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Controls Group Inc.
Single Width
 Direct
Injection has proven to be superior in accurately metering ink to the
printing zone. Injection systems meter ink on a volume basis to each zone
independent of the adjacent zones. Injection systems directly meter a
precise volume of ink to each printing zone. The open fountain blade
adjustment varies ink film thickness to meter ink. Injection systems enclose
the ink until it is metered directly to the ink ball. The enclosed ink
remains clean, dampener free and requires no emptying and cleaning of the
fountain after each press run.
Similar injector systems have been used for years on large-scale web presses
typically associated with newsprint. These systems require a significant
initial investment and do not readily meet the specific needs of the narrow
web commercial printer.
Unlike the existing Digital Injectors developed for use on double width
newsprint presses, this new system does not require the user to return
components to the factory for servicing. The basic package utilizes our
long-life piston/injector components driven by a simplified single motor
drive system. The injectors and drive system are modular and feature
components that are serviceable by the end user requiring limited mechanical
skills and simple hand tools.
A high level of accuracy has been designed into our components so that
zeroing of the system is not required for the life of the product. The
individual zone settings produce a high degree of repeatability regardless
of the level of training. The injector uses a linear drive that does not
rely on an “ink curve” typical with open fountains systems.
The injector system is made up
 of
modules each containing eight (8) zone injectors. The typical narrow web
press utilizes twenty-four (24) zones across the web. To accomplish this we
install three modules. The modules operated via a common drive system,
metering ink to each zone via individual zone hoses. Levers are supplied
with the base system to maintain simplicity. Once metered, the ink is
transferred to the original unit ink ball via the supplied distribution
head.
Each zone setting operates independently from its neighbor, regardless of
its setting from maximum to minimum flow. There exists no fountain zone
interaction across the web.
Injection systems do not utilize fountain levelers or agitators. The ink is
maintained in an enclosed pressurized supply system until metered directly
into the unit.
The system may be ordered in its simplest form utiliz ing
hand adjusted zone settings and then upgraded in stages to the full-featured
system as the needs of the printer evolve.
It may be upgraded at any time to include motorized adjustments with local
control, and/or Integrated into a fully automated remote control console
system with RIP setting capability.
As the system meters ink via volume and not film, the typical adjustments of
the ink ball to pick up roller are limited to “close enough to transfer ink
without roller collision”. Zero settings are not ever required of the system.
To zero a column the injector is placed at its minimum setting resulting in
no movement of the injector piston. Zero is achieved by the lack of ink
delivery to the specific zone. No blade verses ink ball gap are needed to
establish this zero setting.
As the injector meters ink via a pumping action each zone can achieve any
flow setting without
 interaction
from its neighbor. Precise settings across the web are possible without the
typical compromise due to physical limitations the fountain blade.
To accomplish a color change, the operator simply connects the new
pressurized ink supply to the inlet of the injector module and places the
system in the purge mode. Once the new color has been established at the
exit of the distribution head, the new color is ready to print.
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