Hydrair Limited Product Presentation May 2010 1

Automatic ink supply systems

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• Web-offset presses• Sheet-fed presses

Summary

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• Hydrair

highlights• Air operated piston pumps• Hydraulic piston pumps• Rams (pump lifts & inductors) • UV & EB

ink pumps and rams• Ink storage systems• Ink distribution (pipelines & fittings)• System components• Spreader bars and ink sensors• Ink control systems• Installation layout• Reference projects• Hydrair

service• The Samoa Group

Hydrair

highlights

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•

Since 1954

Hydrair

has manufactured equipment and designed & installed systems for the printing industry.

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In 1969

Hydrair

installed its first multi colour

ink supply system in a high speed press.

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Hydrair

is one of the world’s leading manufacturers of ink pumping equipment and associated control systems.

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In Hydrair’s

UK home market, Hydrair

have provided the ink supply system for almost all major newspaper presses.

• Products are manufactured in Droitwich, United Kingdom.

•

Turn-key organization (design, development, manufacturing, delivery, installation, commissioning, maintenance, repair, expansion and upgrades.)

• High quality products and specially designed systems.

• Hydrair

is part of the Samoa Group.

Air operated piston pumps

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Hydrair

pumps lead the competition in technology and innovation and are specifically designed to pump today’s high viscosity inks at high flow rates

Air operated piston pumpsAir motor

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• Precision spool valve•

Generously dimensioned air exhaust port to avoid icing•

Designed for efficient thermal expansion• Highly effective muffler•

High performance air motors manufactured with high quality materials

Air operated piston pumpsWet ends

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Divorced pump design prevents cross-contamination

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Special pump cup design prevents ink leaks

• Different check valves available:- Chop check valve (special design for inks)- Disc check valves- Ball check valves

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Special seals for the increased abrasion resistance required when working with ink

Air operated piston pumps

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• Double acting, positive displacement pumps

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Very robust modular design air motors. Interchangeable pump end

assemblies provide variable ink pressure and flow rate combinations

• Air motor piston diameters from 4-1/4″

up to 16″

(3 x 10″)

• Pump pressure ratio range from 3:1 up to 23:1

• Pump delivery range from 160 cc/cycle up to 3,275 cc/cycle

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High quality carbon steel wet end. Available in stainless steel

on demand

• Highly reliable pump seals specially designed for offset inks

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Different pump valve design: ball check, disc check and chop check (exclusive Hydrair

design)

Air operated piston pumps

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• High performance pumps:- Delivery per stroke up to 3,275 cc- Pressure ratio up to 23:1- Pump speed range: from 5 to 10 cycles per minute

• Minimum maintenance

• Reduced downtime

• Reduced spare parts cost over the pumps lifetime

• High corrosion and abrasion resistance

• No ink leaks at the pump cup

• Easy and accessible installation

• Models available for UV inks

Air operated piston pumpsPump models, pump ratios and capacities

4-1/4″8″6″

10″12″

14″ 16″

Ratio cc/cycle3:1 6255:1 3205:1 32011:1 16011:1 16023:1 80

Ratio cc/cycle3:1 11603:1 11406:1 62510:1 32010:1 32022:1 16022:1 160

Ratio cc/cycle5:1 11605:1 114010:1 62515:1 44020:1 32020:1 320

Ratio cc/cycle3:1 32758:1 11408:1 116016:1 62522:1 440

Ratio cc/cycle4:1 327512:1 121023:1 625

Ratio cc/cycle6:1 327517:1 114017:1 1160

Ratio cc/cycle

23:1 121023:1 1210

Cruiser Dreadnought Warrior Dominator Titan Commander Chieftain

Hydraulic piston pumps

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• Double acting, positive displacement pumps

• Divorced pump design avoids hydraulic motor contamination

• High performance pump:- Delivery per stroke up to 1,210 cc-

Pump pressure ratio 1.55:1 (model H1600), equivalent to an air operated pump with a 16″

air motor piston diameter and 23:1 pressure ratio-

Pump speed: 5 to 10 cycles per minute

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High quality carbon steel wet end. Available in stainless steel

on demand

• Highly reliable pump seals specially designed for offset inks

• Recommended use when pump works more than 18 hours per day

Modelo H1600

Hydraulic piston pumps

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• High performance hydraulic motor• Hydraulic controls to fit each application• Hydraulic power pack to feed up to 4 pumps• Hydraulic oil tanks

Rams (pump lifts and inductors)

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Designed for high viscosity fluid transfer from drums

• Single post rams.

