Since the retrofit of a Baldwin WebCatcher S14 was completed on its Goss M-600 web press in late 2010, Fortune Packaging Corporation, of Parañaque City, Philippines, has experienced substantial process improvements that positively impact productivity and reduce costs.
The WebCatcher S14 is a fully integrated automatic web catching system designed for all popular web offset presses and is distinguished by a very small footprint. It’s installed between the last printing unit and the heatset dryer.
“With the Baldwin WebCatcher S14, we have greatly reduced paper waste, downtime and machine stoppage while avoiding mechanical damage due to web breaks,”stated Rico Hostallero, engineering manager at Fortune Packaging Corporation. “Productivity is substantially increased as we are effectively running at full speed all the time.”
A built-in sensor monitors the web continuously during the printing process. It senses web breaks in the dryer and instantly activates the web catching system. If a web break occurs, the WebCatcher pulls the broken web from the printing unit before it has a chance to wrap around the cylinders and guides it to the floor in front of the dryer.
Costly, unproductive downtime – which can amount to anything between half an hour and two and a half hours following a web break – is restricted to an absolute minimum, and the press can resume production after only a very short delay.
“Baldwin was willing to design a specialized solution for us as we had tight space restrictions. We were very pleased with Baldwin’s solution as we avoided having to move the entire press in order to accommodate the web protection equipment,” remarked Hostallero.
Fortune Packaging needed a solution to a common problem – tight space restrictions. The space between the last printing unit and the dryer was not adequate for positioning new web protection equipment. Baldwin was able to design a specialized rail system so the WebCatcher could slide out of the way when the press operators needed to change plates or maintain the press units.
Another advantage Hostallero reports is more stability and higher efficiency during production and operation, even when running lesser quality paper stocks.
“Installation was quick and easy,” said Lee Chong, Baldwin’s representative on this project. “The mechanical/electrical installation was completed in two days and the Baldwin technician stayed an additional three days to commission the system and train the operators.”
Peter Tkachuk, VP sales and marketing, Baldwin Asia-Pacific, remarked, “Over the years Baldwin has retrofitted our web catchers on existing presses in Australia, New Zealand and Asia. New presses these days come complete with press security and safety with web catching devices and/or web severer protection. In all instances, this equipment has been very successful and proves to be extremely viable in cost justification by reducing and eliminating the damage and severe downtime caused by web breaks and wraps ups prevalent with the high speed presses of today.”
Web break sensor
The heart of this system, a DSA-2 sensor, is a patented, specially developed device that guarantees total reliability.
To compensate changes in the web width or movement of the web edge, two laser beams sense the edges continuously and actively adjust the position of the web break sensor.
Since the sensor position is always ideal in relation to the edge of the web, the sensors facilitate a lightning-fast reaction in an emergency situation.
Web breaks are detected before other web monitoring sensors have had a chance to sense a web break between the last printing unit and the chill roller.
The control electronics form the link between the sensor that detects the break and the mechanism that prevents a wrap-up. They control the sequence of all necessary actions. The electronic control components are clearly and logically arranged in a control cabinet.
The WebCatcher is incredibly easy to use. No manual intervention is necessary during operation. Even after a web break, only a few simple steps are needed to restart the press.
The third element of the WebCatcher is the catching system. It executes a technically precise response to a diagnosed web break, thereby catching the web securely and protecting the printing units. Since there is no mechanical connection to the press, it can be retrofitted without difficulty. This design also allows the upper web in a two-web configuration to be protected by a second web catching system.