Seven years after the market launch of the MetalStar 3, of which over 400 printing units have been installed worldwide, Koenig & Bauer has announced the new MetalStar 4.

To meet the growing demands of the metal decorating market, the MetalStar 4 offers new functions and improvements in the feeder, measuring technology and new functions for monitoring production and enhancing ergonomics.

The MetalStar 4 also includes existing MetalStar technology, such as the short and dynamic inking and dampening unit and high-precision register printing thanks to the sheet travel in the gripper closure, as well as the extensive automation features that reduce make-ready times.

Some of the biggest innovations of the MetalStar 4 can be found at the feeder. Metal printing-specific updates such as new sensors, newly designed blow pipes and scrapers, and adjustments to the infeed table noticeably increase the reliability of the feeder.

The inline colour measurement and control system MetalControl, which is available for the MetalStar 4, measures the ink densities on each color patch in the print control strip or on individual colour patches and regulates the ink zones fully automatically every 10 sheets. This ensures that the specified target densities are always achieved and maintained within the print run – Independent of the operator or the time of day.

In addition, MetalControl supports the operator in color setup for the print job. MetalControl can set up the target densities fully automatically in one print run, utilising a sandwich process. Alternatively, MetalControl can also be used to print individual print runs as usual during set-up. MetalControl then makes a setting suggestion after each print run. 

The new ErgoTronic console is the heart of the MetalStar 4. Thanks to the clear and modern software, the operation of the MetalStar 4 is intuitive. All settings are made via a 23″ touch screen.

The new ErgoTronic console is the heart of the MetalStar 4. Thanks to the clear and modern software, the operation of the MetalStar 4 is intuitive. All settings are made via a 23″ touch screen. The console can be equipped with a 75″ wall screen on which the measuring results of MetalControl and the individual zone openings in each inking unit are displayed. In addition, a live image from one of the observation cameras mounted at neuralgic points on the line can be displayed here. This makes it easy to monitor critical positions live from the ErgoTronic console and intervene if necessary.