Hemlock Installs Heidelberg XL106 UV Press

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We are excited to share the installation process for our newest Heidelberg press – a Heidelberg XL106 UV Press to be specific. We’ll be publishing more information in the coming weeks about what this press can do and when you can get your projects on it, but check back here for regular updates on progress of the installation.

Jump to:
Week One
Week Two
Week Three
Week Four – no updates this week, sorry!
Week Five
Week Six – and installation is complete!

Check out the whole six weeks condensed into one minute:


June 3

Day One – While the process of getting this press to our plant began long ago, the parts from Heidelberg began to arrive this morning.


June 4

Day Two – The remaining printing units arrived today.

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June 5

Day Three – Here are the coater and mechanical/electrical cabinets waiting to be unloaded from our parking lot.

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June 6

Day Four – Today we received the largest single piece of the XL press: the 22′ foot long delivery system.

XL Delivery

Weighing 22,000 pounds, the workers from Heidelberg navigated the system up the centre aisle of our pressroom between our other, live presses.

Navigating XL delivery system

 

Business as usual on the 8 colour.

Business as usual on the 8 colour.

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Things got really interesting when it came time to turn the system 90 degrees to be in line with the printing units. The fantastic installers took their time and were very precise with this process. Here’s the process, sped up 400%:

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June 9

Day Seven – The chiller arrived and was installed on the roof of Hemlock. Jeff, Hemlock’s Senior VP of Manufacturing and Operations, came by the office on the weekend to capture this video of it happening:

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June 10

Day Eight – The start of week two! The big pieces have all arrived and now it’s just a matter of making all the right connections.

What the inside of a printing unit looks like.

What the inside of a printing unit looks like.

The tubes run through the scaffolding, down to the presses.

The tubes run through the scaffolding, down to the presses.

 

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June 11

Day Nine – more cabinetry arrived today, as well as the display console, which is in the wooden box at the front of this photo

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I found this fascinating as well! Look at at the little pieces that are necessary for this HUGE machine:

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That photo shows about one-third of the organization tray containing all the washers, screws and other little parts necessary for the XL106.

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June 13

Day Eleven – the display console has been unpacked

Display Console

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June 17

Day Fifteen – Coming into the plant on this Monday morning, marking week three of the XL Installation, I was greeted by towers of these crates

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I checked with Jeff, our Senior VP of Manufacturing and Operations, to see what we received over the weekend. He confirmed that we have received 13 crates containing a variety of products from catwalks and railings to electrical, air and vacuum components, and that we are expecting five more crates to arrive shortly.

I used the panorama function on my camera for the first time today to try and capture the whole press!

Panorama

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July 5

Day Thirty-Three – it’s been a while since we’ve updated, but the installation is still progressing along. We’ll begin test printing next week, so nearly all of the pieces are in place.

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As you can see, all of the cabinets have been installed, and our mechanical pipes have been connected.

Probably one of the last times we'll see Zero for the "impressions per hour"

Probably one of the last times we’ll see Zero for the “impressions per hour”

Each printing unit has its own LCD display.

Each printing unit has its own LCD display.

Each printing unit also has its own ink agitator. We'll have more technical information available in the coming weeks, but this is one different compenent required for UV ink compared to traditional lithography.

Each printing unit also has its own ink agitator. We’ll have more technical information available in the coming weeks, but this is one different compenent required for UV ink compared to traditional lithography.

While there are many fewer boxes this week compared to our last update, we're not all unpacked yet!

While there are many fewer boxes this week compared to our last update, we’re not all unpacked yet!

This side of the press is much less interesting, but the myriad of copper pipes reminded me of this scene from Willy Wonka.

This side of the press is much less interesting, but the myriad of copper pipes reminded me of this scene from Willy Wonka.

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July 15

Day Forty Three – That’s it! Installation is complete! We are currently working with Heidelberg for training and live jobs will begin on the press in the next few weeks.

There will still be more goodies coming your way to do with the XL106, but in the meantime, here are some photos of the completed installation – probably the last time the press will ever be this clean.

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