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Centralised
Application Machinery
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MicroPOISE™
is a registered trademark of Security Foiling Limited.
Securigrafix® and Datafoil® are registered names
of Security Foiling Limited
Introducing the Crystal 640 SF Cylinder Press |
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Introduction
The Press is based on the proven technology of the letterpress
cylinder
process. This offers all the advantages of the ‘round
on flat’ stamping principle.
It is an ideal machine for stamping and embossing, using
the wide variety of
paper/board and foils available. Being a highly versatile
machine it is equally
capable of producing the finest detail work as it is of
producing large foiled
areas. The Press is also designed for the application
of holograms combining
high quality production with minimal waste levels.
Being part of the Blockfoil Group, Europe’s largest
trade hot foil blockers,
means that Security Foiling Limited presses have been
refined by continual
operator feedback to become what is now the most comprehensive
range of
foiling presses available.
The basis of the design is, reliability, ease of use,
quality of blocking and ease
of maintenance. Sophisticated, but simple to use, computer
controls allow the
Press to perform complex tasks without lengthy set up
procedures. Advanced
computer logic ensures that hologram registration is maintained
even when
operating at high speed. Precise control of the foil positioning
ensures
maximum utilization of expensive holographic foils.
Through many years of experience, in particular with the
hot foil blocking of
holograms, the Press has been uniquely designed for the
application of
holograms. Many features have been incorporated for ease
and efficiency of
operation. These include an adjustable height machine
bed, fast change foil
systems and computer controlled hologram registration.
During the entire build cycle there are four separate
test phases to ensure the
quality and reliability for which Security Foiling Limited
has become renowned.
Each individual process that goes into the construction
of the machine is fully
documented and checked. Customers are welcome to send
representatives to
our factory to monitor the machine build at all stages
in its production. The
Press is offered with a comprehensive installation and
training package.
Extended training can also be arranged at our UK facility. |
General
Description
The 640 SF (CRYSTAL) Security Press’ is designed
to apply
Holographic Hot Stamping Foil and non-Holographic Hot
Stamping Foil
on to sheets of Bank Note paper and other Security Papers.
The
components, performance and control mechanisms are described
in this
document and any authorized addendum to it. |
Base
Unit
The base unit is a Heidelberg KSD press. The best available
quality unit
is purchased at the time of order confirmation, before
a comprehensive
renovation and conversion is completed. Heidelberg manufactured
the
KSD press until 1980 and the exact year of manufacture
of the base
press being converted is only known at the time it is
purchased. |
Press
Conversion
The renovated Heidelberg KSD press is converted to a security
press in
stages as follows:
• Modifications to the renovated base unit
• Replacement bed assembly
• Foil control system
• Electrical system
• Control system
• Security press guarding system
The assembly of this unit uses newly manufactured components
which
are tested, reliable and of good quality. |
Modifications
to the renovated base unit
The renovated base unit undergoes several modifications
to the existing
castings to allow for the conversion of the base unit
into a hologram and
hot foil stamping security press. This operation does
not require any
additional components to be used. |
Replacement
bed assembly
The bed assembly replaces the existing bed and is a unique
design,
manufactured specifically for the Heidelberg KSD press
conversion. The
bed utilizes the latest in casting technology, creates
a casting which
performs exceptionally well under loaded running conditions
and
remains stable in both shape and size during operation.
The bed
benefits from having four individually heated honeycomb
sections, which
can be independently adjusted for height, enabling huge
savings to be
made on make ready times. Each heated honeycomb section
has four
temperature sensing points allowing for total control
of heat distribution
across the whole bed. The specially designed bed insulation
system
minimizes heat transfer from the heated sections to the
bed casting,
thus allowing the bed to be adjusted to closer tolerances.
Foil control system
The foil control system comprises a foil tray mounted
on the end of the
bed near to the cylinder which incorporates several dividing
plates which
position the foil in its correct position and also creates
a line tension for
the foil. 2 full width foil bars are located in the foil
tray. These have
location and tensioning collars fitted along the shaft
for optimum foil
control when applying registered holograms. The complete
foil tray
assembly is purpose built to suit the Heidelberg Press.
Foil movement is activated by the modular foil pull through
the unit
mounted on the opposite end of the bed to the foil tray.
