When was the machine launched and what market is aimed at? The KBA Genius first appeared at Drupa 2004 and the German manufacturer added a UV fitment to the waterless B3 short-run press a year later. The machine was first pitched at the packaging and coldset sectors as an alternative to screen print on plastic film, but the addition of UV technology meant it could also be used to print loyalty and business cards, as well as standard board work. In April of this year, KBA unveiled a changeable-blade chamber system for the press that, it says, can reduce set-up times by up to one-third.

How does it work? Being waterless and rollerless, many of the tasks associated with conventional offset printing have been eliminated. For example, there’s no need to adjust the ink zones, damping units and roller inking units, and you don’t have to control the ink-water equilibrium. When waterless technology first appeared, it received mixed reviews. However, Mark Nixon, executive sales director of sheetfed presses at KBA UK, says the Genius has stood the test of time because unlike rival waterless presses, which were modifications of existing machines, KBA’s waterless technology was built from scratch.

What’s its USP? The Genius is one of currently only a handful of waterless presses available on the market. It stands out as its four or five units sit in a V-shape formation around a fourfold central impression cylinder, which means the substrate doesn’t have to travel through a set of transfer grippers. "What this does is ensure an accurate register – the old adage ‘the fewer moving parts the better’ certainly applies here," says Nixon.

What benefits does the new changeable-blade system give? Nixon says he has seen, on average, makeready times reduced by 30%-40% when the changeable blade system is used. This saving is down to the fact that ink no longer has to be removed from the blade chamber with a spatula while the machine is sitting idle. Once used, the blade chamber is instead simply levered out of the press and replaced with a clean one. The used chamber goes into a washing box offline, which cleans the ink off ready for its next use. In its closed state, the new chamber system can hold more ink than before, and ink can be refilled on the fly, saving more time. "Generally, we would specify a spare chamber for every unit, but there’s no rule to that," says Nixon. "If the fifth colour is the only one that changes, then you would only need one spare chamber." It’s also worth noting that the changeable blade system is retrofittable to existing Genius models.

How flexible is the Genius and what’s the quality like? Running at up to 8,000 sheets per hour with a 360x520mm max sheet size, the Genius handles a variety of plastics including PVC, PC, PS, ABS and PET. Nixon says it’s of great benefit that the press is "up to colour" by the sixth sheet, given the cost of substrates. "A single plastic sheet can cost around 75p. If you use these sheets on a standard press with a makeready of 150 sheets, it’s clearly going to prove extremely expensive over time." Quality is maintained by the fact that the anilox roller, blanket plate cylinder and printing cylinder all have exactly the same diameter, which eliminates the possibility of ghosting.

What level of service and support can printers expect? Nixon describes the Genius as a "very trainable product", and most operators are up to speed in a fortnight. Should anything go wrong with the press, KBA has a significant number of spares at its Watford base, while 23 engineers are on hand around the country – three or four of whom are from Germany. "We always have a few German engineers over here, they bring with them the most up-to-date expertise and factory knowledge," Nixon explains.

How much does it cost and is there a sales target? Prices can vary considerably depending on specification, but the most basic configuration will set you back around £450,000. In what is a relatively niche market, KBA sells on average, a couple of the machines into the UK market every year. No models with the new changeable blade system have been sold yet, but Nixon is hopeful that will change soon.

SPECIFICATIONS
Max sheet size 360x520mm
Min sheet size 210x297mm
Max speed
8,000sph
Substrates
Plastics, carton and paper from 0.1-0.8mm
Units
Four (five optional)
Plate change
Semi-automatic
Price
From £450,000
Contact
KBA UK 01923 699535

ALTERNATIVES
Heidelberg Speedmaster SM 52 Anicolor
Heidelberg’s Anicolor B3 press comes with an inter-deck drying capability and UV is optional. Configurations are flexible and it handles stocks from 0.03mm up to 0.6mm cardboard. It can be speedily changed over from process to spot colours, including opaque white, and can be run with or without water.
Max sheet size 370x520mm
Min sheet size 105x145mm
Max speed 15,000sph
Substrates Paper, plastics,metallised board, lenticular
Price from £473,275 (four colour)
Contact Heidelberg UK 0844 892 2010 www.uk.heidelberg.com

Presstek 52DI
Presstek says its 52DI enables print jobs to go from digital file to sellable colour in 10 minutes. It supports 300lpi and FM screening on a broad range of substrates. A central impression cylinder and single gripper system keeps registration precise and makeready waste to a minimum. An aqueous coater and UV are both optional.
Max sheet size 520x375mm
Min sheet size 110x100mm
Max speed 10,000sph
Substrates any stock from 0.06-0.5mm
Price £319,000
Contact Presstek Europe 020 8745 8000 www.presstek.com