We love being a part of our clients’ big successes.
So we were thrilled when HP—who we’ve partnered with since 2011—asked us to install and commission their recently announced HP PageWide Advantage 2200 with Brilliant Ink for its European premiere at Hunkeler Innovationdays 2023.
Held this year at the Lucerne Exhibition Centre in Switzerland from February 27th to March 2nd, Hunkeler Innovationdays is an international event that brings together some of the highest-profile digital printing and finishing companies across the globe to showcase their innovations.
We had just twelve days to assemble, commission and test HP’s new inkjet press in time for the event’s start date. We faced our fair share of surprises along the way, but our experienced team of engineers rose to the occasion every time.
The Equipment Arrives and We Begin Assembly
The press was being shipped to the centre in Switzerland all the way from the HP factory in Corvallis, Oregon. Because of this, we’d planned for shipments to arrive in staggered deliveries across the first two days of the project.
The first batch of crates arrived on day one and contained many essential modules and parts—including the print engine module (PEM), turnbar module, passive web cooling module and the WCM electrical cabinet.
While we anticipated the arrival of the rest of the crates, we began to uncrate various modules and marked reference lines on the floor ready for us to begin assembly on day two.
More crates arrived the following morning, but a few were delayed by a cancelled flight. This would be a challenge, as the delayed shipment contained vital parts such as the dryer to web cooling module tunnel, electrical schematics, labels and more.
But this didn’t cause too much of a problem. We split our engineers into three teams so we could start assembling the press while unloading the shipments, with the first team unloading crates, the second uncrating and the third starting to assemble the press. We also sought to find alternative ideas and solutions to help us progress in the absence of the delayed parts.
Our assembly team started by aligning the PEM with the reference lines we’d drawn out the day before and levelling it. We then aligned the turnbar module, levelled it and anchored it to the PEM, and also secured the cooling module to the PEM.
Next, we located the ink distribution system (IDS) in its final position and connected it to the press. To finish off, we positioned both dryers within one to two meters of their final destination.
Thankfully, the delayed parts arrived the following morning. But we’d already made great progress despite their absence.
By the end of the third day, we had uncrated all remaining items, as well as positioned and connected the press side rack to the press, trammed and levelled the Hunkeler Unwinder UW8 to the turnbar infeed and fitted the tunnels from dryer one to dryer two and the door skins for both. We’d also already completed 90% of the wiring.
This put us in a good position to start integration on day four. But this is where things got a bit more challenging…
An Unforeseen Challenge Arises…
A few days into the project, we found out that the install media would be delayed until the following week.
This would have been a huge challenge—if we weren’t at an industrial print press trade stock show. Luckily, we were able to use media from the show for the printhead-to-paper spacing (PPS) and initial calibrations while we waited for the delayed shipment to arrive.
This meant we could progress as planned and remain ahead of schedule, so over the next few days were able to successfully carry out the installation and fully complete the wiring.
We started by aligning, tramming and levelling the Hunkeler Rewinder UW8 to the press outfeed and the Weko moisturizer between the press and rewind. We then fitted the web cooling module doors and safety switches, installed filler panels between electrical cabinets and connected the press side rack to the press.
After this, we verified and calibrated the load cells, threaded up the press and completed paper run. Finally, we began testing the new Hololens ahead of the event and started installing the label and logo to showcase HP’s incredible product.
A Final Test for the Team
Despite a small bump in the road earlier in the project, we were almost there… However, the project had one final surprise in store for us.
As we neared the end of our installation project, we found an issue with the exhaust ducting. And the parts we required wouldn’t be available for another two days—which would be too late. Once again, our team had to think on their feet.
We sourced ducting locally and fabricated our own reducers that could be integrated with the existing exhaust ducting. This meant we were able to complete the ducting of the dryer exhaust, web cooling module and aerosol in good time.
We then finished setting up the internet protocol camera (IPC), colour collaboration sensor and compute system and print arch-to-arch, arch-to-IPC and startup calibrations.
Finally, we tested and verified the Weko moisturizer and collected alignment stability and high-speed data.
To finish off, we printed at 800fpm! Once we did this, we knew we’d done our job right. This meant everything was set up and ready to go for the event.
Another Successful Project by IES
Some projects don’t make it easy. And no amount of planning can rule out unforeseen challenges along the way.
This is when having decades of experience handling complex, high-technology equipment becomes priceless. And because our team has seen it and done it all before, they know what to do in a tight spot.
Our team not only set up the press ahead of the event but also stayed on-site throughout the event to provide technical support, immediately solve any issues that might arise and keep the press operational.
This proved to be a rewarding and helpful addition, as an hour before doors opened, we needed to troubleshoot an incoming air pressure issue that could’ve potentially stopped the press from running during the show.
The show went off without a hitch thanks to our careful planning and ongoing support throughout. In fact, here’s what HP had to say about working with us:
“[IES] were instrumental in all facets of the show; installation, show support and also through the press de-install. We had a very tight delivery schedule with little room for error. We wouldn’t have been able to deliver our press on time without the efforts of [the] team. The professionalism and skill of [the] entire IES team were evident throughout the project.”
Install Complex Digital Printing Equipment With Confidence
We’ve been helping digital printing equipment manufacturers to install and commission complex digital printing equipment since 1991 and have close relationships with renowned OEMs across the globe.
For example, we’ve been HP’s strategic partner for the past twelve years and have recently completed the first-ever in-field installation of their PageWide Web Press T250 HD (achieving two world firsts in the process).
Our global turnkey service covers every step of your installation process, from site surveys and construction design management (CDM) to assembly and commissioning.
Learn more about our equipment moves and installation service for digital printing equipment here.
