DUO#Toolbox™ – Safety, Performance, and Control Features for DUO#Drying Systems
Enhance process reliability, ease of use, and drying quality: The DUO#Toolbox™ adds intelligent monitoring, control, and safety functions to DUO infrared dryers—retrofit-ready and practical.
Why a DUO#Toolbox™ for Drying Systems?
In flexographic and packaging printing, drying is not just a matter of performance—it is, above all, a matter of process reliability, control, and consistent production. This is exactly where the DUO#Toolbox™ comes in: It bundles retrofittable safety and performance modules that monitor the drying process, detect risks early on, and significantly simplify operation.
The DUO#Toolbox™ is primarily designed for DUO#infrared dryers.
DUO#SafetyGuard (Standard)
The DUO#SafetyGuard enhances the safety monitoring of the dryer unit with an additional safety curtain above the protective grille. It detects issues such as sheet jams or loose paper in the drying area and can trigger an automatic machine shutdown in the event of critical incidents. In addition, basic dryers are equipped with a safety curtain beneath the grille to keep particles out of the drying area.
Your benefits: Increased operational safety, reduced risk of jams.
DUO#SentryCamHD (optional)
The DUO#SentryCamHD is an HD real-time camera designed for visual monitoring of the area above the dryer unit. The operator can see live what is happening at each printing unit (e.g., via monitor, split screen, or HMI integration) and can intervene early on.
- Benefits: Quick overview, early response, less downtime.
DUO#SentryCamActiv / SentryCamActiv+ (optional)
The DUO#SentryCamActiv is a thermal imaging camera installed on each dryer unit. It measures the temperature of a system-specific area between the dryer and the conveyor. If the target value is exceeded, the dryer shuts down immediately. Optionally, PowerDropDown can also be activated.
- Benefits: Active temperature monitoring, automatic response when limit values are exceeded.
DUO#PowerDropDown (optional)
DUO#PowerDropDown schwenkt die Trocknereinheit automatisch nach unten, wenn während des Betriebs eine Störung/Stoppsituation eintritt. Dadurch wird verhindert, dass Bögen oder Papierstücke auf der Oberfläche verbleiben. Der Trockner wird automatisch abgeschaltet.
Ihr Nutzen: Zusätzliche Schutzfunktion bei Maschinenstopp – reduziert Risiko durch liegenbleibendes Material.
DUO#DryControl (optional)
DUO#DryControl incorporates a pyrometer (located in the center of the drying unit) that measures the temperature of the sheet surface. The dryer output is regulated to a target temperature. The operator can set the target value based on the job and printing unit; data can be saved and retrieved. In practice, energy savings of up to 20–60% are possible, depending on the print job.
- Benefits: Reproducible drying, less over- or under-drying, targeted energy use.
DUO#SmartControl (optional)
DUO#SmartControl is a software tool for saving specific dryer configurations for individual print jobs. Configurations can be saved and reloaded for the next job. The presentation notes that when the print unit is changed, automatic adjustment is not possible and must be performed by the operator.
- Benefits: Faster setup processes, fewer operator errors, and repeatable settings for production runs.
Depending on the system design, individual modules can be combined in a targeted manner and adapted to the specific requirements of the printing line.
- Request for a suitable configuration
Advantages of the DUO#Toolbo
The DUO#Toolbox™ specifically enhances DUO#DryingSystems with additional safety, process monitoring, and control functions. This allows existing systems to be upgraded to a significantly higher level of process reliability, ease of operation, and energy efficiency without major modifications.
- Increased process reliability: Early detection of critical conditions reduces the risk of malfunctions and unplanned downtime.
- Greater transparency in the drying process: Camera and temperature systems give the operator full control over each drying unit.
- Optimized energy usage: Temperature-controlled regulation prevents over- or under-drying.
- Faster response times in case of malfunctions: Automatic protection functions activate immediately in the event of an incident.
- High retrofit capability: Existing DUO#InfraredDryers can be upgraded as needed.
- Future-proof system strategy: Modular expandability allows for step-by-step expansion.
Typical Applications of the DUO#Toolbox™
The DUO#Toolbox™ is primarily used in applications where there are heightened requirements for process monitoring, safety, and reproducibility.
- Corrugated flexographic printing at high production speeds
- Inline post-printing systems with heightened safety requirements
- Systems with frequently changing print jobs
- Retrofit projects for modernizing existing IR dryers
- Production environments with high quality requirements
- Lines where operator support and transparency are key priorities
Especially in high-performance flexographic printing lines, the Toolbox supports stable, controlled, and cost-effective production.
Retrofit and Compatibility
The modules of the DUO#Toolbox™ are designed as retrofit solutions to specifically enhance existing DUO#drying systems—from additional safety monitoring to control and job storage functions. This allows the performance of existing DUO#drying systems to be expanded in a targeted and phased manner. The current focus is on applications with DUO# infrared dryers.
- Check the retrofit compatibility of your system
Frequently Asked Questions About DUO#Toolbox™
Which Toolbox modules are standard?
SafetyGuard is included as a standard safety feature; additional modules are available as options.
Can I combine multiple modules?
Yes. Certain functions work well together (e.g., SentryCamActiv with the optional PowerDropDown).
Is DryControl more about “quality” or “energy”?
Both: Temperature control increases reproducibility and can—depending on the job—reduce energy consumption.
For which dryers is the Toolbox intended?
Primarily for DUO#InfraredDryers; hot air/hybrid is currently still being tested.