We have considerable experience of Cerutti press service and Cerutti support, and also other rotogravure press control systems and press service particularly in security printing applications. We recently completed the recommissioning and reconfiguring of a Cerutti rotogravure press from security printing to label manufacturer. The Cerutti press was de-commissioned and dismantled from its original location in Melbourne to the new client location. We worked closely with the clients technicians and engineers in providing consultancy service to support the re-installation of the press at their site and then went to site to re-commission and complete FAT tests on the press.
The Cerutti press will ultimately be re-configured to allow the machine to run the clients process, the major differences are:
- Thinner substrate
- Narrower substrate
- Additional gravure units
- Addition of embossing and die cutting units
The re-installation required certain functional units to be removed, and the control system reconfigured. This required modifications to the four Siemens PLC’s, Siemens FM458 motion controller, Siemens Masterdrive Servo controllers and the Wonderware Intouch V9.5 HMI screens.
Budget restrictions did not allow a control systems upgrade, so the existing control system was modified which involved modification of Siemens Step 7, Siemens D7-SYS, Siemens Drives ES and Wonderware Windowmaker software packages, leveraging our expertise in control and automation systems design Control System Engineering
We also supplied an on-board control system monitoring and programming PC (CMS system) with full online access to all of the PLC’s, HMIs, Motion Controllers and Wonderware SCADA so that the system can be monitored and modified both locally and remotely. The principal challenge with this was the legacy nature of the control system major components presenting major challenges with current Windows compatibility. The CMS system is a key component in Cerutti press service tasks.
The Cerutti printing press also had numerous supporting units that required re-commissioning and / or reconfiguring:
- Vigitek print inspection system. Now serviced by Baldwin Baldwin Inspection
- Eltromat registration and viewing system BST-Eltomat
- NIRA LEL monitoring system Solutions – NIRA
- E&L web guide systems Web guiding systems
We created a comprehensive re-commissioning and FAT schedule which included rewind / unwind calibration, load cells calibration, safety device check, temperature sensor calibration, hazardous area design review, compliance checklist and dry / wet performance check.
The FAT testing and fingerprint test was completed within two weeks of powering the system up, and we are providing on-going site based and remote support to the client.
We are now working with the client in providing consultancy and support for the addition of several gravure units to the printing press, as well as some other specialist functional units. These all have self-contained orphan control systems that must synchronize to the main Electronic Line Shaft and communicate with the main control system for safety, control, indication and fault reporting purposes. We have decades of experience in complex motion control solutions and so this aspect will be seamless.
For any Cerutti press service or Cerutti support applications, or gravure printing re-configuration projects please do not hesitate to contact us. We can make improvements to your press to reduce make ready times, reduce downtime and provide integration for reporting and IoT strategies to support plant wise initiatives.
