Cartridge type Cylinder and Ink loading

Cartridge type loading of Feed Rolls

Distributed Control Panel

Split able in to two machines

Universally reversible for both side printing

Servo-controlled registration and web-alignment

      The basic design is made from the point of view of machine-operator and is user friendly. The print view and inspection is made easy by providing peculiar window for that purpose. Oil-dipped worm gear box for the transmission makes the machine run smoothly and silently. The air circulation through silent blowers makes the efficiency of the print drying faster and with less pressure on the substrate, reduced noise, and less electrical power.

    The initial tasks like loading of cylinders, loading of rolls, register synchronization are made easy through new mechanisms. Once printed cylinders can be reloaded and printed with out going through much of the register synchronization tasks and avoids wastage of substrate.

Cartridge Loading of Print Cylinder Inking System

    It is an altogether new idea and bold introduction to the printing machine. The cylinders (printing block) is normally mounted on the machine inside the printing unit. For mounting cylinders normally a shaft is used or a shaftless corn mechanism is used. For both this the operator has to carry the cylinder varying about 10 kg to 25 kg inside the machine which carry a lot of risk of damaging the cylinder. The unloading and loading of printing cylinder in the machine usually takes above 15 to 30 minutes for each colour. The job changing requires printing cylinder to be cleaned before unmounting and the inking system has replenished or change before unmounting the cylinder. These operations takes up a lot of time leaving the machine idle for considerable time.

     In Thaimadam machines most of the job changing operations are done outside machine while the printing machine is running. The cylinders are loaded on the shaft and mounted on the cartridge. The required ink is then filled in the tray of cartridge. And thus the cartridge is made ready for mounting on the machine even while the previous job is running on the machine. When the job is finished the finished cartridge is unmounted by slipping out the used cartridge and the new job cartridge is  mounted on the machine by pushing inside. For job changing of the colour the idle time required for the machine is less than 5 minutes. The cleaning of finished job is done outside the machine while the new job is running on. The cylinder is cleaned and the ink is drained to the tanks and the cartridge is clean to the accept the next job, outside the machine. This new technology safeguard the security of printing cylinder and eliminate the risk carrying heavy cylinder inside the machine. For a six colour job change Thaimadam machines - Six Colour printing machine requires only less than 10 minutes. This saves considerable idle time of investment and boost up production when compared to other machines.

Cartridge Loading of Feed Rolls

    Feed rolls are usually heavy and occasionally is very difficult to mount on the normal machine. The mounting operation is done by either fixing on a shaft or on mounting shaft less holds. Both this operation requires lifting of the rolls and carrying on to the machine. For heavy rolls having more than 100 kg this operation is nightmare for the operators.  But in Thaimadam Machines this operation is made simple.  The mounting shaft is fixed to the core of the rolls and is mounted on the mounting cartridge at the place specified for the purpose away from the machine. Hydrolic jack mechanism or Chain pulley mechanism can be provided for lifting up the heavy rolls to place on the cartridge. Then the cartridge is carried to the machine on its wheels and slip inside the machine to fix it on the machine.

Insert ability to feed rolls in between printing units

    Each printing unit is having a separate roll feed mounting rails, placed just before the printing unit. Thus a normal Thaimadam Machines with six colour printing capability is having six feeding stations. This facility reduces the substrate length considerably and their by reduce the probable wastage. Even while the printing operation is going on, next feed roll can be mounted on the feed cartridge and made ready on the available nearest feed stations. When the running roll is finished the machine need be stopped only for seconds to start the next roll and get running. This mechanism reduces the idle time on the printing machine, for roll change. This type of feed mechanism helps to split the machine to act as two machines.

Split ability of the machine

    Thaimadam printing machine can be split into two to act as two separate printing machines. Thus on a six colours printing machine we can do either a single colour and a five colour job simultaneously OR a two colour and four colour job OR two three colour jobs simultaneously. The splitting operation is made very simple and requires only few minutes to make the machine ready for doing two print jobs and viz. This enable the machine to give double output.

Universal Reversibility

    The machine is universally reversible to print on both side of the printing format. To print on Poly film tubes to make poly bags both side printing is necessary. The Cross-Bar Flim Reversing Mechanism twist the format to the other face enabling the the other face printing and it is easily movable in between printing units . The adjustments to reverse the machine convenient to print on both sides is well designed so that the operation will take only very little time.

