the AMS system we don’t need to coat, so we can run every job at up to 16,500 sheets per hour – that’s 20% faster.”

“Second, because the sheets printed with AMS LED UV curing are dry in the delivery they are ready for immediate printing on the reverse side and downstream processing. This means we can promise better turnaround times to our customers – even on the same day – and it has a major impact on our pressroom practice. Previously, on turn-and-tumble work, especially where uncoated or smooth papers were involved, the operator would output 8 plates because the job would have to wait – maybe overnight, or even longer – before the piles could be turned and put back through the press. Of course, then another 10 minutes would be lost in getting the settings back to the correct levels… now we just turn and go ahead. If you try to quantify that – it’s amazing. It also gives another dimension to our planning because the timings have become predictable.”

“And thirdly, by eliminating spray powder we not only make life easier on the press and in the bindery, we are increasing the production time available on the press,” continues Marc de Jong. “We used to take 3 hours at the end of each week to de-powder the press, and the same was true of a lot of the finishing machines, now that is no longer required it becomes more available production up-time. This all factors in to our bottom line. We also save as much as one more hour each day because the LED UV inks can stay in the ducts overnight, and even more time at the coating unit, where we used to have to change plates and clean up between different jobs.”

The impact of the changes on workflow is clearly visible in the Deltabach press hall where a large floor space is marked out into eight ‘lanes’. This was formerly the marshaling yard where pallets of print were held and shuffled as they waited to dry before turning and reverse printing, or moving to post-press. Now only two lanes are used as a buffer zone for print that is immediately ready for the next process, leaving plenty of free space for, possibly, the next press investment.

With as much as 70% of its business being with agencies, brokers and other printers, production efficiency is essential for Deltabach to protect its margins while keeping its prices competitive. The advantages of the AMS LED UV technology are helping win new business and Mr de Jong concludes, “The moment we saw the AMS LED UV solution in operation we were convinced that it was the right choice for us.