Ironman™ Integral Web Cooling Process System - Megtec

IronmanIntegral Web Cooling Process SystemHigh Performance Commercial PrintingThe technical requirements production demands for web offset printers are constantly increasing. Moreand more printers are producing high quality work with lower grade paper and higher ink coverage.To maintain profitability, printing presses need to operate under optimum conditions – at maximumpossible print speed and with minimum paper waste. Ink coverage and diverse chemical makeup havebecome increasingly difficult to dry. Less expensive paper grades used by the printer to remain competitivelypriced also can present added challenges to the heatset drying process. Press speeds at or near maximumare essential. These factors, individually and in combination with each other, have generated the need fora better means of technically managing the drying and chilling process in web printing. The new IronmanIntegral Web Cooling Process system provides a solution to 3 major problems in high speed heatset printing:• Condensate on the chill rolls • Marking on downstream rollers • Smoke in the pressroomBy design, the Ironman handles the difficulties experienced in today’s heatset printing environment andenables the presses to run faster with trouble-free operation.The bottom line is process knowledge

IronmanIntegral Web Cooling Process SystemRobust steel rollers are driven, allowinguse of conventional rotary unions andbearings.Innovative silicone applicator with cooledrollers for even and low film weights.Web is turned through steering guide, passesinto the opposed rollers of the silicone anddirected to the chill stack unit.Performance Benefits ofIronman• Increase of production speedat difficult drying jobs• Increase of press up-time dueto higher speeds and reducedmaintenance time• Less maintenance for presscleaning• Better working conditions forpressmen due to a smoke-freepressroom area• Reduced silicone consumptiondue to improved uniformity ofapplication• Paper drying temperaturecan be lowered by typically10-15°C• Increased residual moisture inthe paper• Simple operation eliminatesoperator errors• Easy to use automatic processcontrol• Integrated web guide• PLC with diagnosticassistance and modem• Reduced floor space• Easy installationThe New Ironman• No Chill Roll condensate• No marking on downstream rollers• No Smoke to pressroom• Increased productivityWhat is it?The Ironman Integral Web andConditioning unit consists of an L-wraproller which turns the horizontal webdownwards by a 90° angle. This rollerhas a web guiding function and replacesconventional tilt-box design web guidesdownstream. Following the L-wrap roller,a highly innovative silicone applicationunit seals both sides of the web andincreases web moisture. The web thenpasses through a modular chill stackwhere it is cooled down to press roomtemperature. The number of rollersdepends upon the speed of the press.The Ironman has been conceived,developed, engineered and prototypetested using the full portfolio ofMEGTEC’s DFSS (Design for Six Sigma)tools. Customers around the worldhave been interviewed and the requiredquality and operational functions havebeen carefully incorporated into thedesign. MEGTEC’s experience overdecades and the stated requirementsof end-users and press manufacturerscompleted the basis for a precisespecification for the Ironman. Availabletechnology and components have beencarefully evaluated, and technology hasbeen developed as necessary to meetthe demands of today’s high speedheatset web offset printers.No Chill Roll CondensateThe dried web leaves the heatset dryertypically at 100-150°C before havingcontact with the chill roll. Smoke,condensate and marking of rollersare occasional unwelcome effectson production and are dependent onproduction speed, paper, ink, dryerperformance and adjustment.The evaporative cooling effect of theIronman’s innovative silicone applicationsystem, reduces the solvent vaporpressure that helps to create the gapbetween the web and chill surface.Additionally, the small roll diameter of7.5” (180 mm) of the Ironman chill rollsassists in minimizing the web “lift-off”as compared with traditionally largerdiameter chills.The Ironman rollers are not subject tothe troublesome level of condensationand thus they stay clean.Chill roll condensate is typically causedby the accumulation of solvent in theboundary layer between paper andchill roll. With the bigger diameter ofconventional chill rollers, the thicknessof the boundary layer is quite significantand this presents two physical problems:first the boundary layer resists heatflow from the web to the roller reducingthe desired web cooling, and second,the boundary layer constantly deliversa volume of air containing solventvapor such that an oil film develops bycondensation on the cold roller surface.If the chill roller surface is increasedto counter this, condensation may