Unique Viewing Window

    In the conventional machines, the operator has to sit down and look upwards the leaning inside the machine to get a view of the printed format or the doctor blade assembly if anything goes wrong the operator has to face a lot of troubles to get a clear picture of this situation. Almost all the upper area constituting drying chamber is enclosed and cannot see inside of the machine. This problem is completely eliminated in Thaimadam Machines.

    The design of the printing machine is made in such a way to provide a unique viewing window for the operator for inspection of the printing operation. The front portion of the drying chamber is opened up as a window and is protected by glass. The glass faced window provide easy view of the complete printing process at the same time protect hazardous solvent vapor. This enable the clear view of doctor blade assembly, impression rollers and the printed substrate inside the window is adequately lighted up so that the printing image is clearly visible to scrutinized its colour and print registers. This protects the operator from the hazardous vapor of ink and solvent. The appearance of the machine is made simple and elegant by the cylinder. The control panel is placed immediately  near to the viewing window, the operation and necessary correction can be done while viewing through the window.

 Distributed Control Panel

    In normal machines the electrical controls of different drives are placed on a control panel which is separated from the machine and placed and the back of the operator side. The Rotogravure Printing Machine are very long in size, the operator has to come to the control panel for every operation of the control like on /off drives to boost up its power and down and the likewise operations. Similarly on emergency the operator has to run to the control panel to take immediate action. In Thaimadam Machine, the control panel is distributed through each printing unit and winding station. Almost all operations can be done from any control panel because clone switches are given for almost all operations. The operator can do any operation from any point where the operator is standing just by a stretch of hand.

    The built-in distributed control panels are extremely comfortable for the operators. Almost all the basic operations on run-time can be done from any of the panel attached to each printing units. The operator can on / off any drive like winding drive, main-drive, dryer-air-circulators, lights etc., increase / decrease the winding torque, speed of main-drive etc., adjust web alignment etc., from any control panel. Power distribution is from very safe buss-bars supported by high quality MCB and circuit terminators. The electrical equipment like dimmer state, rectifiers etc. are isolated from machine and are enclosed in separate cabin placed suitably away from operation side. Necessary pilot lamps are provided so that the status of the machine and switches can be ascertained at any point of time.

Register Synchronization:

    The register synchronization (Calendaring) is done by motor drives. Feather touch push button switches for that purpose is very comfortably placed in each of the control panel. Actuate register can be easily attained and maintained with out much efforts for the operator.

Micro processor Controlled Automatic Register Controls are available as optional attachment. This eliminates the viewing error at high speed printing and assures the accurate register of all colours resulting very high quality print out put.

General specifications

Electrical specifications of the available sizes

All drive motors are three-phase AC motors with Variable Frequency Dive

Optional Attachments :        

1.        Web Tension Controller :    Micro processor controlled Web Tension Controller  is typical attachment for accurate maintenance  of print registration. Irrespective of the the feed roll size the tension of the web will be maintained uniformly through out printing session using electronic tension sensors. Micro computer based electronic system assure the accuracy of the operation. 

2.        Web Aligner :    The attachment can be mounted at the feed section and/or at the winding section. If attached at the feed section, it will assure the alignment of the feed rolls even if the feed roll is slipped or is not properly wound for use in printing machines. One edge of the feed film is sensed by air sensors (pneumatically) or by electronic light sensors and the feed roll is aligned and adjusted to the main web line. If it is fitted to the winding section, it will assure the perfect wound rolls in the out put, even if the feed rolls are defective in winding, or if some operational mistake occurred so that it may vitiates the  proper winding. It will help the subsequent use of the printed rolls in automatic packing machines.

3.        Additional Cylinder Cadridges :    It will help to increase the production by saving job changing time. Since the ink and cylinder are provided in the Cadridge, pre-loaded Cadridge will reduce the change over time considerably.

4.        Additional Feed Trolley :    It will help to increase the production by saving feed roll changing time. The feed rolls can be  pre-loaded on the Trolley and quick change over of Trolley will reduce the changing  time considerably.

5.        Micro processor Controlled Automatic Register Controls are available as optional accessory. This eliminates the viewing error at high speed printing and assures the accurate register of all colours resulting very high quality print out put.