This foil pullthrough
unit is built up of a combination of nip rollers, which
will
comprise upto 2 full width and upto 6 narrow width units.
The 6
individual narrow width units are mounted on a dovetail
bar and can be
positioned at any point across the width of the bed.
The nip rollers are turned by means of precision stepper
motors, which
can achieve a pull resolution of 0.1 mm which is essential
for accurate
application of registered holograms. A foil counter can
be set to monitor
the foil usage and, when exhausted, will automatically
stop the security
press. Foil pull velocity is automatically minimized for
optimum foil
control. A trash shaft mounted directly above the nip
rollers collects the
waste foil. This trash shaft utilizes a disposable foil
core, which makes
trash collection and disposal fast and efficient.
Electrical system
The electrical system uses internationally renowned Allen
Bradley
components. These are of the highest quality, available
worldwide and
used as an industry standard for electrical system components.
The electrical control hardware is located in an electrical
cabinet that
conforms to applicable CE standards and is located at
the end of the
machine. It contains the Programmable Logic Controller
(PLC) which is
the key component to the control of the security press.
The PLC has a
system of lights for its input and output signals which
provides a clear
display of the current status of the security press. This
is used for
straightforward faultfinding and maintenance. The remainder
of the
hardware components consist of electrical switches and
relays, plus the
transformers and the drive control unit. All hardware
components are
clearly defined in the comprehensive technical manual,
which
accompanies the security press. The electrical system
is designed to be
easily controlled using menu-driven screen displays.
Control System
The principal part of the control system is the Computer
Control Unit. It
provides a clear on-screen menu driven display which allows
settings to
be programmed for the various operations of the security
press. These
include
• Control message display: gives the current status
of the security press.
• Pre-set speed display: allows a pre-determined
speed to be entered.
• Bed plate temperatures: pre-set and constantly
displayed.
• Foil management parameters include (a) the setting
of up to 5 different lengths of foil pull (b) the number
of times each foil pull is required and (c) the foil start
quantity.
• Hologram package set-up screen: to adjust the parameters
for application of holograms.
• Engineering screen: to allow machine parameters
to be adjusted.
• Sheet detection mechanism: to automatically prevent
‘no-sheet’ processing and ‘double sheet’
processing.
• Fully controlled, pre-programmable production stop
cycle and security press running speeds: to ensure constant
quality. In addition to the main control station there
are two other control stations.
(i) The central control station: this controls
• Inching all foils
• Press speed increase
• Press speed decrease
• Press speed reset to pre-set speed
(ii) The paper feed station: this contains a counter that
records the number
of sheets delivered and an emergency stop button.
Guard System
The security press is fitted with guards throughout. This
includes metal
and Perspex guards, which protect the security press operator
from any
moving mechanical components and also any electrical components.
The guards are part of a fully interactive system, which
incorporates
mechanical and electrical interlocks. These prevent the
security press
from operating if all contacts are not made. The security
press will also
stop running if any of the guards are disturbed in any
way and a
message will be displayed on the main control station
to show the status
of the security press, including which guard is open.
The guards play a major part in the safety of the security
press, which is
paramount to the safety of the operator. In addition to
these features
there are a selection of emergency stop buttons placed
strategically
throughout the security press. The comprehensive manuals
supplied
with the security press give clear safety messages, which
must be noted
when being trained in operation of the security press.
Paper Handling
1. There is a fully adjustable stream feeder head incorporating
forward suckers, an air sheet separator and an air blast
for lifting sheets during the forward cycle.
2. All are fully adjustable to deal with different paper
types.
3. A pre-loader allows continuous paper feeding.
4. An automatic registration device ensures that the paper
is positioned correctly.
5. The cylinder is ground to high tolerances to give a
consistently high quality print finish.
6. Delivery grippers transfer the sheet to the delivery
conveyor, and then to the open delivery pile, allowing
full quality inspection whilst the press is running.
Foil Handling
1. The foil tray is made from 2mm passivated steel, with
an easy release lid to full access and positioning of
up to 14 foil rolls
2. The foil rolls are automatically kept under tension
from the maximum roll to an empty core.
3. The honeycomb form bed is made from high-grade cast
iron, machined and ground to high tolerances.