Ironman process unit includes chilled L-wraprollers, steering guide and chilled siliconeapplicator with opposing rollers.Effective evaporative cooling and uniformsilicone application.A cool bead of silicone being applied to theweb by chilled applicator rollers.be reduced but the web is then notsufficiently cooled following the roller,often resulting in increased smokingin the room. Further, there is thena tendency for ink “picking” from thesurface of the printed web which is thendeposited on the roller surface.The Ironman’s small roll diameter of7.5” (180 mm) of the Ironman doesnot allow the creation of a sufficientlyhigh boundary layer at any speed orweb tension. In addition, the surfacetemperature of the L-wrap roller isprecisely controlled to maximize theweb cooling function while solving thecondensation/picking problem. The rollerstays clean from condensate that wouldotherwise cause web marking.No Smoke in the Press RoomConventional dryer/chill systemsallow the formation of visible aerosolscomprised of millions of tiny liquidspheres in the area approximately 0.5 m- 1.0 m after the dryer. The refraction anddiffraction of light through these particlescreates a “smoke effect”. The web exitingthe dryer is still appreciably hot and hasan evaporation rate that enables themoisture in the web to be turned intowater vapor. When that vapor exits theweb and hits the colder atmospheric air,it expands and cools rapidly, condensingto produce the aerosol particle.To counter this physical phenomenon,the web path to L-wrap roller of theIronman is kept very short – lessthan 300 mm - and is fully enclosed.Consequently, the L-wrap roller coolsdown the web before the aerosol creationcan take place.No Marking on RollersAs the web cools and is guided aroundchill rollers and path rollers, there can bea tendency to deposit ink on the surfaceof the rollers, especially rollers which donot turn in precision with the speed of theweb. This can be avoided by two means:elimination of sliding friction by matchingspeed of the roller surface to speed ofthe web, and by applying silicone to theweb to reduce friction. The Ironman usesboth methods in a unique way. The initialL-wrap roller is driven to match the webspeed and eliminate sliding friction. Theweb then passes through the siliconeapplicator that applies silicone fluid toreduce friction throughout the remainingweb path into and through the folder. Allof the chill rollers of Ironman are driven,thereby minimizing the friction betweenthe web and roller surface, thus allowingfor a minimal consumption of siliconewhile eliminating roller marking.Immediately after the first roller siliconeis applied on both sides of the web,protecting the surface and performanceof all rollers further down the path.Without silicone coating an unprotectedink film has a tendency to mark chills andespecially rollers which do not turn inprecision with the speed of the web. Toavoid ink marking the Ironman has drivenrollers; the first roll has a proprietarycoating and is temperature controlled.Robust DesignThe mechanically driven rollers ofthe Ironman allow the use of robustconventional bearings and rotary unions.Furthermore, the silicone applicator islocated further downstream from thefirst L-wrap cooling roller providing lowersilicone roll contact temperatures anddramatically reducing production ofairborne silicone. Less silicone in the airmeans less need to clean this area.The silicone applicator is sealed in ahousing which protects the environmentfrom silicone misting. No silicone mistcan be transported by the dryer into theoxidizer system where silicate could plugthe oxidizer’s heat exchange system.Evaporated water and silicone mistare immediately condensed on thechilled applicator rollers and flow backinto the silicone pans, keeping siliconeconsumption low and increasingmoisture in the web.The cooling feature of the siliconeapplication rollers is patent appliedand ensures that contact between weband roller always has a fluid film. Bymaintaining the fluid film, the rotationof the silicone rollers can be operatedin either direction without any build-upof ink on the roller even at very lowapplication rates.Both silicone applicator rolls always havea constant kiss angle which delivers veryuniform silicone application across theentire web width for all application ratesand at all web steering angles.

IronmanIntegral Web Cooling Process SystemAMERICASUnited StatesMEGTEC Systems, Inc.Telephone: +1-920-336-5715Toll-free: +1-800-558-2884Solvent Recovery DivisionMEGTEC Systems, Inc.Telephone: +1-772-567-1320BrazilMEGTEC Systems, Inc.Telephone: +55-19-3885-6116EUROPEFranceMEGTEC Systems SASTelephone: +33-1-69-89-4793United KingdomMEGTEC Systems, Ltd.Telephone: +44-1628-59-1700MEGTEC Environmental Ltd.Telephone: +44-1257-42-7070GermanySequa GmbH & Co.MEGTEC Systems KGTelephone: +49-6181-94040SwedenMEGTEC Systems ABTelephone: +46-31-65-7800MEGTEC Systems Amal ABTelephone: +46-532-62900ASIA-PACIFICSingaporeSingapore Sales Branch -MEGTEC Systems SASTelephone: +65-6298-4666ChinaMEGTEC Systems (Shanghai) Ltd.Telephone: +86-21-6769-7878Space Savings – Process IntegrationThe Ironman is available in combination with all series of MEGTEC dryers -- the Dual-Dry, Coanda Plusand MEGAIR Compact. By its compact design and process integration, the Ironman saves floor-space incomparison to a traditional dryer-chill-roll combination with tilt-box web guide and silicone applicator, whichoften require additional structure in the press.Web break detectors, colour density controls and load cells to measure web tension can be integrated intothe system. The chill stack drive is prepared to be integrated into the press drive concept. A MEGTECdrive solution is available upon request.Standard Features for IronmanMaximum web speedMaximum paper web widthsStandard paper weightConfigurationsWeb directionControl3540 fpm (18 m/s)965, 1475, 2060, 2380, 2860 mm30 – 150 g/m² (27- 250 g/m² on option)Horizontal, single or double webLeft hand or right hand configurationPLC with modemNumber of Chill Rolls 2 + 4 or 8 or 12Electrical powerNorms and safety400V/50Hz or 460V/60HzCE standards & U.S. and Canadian norms including UL/CSAIndiaMEGTEC Systems India Pvt. LtdTelephone: +91-20-3231-2877 (78)JapanMEGTEC Systems, Inc.Telephone: +81-78-783-0161AustraliaMEGTEC Systems Australia, Inc.Telephone: +61-3-9574-7450www.megtec.comJanuary 2008This document is not contractual. © MEGTEC®