• Twin post rams

Single post ram

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Ram air cylinder pushes the pump and inductor plate into the fluid, to help the pump suction and lifts the pump out of the drum for drum changeovers

• Available for 20, 50 and 200 kg drums

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Pump and inductor plate packages available with Cruiser, Dreadnought and Warrior pumps

• For stationary and mobile units

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Double acting 3 ¼″

diameter air cylinder

•Maximum air cylinder lift: 940mm

• Built-in pump, lift and compressed air supply controls

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Twin post ram

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Two air cylinders on the ram push the pump and inductor plate into the fluid, to help the pump suction, and lifts the pump out of the drum for drum changeovers

• Very robust and reliable twin post construction

• Can be used with all pump models and sizes

• Single and double lip inductor plate wiper seals

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Double acting air cylinders. Air cylinder diameter: 3½″

(RAM models) and 5″

(POWER RAM models).

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Standard ram for 200 kg drums (straight and/or ribbed sides)

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Special rams available for any container size (300 kg, 500 kg, 700 kg, etc.)

UV and EB

ink pumps

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• Pumps specially designed to work with UV and EB

inks

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Minimum friction contributes to reduce heat in pump operation

• Prevents UV ink exposure to light

• Models available with 6″, 8″

and 10″

air piston diameters

• Models available with 5:1, 8:1 and 10:1 pressure ratios

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Pumping capacity from 4 to 20 kg per minute (depending on ink viscosity, room temperature and pipeline size)

• Very robust stainless steel construction

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Complete line of components and accessories for UV and EB

ink supply systemsPump with 10″

air motor

UV and EB

ink pumps with rams

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• Complete packages including pump, ram (pump lift & inductor plate) & pump controls • Available for 200 kg and 20 kg drums.

Model 1350M with 8″

pump for 20kg drums

Model 100000408SA with 10″

pump and Poweram 2050

Model 800000510SA 8″

pump and 2035 ram Model 600000510SA with

6″

pump and single 1055 post ram

Ink storage systems

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Tanks built in carbon steel specifically designed and manufactured for each site, with capacity from 5,000 kg to 20,000 kg• Four ink levels monitored in each tank

Ink storage systems

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Mother / daughter IBC storage facility, with level sensors and transmitter with remote readout.

Ink distributionInk pipelines and fittings

• High pressure steel pipe lines: 2″, 3″, 4″

or 6″

pipe lines• High quality and precision valves, flanges, elbows• 2″

hoses

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System componentsManifolds

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Custom made manifolds to fit each application

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Manifold foot with 1 m x 3″

suction hose

• Mobile tote manifolds

System componentsFilters, valves, flow meters, level sensors

2″

ink filter 1″

ink filter

1″

spool valve 1/2″

spool valve Level sensor

Custom made filters

(available in 2″, 3″,and 4″

versions)

Flow meter21

System components1″

ink pressure regulator

1″

ink pressure regulator

1″

pressure regulator assembly incl. pressure sensor and protection valve

Ink pressure regulator mounted on a press, reduces ink pressure to five bar

Ink pressure regulator panel for eight pressure regulators 22

Spreader bars & ink sensors

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Spreader bars and ink sensors.Ink fountain spreader bars are engineered with positive location brackets to suit all presses

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Adjustable ink flow control nozzles to balance feed across the duct•

Spreader bars can be easily detached for cleaning and color changeovers•

Bespoke ultrasonic or capacitive ink level sensors provide automatic multi-switch ink level control•

Sensors can be easily networked to expand the system to incorporate different operator interfaces

Ink control systems

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Hydrair ink controllers incorporate the latest state of the art technology and provide a cost effective solution to automatic ink level control on commercial and newspaper presses of all sizes.

Modular concept; choose an affordable system and later enhance the system as requirements evolve •

Capacitive and ultrasonic sensor to measure ink level • Colour touch-screen operator display • System fault alarm analysis •

Ink storage and consumption monitoring •

Remote tank level monitoring by ink supplier.

Ink control systems

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Control cabinet• Ink tank control• Ink tank content readout•

Automatic or manual operation• Pump selection• Alarm system• Pump protection• Automatic tank changeover

Ink bulk tank offset fill station• Ink tanks content readout• Tank overfill alarm

Installation layoutOffset presses

• Ink supplied in mobile or stationary tanks•

Each layout is carefully studied to meet system requirements

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Installation layoutSheet fed presses

• Ink supply in 200 Kg drums•

Each layout is carefully studied to meet system requirements

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Reference projects

• Web-offset presslines

• Sheet-fed presses

Newsprinters Broxbourne (London), UK

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Newspapers: The Sun, The Times, The Daily Telegraph, The Financial Times, The Sunday Telegraph

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One of the largest automatic ink supply systems in the world

•Pumps: twenty-six Chieftain H1600 pumps with hydraulic motor, equivalent to 16″

air operated pumps with a 23:1 ratio

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Press-lines: Two

Man Roland Colorman XXL

Each press-line with fifty four high towers, one hundred ducts per colour and ten presses

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Newsprinters Knowsley, UK

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Newspapers:

The Sun, The Times, The Daily Telegraph, The Financial Times, The Sunday Telegraph• Production: more than 33 million newspapers per week• Press line: One

ManRoland Colorman•

Tanks: eight x 15,000 kg tanks and eight daily consumption tanks with 4,000 and 2,000 kg capacity.•

