Retrofit Solutions for W&H Printing Presses

High efficiency, top quality and maximum flexibility at low prices - the market demands highest performance from flexible packaging manufacturers. However, investing in new machinery is not always the best solution to meet these requirements. With our retrofit solutions, new functions or modules can be added to existing printing presses. The development of customer-specific special solutions is also one of our core competencies. This enables you to react to new challenges at any time.
Our retrofit solutions address individual needs, such as:

  • Quality improvement & monitoring
  • Industry 4.0
  • Process engineering
  • Energy saving
  • Cost reduction
  • Operator friendliness
  • Performance increase
  • Occupational safety

DOWNLOADS

Retrofits Solutions for Printing Presses
Drying Expert Consulting
Software Modules

CHOOSE FROM DIFFERENT RETROFIT SOLUTIONS FOR YOUR PRINTING MACHINE

Energy Monitoring

Printing presses consume large amounts of energy in form of electricity, heat (gas, thermo-oil, etc), compressed air and chill water.
Annual energy consumption can be tracked easily but it is difficult to track the actual consumption per print job.

BENEFITS

  • Our Energy Monitoring can help to monitor, control and reduce the energy consumption significantly

RETROFIT SCOPE

  • A summation current transformer in the electrical supply line to measure the electrical capacity
  • A turbine wheel flow meter in the gas supply line to measure the heating capacity
  • An ultrasonic flow meter and thermostat in the cooling water supply/return line to determine the cooling capacity
  • A volumetric flow meter in the air supply line to measure the compressed air
  • Job specific storage of all input parameters in PROCONTROL

INSTALLATION

Approx. 2–3 days

Drying Expert Consulting

Due to the increasing relevance of energy efficiency and the rapid advancement of technological development, there are many opportunities to improve energy efficiency and performance of your W&H printing machine.To help you identify the individual potential, W&H offers customized consultings by our drying experts.Each generation of printing machines has different savings potentials. These can be matched to individual customer needs such as reducing CO2 emissions, cost savings (e.g. through energy efficiency-related modifications) or increasing the autothermal operating hours of the Regenerative Thermal Oxidizer (RTO).

BENEFITS

  • Quick and easy initial consultation via video call
  • Identification of hidden potentials in your printing machine and drying system
  • Customized advice from our W&H drying experts
  • Individual solutions tailored to your requirements
  • Increased drying performance
  • Savings in energy and costs

SCOPE

  • Individual consultation
    Together we identify your individual needs and discuss possible improvements via video conference.
  • In-depth analysis
    Our experts will analyse your individual machine combined with your specific needs.
  • Advice on optimization
    Based on your individual requirements, you will receive recommendations for optimization from our experts.

INSTALLATION

Depending on effort

Ink cooling

High ink temperatures have a negative effect on the inking process and can cause „ghosting“ effects. In addition, high ink temperatures also increase the solvent evaporation (especially in rotogravure).

BENEFITS

  • 50% less evaporation at 30°C
  • Significant anti-ghosting effect
  • Integrated into the PROCONTROL (no additional recipe, no double-inputs)

RETROFIT SCOPE

  • Compact but powerful ink cooler/heat exchanger at each Turboclean unit
    (1.7 kW cooling power based on delta T=7°K)
  • Integrated into the ink cycle
  • Automatically washed with each cleaning cycle
  • Pre-conditioning of the ink possible (Temperature adjustment of the ink before the print job starts)
  • The heat exchanger will be installed on the pressure side of the return pump
  • Best possible cleaning results
  • No impact on diaphragm lifetime
  • The ink cooling will be integrated into the PROCONTROL operating and recipe system

INSTALLATION

Approx. 5 days

Independently driven Inking Rollers

Driven inking rollers allow an optimal inking of the cylinders. But different inks require different inking roller speeds for a perfect print result.

BENEFITS

  • Individual optimization of inking roller speed for special inks such as white or cold seal
  • Higher production speed if white or cold seal was limiting factor

RETROFIT SCOPE

  • Individual frequency converters for the inking roller of each print station
    (either at all stations or just dedicated ones)
  • Inking roller speeds can be separately adjusted on the PROCONTROL screen

INSTALLATION

Approx. 1.5 printing units per day +1 day for integration in PROCONTROL

Repeat length monitoring and control

Repeat Length Monitoring allows continuous measurement of the actual print repeat length during production and displays changes in print repeat length over time (trending). The repeat can also be manually corrected during production without register errors.