4. Heat transfer from the heater plate to the base is
minimized, saving energy as well as minimizing risk of
thermal distortion.
5. The foil rewinds are mounted at the end of the bed;
each foil rewind has a microprocessor control to allow
5 different pull lengths with up to 99 repeats of each
length per program.
6. A rotating bar rewinds the spent foil, which can then
be easily removed for disposal.
7.The speed of the foil is automatically minimized offering
excellent foil control and minimum foil wastage. |
Performance
Specification
Description of 640 SF (CRYSTAL) Security Press Performance
The 640 SF (CRYSTAL) Security Press’ is designed
to apply Holographic Hot
Stamping Foil and non-Holographic Hot Stamping Foil on
to sheets of tax
stamps, security papers, bank notes and general products
according to the
configuration of the press as detailed in the Technical
Specification.
Operating Speed
A maximum speed of 5000 sheets per hour would be possible
subject to all
other operating conditions and criteria being optimized.
The speed is
determined by
(a) the characteristics of the paper being processed and.
(b) the type of foil being applied.
Hologram Registration
The hologram registration system has a positional resolution
of +/- 0.1 mm.
When multiple impressions are made on one sheet, using
one foil rewind unit,
in a single pass, then only 1 of the holograms will be
placed within the given
tolerance. All other holograms will be dependent on the
tolerance of the image
position on the foil in relationship to the first image
registered. Therefore the
positional accuracy of the registered hologram images
in the foil is critical and
will affect the positional accuracy of features being
applied by the 640 SF
(CRYSTAL) Security Press.
Paper Characteristics
Size: Paper sizes from 125x150mm to 460x640mm can be processed.
Weight: Sheet thickness varying from 80 gsm to 180 gsm
can be processed.
Security Threads
The 640 SF (CRYSTAL) Security Press when applying holograms
can
accommodate security Threads in bank note paper. However,
holograms
should not be placed over the security thread. Attempts
to do so could
adversely affect the performance of the 640 SF (CRYSTAL)
Security Press and
the quality of the hologram being applied. |
Foil
Characteristics
Size
Narrow Width Foil Pull-Through Units: Foil can be processed
in rolls up to a maximum width of 100 mm. The maximum
diameter is 90 mm.
Full Width Foil Pull-Through Units: Foil can be processed
in rolls up to a maximum width of 640 mm. The maximum
diameter is 90 mm.
Foil Type
Polyester-based foils can be used which vary between 12
and 20 microns thick.
Layout
The Layout of the holograms on the paper being processed
must be within 20
mm of the edge of the paper. It must also comply with
any other requirements
in the Technical Specification. |
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Technical
Specification
Paper Handling
Maximum
Mechanical Speed 6000 impressions per hour
Maximum Sheet Size 460 x 640mm
Minimum Sheet Size 125 x 150mm
Maximum Stamping Area 440 x 620mm
Maximum Sheet Thickness 0.65mm
Minimum Grip Distance 10mm
Height of Feeder Pile 325mm
Height of Delivery Pile 450mm
Foil Handling
Maximum foil diameter 90 mm (approx. 1500ft @12 micron
depending on foil type)
Foil core size 25.4mm
Minimum distance between foil rolls 2mm
Number of foil rewinds Up to 2 full width Upto 6 narrow
width
Maximum foil roll width 800mm (full width units only)
100mm (Narrow width)
Number of Lengths per program 3
Number of pulls per length Up to 99
Pull Resolution 0.1mm
Hologram positional tolerance +/- 0.5mm
Hologram Registration Mark 5mm x 5mm Bi-directional
centered on image (recommended)
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Heating
Heat Zones 4
Temperature range 0-200 degrees centigrade
Temperature sensors 16
Adjustable Height Bed (Optional) +/- 0.3mm (0.6mm total)
Die height 6.35mm or 7.00mm versions available |
General
Dimensions approximate 1870mm(H) 1790mm(W) x 3720mm(L)
Weight (kg) 4000 kg (approx.)
Air Supply 5 bar (75 psi) of clean air
Machine power supply 3 phase neutral and earth connections
380 / 415 / 440 V
50/60 Hz
63 amps per phase
22 kW ma
Duty Cycle Continuously rated |
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