An eight colour printing machines rollers were damaged when an 8mm Allan key went through 6 cylinders damaging both plate and blanket cylinders. The cylinders were impossible to print on. The repair was needed immediately because the customers order book was extremely full.
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Conventional repair
- Remove rollers from machine by breaking machine into three stations, 5 days each station.
- Weld rollers, Grind back, Re-chrome, Re-grind
- Assemble rollers in machine
- Re Assemble stations
- Test print and adjust
- Time approx 4 weeks
- Estimated cost Approx $80000-$100000
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Selective Brush Plating Repair
- Mask area in situe
- Electroplate Copper
- Dress Back
- Cap with Nickel
- Time approx 6 days
- Cost Approx $25000
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This example shows that a considerable amount of savings in time and money can be achieved by using the brush plating method.
The repair was carried out by two people working 10-15 hours a day.
Test printing was carried out and a small amount of time was spent re-sizing a couple of low spots. Brush electroplating was the best method for this repair.
The work was carried out in situe, stopping expensive down time of 4 weeks and little stripping down was needed. The repair was started 1 day after the damage was reported.
Printing machines are one of the most accurate machines to work on.
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