Pumps: thirteen Chieftain H1600 pumps with hydraulic motor, equivalent to 16″

air operated pumps with a 23:1 ratio• Pipeline length: 150m, 2″

pipe

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Newsprinters Eurocentral, Glasgow, UK

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Newspapers: The Sun (Scotland), The Times, The Daily Telegraph, The Guardian• Production: 1 million newspapers per day• Pressline:

One ManRoland Colorman• Tanks: two 15,000 kg and six 9,500 kg tanks.•

Pumps: nine Chieftain H1600 pumps with hydraulic motor, equivalent to a 16″

air operated pumps with a 23:1 ratio• Pipeline length: 170m, 2″

pipe

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Trinity MirrorBirmingham, UK

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Newspapers: Daily Mirror, Sunday Mirror, The People, The Birmingham Post, sales flyers for Tesco, Morrisons, etc.• Production: 1 million units per day• Pressline: Goss• Tanks: eight x 15,000 kg tanks• Pumps: eight Titan 12″

air operated pumps, 12:1 ratio• Pipeline length: 100m, 2″

pipe • Ink control system

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Mirror Colour Print Watford, UK

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Newspapers: The Daily Mirror, The Independent, The Sunday Mirror, The Daily Record, magazines and local newspapers• Production: More than 1.5 million units per day• Pressline: ManRoland Colorman• Tanks:

four 15,000 kg and six 12,000 kg tanks•

Pumps: thirteen Chieftain 16″

air operated pumps, 23:1 ratio.• Pipeline length: 180m, 2″

pipe • Ink control system

Guardian Media News London, UK

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Newspapers: The Guardian, The Observer, The Guardian Weekly• Production : 1 million newspapers per day• Pressline: Man Roland Colorman• Tanks:

five 10,000 kg tanks•

Pumps:

ten Commander 14″

air operated pumps, 17:1 ratio• Pipeline length: 180m, 2″

pipe• Ink control system

Polestar PettyLeeds, UK

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Media printed: Radio Times, TV Times, Woman, Hello, retail, travel, financial magazines, brochures and flyers.• Production: 11 million units per day• Presslines: eight in total, Man Roland and Heidelberg.• Tanks: four 7,500 kg and four 10,500 kg tanks.•

Pumps: twelve Dominator 10″

air operated pumps, 16:1 ratio, and eight Commander 14″

air operated pumps, 17:1 ratio• Ink control system

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ArtisanLeeds, UK

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Media printed: Commercial magazines for Marks & Spencer, British Airways, retail, travel, financial magazines and brochures

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Presslines: five in total,

ManRoland and Heidelberg• Tanks:

eight x 7,500 kg tanks•

Pumps: twenty Dominator 10″

air operated pumps, 22:1 ratio, and Commander 14″

air operated pumps, 16:1 ratio• Ink control system

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Brighton, UK

•Tanks: four mother / daughter 1,500 kg tank systems, with low level alarms and pump auto-stop when empty

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Pumps: four

Warrior 8″

air operated pumps, 20:1 ratio

• Ink control system

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Woods Perth, UK

• Media printed: catalogues, brochures and books• Presses: three Mitsubishi sheet fed presses•

Pumps: five Warrior 8″

air operated pumps, 20:1 ratio, each with single post ram for 200 kg drums• 1½″

pipelines• Ink control system

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Nottingham, UK

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Media printed: catalogues, brochures and books •

Presses:

three Mitsubishi sheet fed presses•

Pumps: eight Warrior 8″

air operated pumps, 20:1 ratio, each with twin post ram for 200kg drums• 1½″

pipelines• Ink control system

Other reference projects

Web-offset presses

•Express Newspaper West Ferry London, UK

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Apple Daily Printing Taipei, Taiwan

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Apple Daily Printing

Kaohsiung, Taiwan

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Al -Media Printing & Publishing CO Jeddah, Saudi Arabia

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New Vision Kampala, Uganda

Sheet-fed presses

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Martano Editrice Bari, Italy

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Mediastampa Spa Begonia, Italy

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Hydrair service

•Turnkey organization (design, development, manufacturing, delivery, installation, commissioning, maintenance, repair, expansion and upgrades)

• Quick reaction to customer specific needs.

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Use of skilled mechanical and electrical engineers to install systems including all pipe work, electrical and pneumatic services and controls.

•Thousands of spare parts in stock ready to dispatch immediately.

•Telephone support and responsive call out service.

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The Samoa Group

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Since 2006 Hydrair is part of the Samoa Group

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The Samoa Group headquarters are located in Gijón, Spain

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The Samoa Group designs, manufactures and distributes systems and components for viscous fluid handling -

pumping, measurement and control -

for the vehicle maintenance, manufacturing, process, mining, construction, farming, paint, water treatment, chemical, etc. industries.

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The Samoa Group products are available in more than 100 countries through its own subsidiaries and a select distributor network.

Samoa Group main production plant and Corporate Offices in Gijon, Spain

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