Optionally, our Repeat Length Control allows the continuous control of the repeat length and an automatic correction in case of any deviation.

BENEFITS

  • Repeat length correction during production, even at full speed
  • Consistent repeat length even with changes in substrate quality (e.g for breathable films)
  • Continuously high product quality

RETROFIT SCOPE

  • Repeat length deviations are measured through speed changes of format cylinders and draw units
  • Repeat length can be corrected by sequentially adjusted relative speeds between format cylinder and CI
  • Repeat length correction without register error
  • All drive corrections are synchronized to the printing deck positions around the CI
  • Full register quality even at max. speed!

INSTALLATION

Approx. 1 day (remote installation on request)

Insetter controller

The Windmöller & Hölscher insetter controller is used for register-true printing of a pre-printed web during a second web path. The process is predominantly used for printing flexible materials.

BENEFITS

  • Register-true printing on both sides of your substrate with the full range of printing colours on each side
  • The ability to change rolls at full speed while keeping the print in perfect register

RETROFIT SCOPE

  • Installation of a high-resolution, motor-adjustable sensor (3-colour LED technology)
  • Adaptation of the software

INSTALLATION

Approx. 4 days (including training)

Remote calibration of LEL-Sensors

Retrofitting LEL sensors for remote maintenance is much more convenient, saves time and results in significantly less downtime. Our W&H IDC experts are able to read out error and warning messages, perform a soft reset or calibrate the zero and calibration point remotely.

BENEFITS

  • Reduction of faults and unplanned machine downtimes
  • Increased availability of the printing machine

RETROFIT SCOPE

  • Exchange of LEL sensor with new hardware
  • PROCONTROL update to display an overview of current values, faults and warnings

INSTALLATION

Approx. 1–2 days

RGB LAB CHECK

System for relative color measurement and detection of deviations in ΔE, based on RGB sensor data.
Comprising of:

  • Trend display ΔE and ΔD
  • Visualization in LAB color space
  • Limit monitoring with alarm and warning function
Measuring spots can be freely selected (print design or control bars).

BENEFITS

  • Inline monitoring and detection of color deviations to guarantee consistent quality for your customers

REQUIREMENTS

  • VISION FULL and VISION CHECK

INSTALLATION

1 day (remote installation on request)

BARCODE CHECK

  • Statistical 1D barcode and 2D/QR code verification using the VISION ZOOM matrix camera
  • Real time code quality evaluation in accordance with ISO/IEC 15415 (2D codes) and 15416 (1D barcodes)
  • Roll and Job Protocol including barcode statistics

BENEFITS

  • Inline monitoring and reporting of barcodes to guarantee consistent quality for your customers

REQUIREMENTS

  • VISION ZOOM and VISION CHECK

INSTALLATION

1 day (remote installation on request)

PREVENTIVE MAINTENANCE

Advisor for upcoming maintenance work, integrated in PROCONTROL.

Detailed descriptions and advices for maintenance procedures, comprising of:

  • Safety relevant lubrication
  • Standard lubrication
  • Inspection of machine components
  • Cleaning of parts

BENEFITS

  • Less unplanned downtime – reliable production
  • Increased machine availability
  • Increased machine lifetime

INSTALLATION

Approx. 1 day (remote installation on request)

SOFTWARE MODULES

Increase your machine performance with optional software modules by W&H

Benefit from the possibility to increase production quality, machine availability or efficiency of your extrusion line or printing press even more easily. Direct online access to your machine allows you to add new features or connect to RUBY, the W&H IoT system, without requiring hardware or an on-site visit.

Using a secure internet connection, W&H specialists can connect directly to your machine and modify the software configuration. This enables the installation and commissioning of new features, e.g. RUBY, BARCODE CHECK, RGB-LAB CHECK and many more. After successful commissioning, W&H provides your machine operators with helpful information to efficiently use the newly installed functions.

BENEFITS

  • Latest software modules for your machine – no additional hardware needed
  • Easy installation via remote access to the machine
  • No need for a technician deployment on- site – no extra costs
  • Choose from different modules to increase your production quality, machine availability and efficiency

RUBY

Learn more about RUBY - the IoT system by W&H

Original Spare Parts

Learn more about Original Spare Parts

Customer Trainings

Deepen your knowledge of W&H machines and modules at one of our numerous Trainings