Super Special Blade Clean 3G | Cleanprint

Special Blade Clean 3G

The Revolutionary NEW Special Blade Clean 3G

An Automated Inline Cleaning System for Ink Delivery Systems

Never remove your Anilox rolls for cleaning again

Your equipment will look like this when using CleanPrint’s Inline Cleaning System:

Your equipment will look like this when using CleanPrint’s Inline Cleaning System
This is Cutting Edge Technology that makes you money

Dirty ink delivery systems, anilox rolls, doctor blades, rubber rollers, ink chambers, ink pumps, due to poor cleaning methods and tight schedules cause:

  • Lost production time
  • Reduced revenue
  • Potential machinery damage
  • A poor printing result,
  • Wasted ink
  • Longer clean up times
  • Increased OH&S potential problems

Dirty Ink Cell problems – If the operator turns up the ink this leads to:

  • Excess ink use
  • Bleeding in print
  • Poor registration (failed barcodes, substandard print) Dirty rolls need more ink to do the same job
  • Ink spills which not only leads to waste but time to clean up

If the operator does not turn up the ink this can result in:

  • Scrapped product due to incomplete transfer of ink
  • Faded/Incorrect colour
  • Failed Barcodes
  • The operator turning up the pressure on the plate to maintain print quality which can result in weaker boxes, damaged plates and breakdowns
Solve these problems with Special Blade Clean 3G
and your approximate saving per converter is $20,000 per year

A six converter plant saves $120,000 per yearSpecial Blade Clean 3G an Automated Inline Cleaning System that deep cleans your ink delivery system in every rinse cycle
Typical Roll condition before using Special Blade Clean 3G - Magnified View. No LED lighting reflection
Typical Roll condition before using Special Blade Clean 3G – Magnified View. No LED lighting reflection
Roll after using Special Blade Clean 3G for 6 washes. Note LED lighting reflection in base of clean cell
Roll after using Special Blade Clean 3G for 6 washes. Note LED lighting reflection in base of clean cell

 

Typical dirty trays before using Special Blade Clean 3G

Typical dirty trays before using
Special Blade Clean 3G
Trays after using Special Blade Clean 3G. This will reduce maintenance shut-downs per week per converter from 4 hours to 3 hours
Trays after using Special Blade Clean 3G. This will reduce maintenance shut-downs p/ week p/converter from 4 hours to 3 hours
Screen grab from a video showing first wash, look how dirty the sprays, trays and rolls are.

Screen grab from a video showing first wash, look how dirty the sprays,
trays and rolls are.
after 2 months of normal operation, shows no hard ink lumps left that fracture blades score rubber rolls block and damage ink pumps
After 2 months of normal operation, shows no hard ink lumps left that fracture blades score rubber rolls block and damage ink pumps
Save money with CleanPrint’s Inline Cleaning System
Reduced Downtime             $???
Increased Production          $???
Quicker set-up                       $???
Improved reproduction – less rejected print       $???
Savings of approx $20,000 per converter per year in maintenance and ink cost
Less maintenance required, helps free up staff for other work
Generate more revenue with CleanPrint’s Inline Cleaning System
Each plant gains a conservative 60-90 min production per shift
This could mean an extra 5,000 – 10,000 boxes per shift
This means an extra $20,000 per (2 shift) day in increased revenue
(This figure is a conservative variable depending on your plant and could be a lot more)

WHERE ARE THE SAVINGS AND EFFICIENCIES?

Anilox rolls being clean achieves

  1. Full ink pick up so immediate ink transfer, reducing ink usage enabling light press printing (kiss printing), no print bleeding and reducing excessive build-up of ink on the equipment. This leads to maintenance/capital savings and reduction in product wastage
    Savings achieved:

    1. Ink wastage reduction 20 litres per machine per month at $5-$25/litre. Saving
      $400/machine/month
    2. Labour in cleaning up ink spills, 4 hours per month per machine $40/hr including all overheads
      $160/machine/month
    3. Correct print, so no wastage of product or return of product due to incorrect colour or bar code not reading etc. Value $$$
    4. No increasing pressure on the machine on the printing plate, so reduced damage to printing plates and damage to equipment due to pressure applied. Value $$$
  2. Reduction to elimination of manual anilox cleaning
    1. Reduced down time due to stoppages because of bad print results. Value cost of machine hours
      $200/month/machine
    2. Eliminated labour to clean the anilox rolls. Value cost of labour and materials
      $200/machine/month
  3. Reduction of replacement of anilox rolls
    1. Down time savings. Value $$$
    2. Capital cost of equipment. Value combined with replacement of chambers and lines due to corrosion $800/machine/month
  4. Reduction of ink pump repair and replacement
    1. Downtime $70/machine/month
    2. Capital cost and labour $200/machine/month
  5. Reduction of replacement of doctor blades and rubber rolls
    1. Ink corrodes if left on surfaces so keeping doctor blades clean of ink reduces corrosion.
      Value $$$
    2. Solid ink pieces fall between rubber rolls and anilox rolls scoring the rubber roll, this is eliminated.
      Value $$$
    3. Reduced down time – Value $$$
  6. Clean up times reduced or eliminated
    1. Trays are clean,
    2. Anilox rolls are clean,
    3. Chambers are clean,
    4. Ink pump and lines are clean – Value total save 36 minutes per shift $$$
  7. Set up times
    1. Due to complete rapid transfer of ink, change over from dark colours to light colours is immediate
    2. Due to reduction of rinse cycle, quicker set up if using the same anilox roll being rinsed –
      20 minutes per shift Value $$$
  8. Much improved graphics – Value $$$
  9. It is estimated that each plant will gain 1 hour production per shift once CleanPrint’s system and product has been installed and operators trained on the correct settings to run the machines with this system
    Value $$$$$$$$

All of these savings add up to $20K per month plus this allows more time for engineering staff to attend to other preventative maintenance, more volume and better quality production.

The extra production time will allow between 5000-10000 extra boxes per shift. This is an extra $20,000 revenue per day per plant

EXTRA PRODUCTION TIME PER SHIFT

  • Ink pump break downs can take 40 mins – 1 hour as they have to get the staff and the equipment (say 8-10 pumps/month reduced to 4-5 pumps)5 hours 40 shifts 7.5 minutes /shift
  • Reduction or replacement of doctor blades and rubber roles is very hard to estimate, down time and lost ink due to miniature fractures, time loss to replace doctor blades?? Time saved????
  • Reduction or replacement/refurbishment of anilox rolls and chambers $800/month Time saves 2 minutes/shift
  • Labour in cleaning ink spills per plant 12 hours per month at $40 per hour
    Time saving 15 minutes per shift
  • Correct print immediately, so no wastage during set up value?? Time savings 5 minutes per shift
  • Hugely reduces double rinses as it cleans first time every time Time saving 6 minutes a shift
  • Automatic Clean-up of internals. Reduces scheduled maintenance by 1 hour per machine per week
    Time savings – 36 minutes per shift
  • Sometimes set up times are dependent on the rinse cycle. (Lets estimate 5%). An average of 150 rinse cycles per shift with the average rinse time a minimum of 6 minutes. Our standard is 4 minutes –
    Time saving 15 minutes per shift

THAT IS ALREADY 86.5 MINUTES PER SHIFT SO 1 HOUR A SHIFT IS A FAIR ESTIMATE.

CleanPrint’s Inline Cleaning System saves money and increases revenue

Special Blade Clean 3G was last modified: October 28th, 2015 by websm