Keep extruding high quality coding standards while achieving 35 percent savings with CCS3100

Industry: Leading manufacturers of cables & wires, with over 25 manufacturing facilities located across the state of Gujarat, Maharashtra , Uttarakhand & Daman & Diu

Reasons for choosing CCS3100: 

Big saving: CCS3100 with 50micron nozzle print head consumes 35% less ink & solvent than 70 micron nozzle used by customer earlier. 50micron nozzle allows customer to print at tighter dimensional tolerances. 

High Production Efficiency: After rigorous testing on the customer substrate, the customer was advised to use specialised dye & pigment based ink to achieve best ink adhesion. They had previously faced production losses and material loss due to mirror printing. 

Reliability: Frequent nozzle cleaning by operators due to contamination in typically run 24/7 extrusion lines result in production losses. The CCS3100,  a true specialist in the wire industry, proven to be a reliable production partner that doesn't require frequent cleaning.

Print Accuracy:  CCS3100 can code easily on small cable sizes with a diameter of 0.5mm and prints high-quality codes on curved surfaces. The inks that adhere to the substrates are strong enough to withstand any environmental changes.

Inks for various substrate: For the cable & wire industries, KGK has a wide variety of dye and pigment-based inks.

Key benefits of CCS3100:

Operational efficiency : KGK patented Nozzle Capping Technology close the print nozzle when the printer is not in use. This prevents Ink from drying and frequent line clogging. CCS3100 ensure 24x7 non-stop production with no clogging, no cleaning, simply smooth printing.

Trusted Metre Marking: In-built metre marking software is used by the CCS3100 to mark accurately at the right intervals during variable line speeds.  The KGK Jet reliable metre marking solution is built to measure cable length by utilizing encoder signals.

Faster start : Auto start-stop feature designed to auto maintain and schedule start the machine immediately even if machine is not operated for very long time. This feature minimises servicing needs at the same time as reducing consumable use, results in high uptime and a low cost of ownership.

Positive Air Pressure Protection: Air pressure guards against splashback ink buildup in the print head and prevents breakdown by blocking dust and humidity from entering the print head.

Key Reasons for Choosing KGK Jet: 

• KGK Pan India installation & team in-depth knowledge of the industry.
• Ink manufacturing facility in India for product pre or post-sales support. 
• Integrating KGK solution without disturbing existing production line. 
• Quick & proficient service team who responds to 24x7 customer queries.  
• Our Japanese DNA for continuous research & improvement of product & services. 

Challenges & Opportunities: 

Non-Stop Production: The extruder lines are operational at a minimum of eight hours a day, six days a week in a single shift. It is vital for coding machine to complement the production. 

Pre & post manufacturing challenge: Cable production environment has temperature fluctuation, dusty & high moisture. Coding machine should perform flawlessly without disturbing production schedule. Due to composition of substrate plasticizer (sweating), PVC insulation leaves oil on surface compromising coding.

Mirror Printing: The cable was rolled in large bobbins after being printed using a CIJ machine, but there were chances of mirror printing or ink transfer due to poor ink adhesion to other cables, resulting in losses.

Matching variable speed: Extruder can produce various size cable with different speed which need to synchronized using encoder. 

Metre Marking Software: The process of meter marking on the cable is very important, and if the meter marking is incorrect, the customer will experience monitoring losses due to the high cost of the conductor.

Objectives: 

• Understanding customer production and suggesting KGK products in an already established production line with minimal modifications. 
• Accurate & reliable coding needed on various substrates such as PVC, PE, XLPE.
• The cost of ownership is low because of savings on consumables and eliminating production losses.