FLEXO EXPRESS

16 May 2005



News from the flexo scene


Labels look like litho

Since commissioning a new MPS 300 flexo/screen combination press, Harlands Labels has begun to compete with the traditionally perceived higher quality of litho. The Hull, UK, based company's largest market is the health and beauty sector and the business is said to be making further inroads with the subtle tones, vibrant colours and exceptional print quality of the new press.

Managing director Ian Wright comments: "This press has really pushed the envelope of flexo in terms of a quality printing technique. We can now confidently compete against litho."

One customer said to be "singing the praises" of Harlands' new investment is DDD, producer of the Astral skincare range. This company decided to move from direct print to a decorative label but thought that the complexity of design would mean litho was the only option.

Packaging technologist Adrian Miles explains: "The design contains an extremely fine vignette and we were sceptical as to whether it could be achieved without using litho but were willing to give Harlands' new press a try. The results achieved using flexo really have changed my perception of the technology; it has clearly developed in leaps and bounds."

The nine colour MPS 330 is a servo driven machine said to achieve excellent standards of print and minimum dot gain through an "automatic register" system that makes 14,500 checks a second. Exceptional quality can be achieved and sustained with minimal adjustment during the print run, it is claimed.

The combination press offers flexo and screen (on nine print stations) in one pass, giving a good range of different effects and finishes. The sequence of the stations can be adjusted according to the requirements of a particular job, along with the added ability to include hot and cold foil blocking, embossing and varnishing.

It has boosted Harlands' production flexibility, as it can print larger labels on a wider range of substrates and with more rapid turnaround times reducing downtime and associated costs.

A Vista of Mark Andys

Vista Labels is investing more than £1.3M at its production site in Stockport, UK. Additional production space will allow the company to re-organize its workflow to make better use of its label presses, the most recent of which is an eight colour, 10in Mark Andy 2200 model, installed at the beginning of 2005. This latest press brings the company's Mark Andy machine count to eight.

Vista managing director Don Grice comments: "The day-in day-out performance of the 2200 series has been fundamental to this company's success. It's a relatively simple press that does everything well – what else does a label printer need?"

In association with a major foil manufacturer, and with support from Mark Andy, Vista has assisted in the development of rotary cold foiling. Available on most Mark Andy presses, this technique offers lower set-up costs and substantially better running speeds.

Says sales director Tim Grice: "We see cold foil as having its own unique advantages. It's brighter and more rub resistant than the more traditional hot foil, and can be run at least seven times as fast. It has allowed us to add value to areas of the label market that previously were out of reach."

More than just mounting

3M's Cushion-Mount Plus high performance flexo mounting tapes use an advanced liner system that creates a network of continuous microchannels in the adhesive surface. During mounting, these channels allow trapped air to escape - delivering consistent adhesion and a level surface for excellent print quality, it is claimed.

The adhesive formulation also permits easy repositioning during mounting. The microchannel liner system is said to minimize air entrapment, saving time and eliminating high spots and the resultant quality defects.

During use, the adhesive delivers perfect grip, but still comes off quickly and cleanly for fast change-overs and minimal downtime, according to 3M. Cushion-Mount is available in five densities to suit every print job.

Label leader scores hat trick

Royston Labels swept the board at the 2005 EFTA Print Awards, winning the top prize in all three label categories. Royston's first Gold of the evening was awarded to a label in the King British Fish Food Range. It was singled out by the judging panel for its fine photographic representation of a goldfish, delicate half tone images and tightly registered reversed-out copy produced on a paper substrate.

The company also took both Gold and Silver in the Plastic Process category. The winning print, produced for the Taylor of London Freesia Body Spray, was praised for its subtle vignettes and precision silver foiling. Stubble Stop Post Shave Balm clinched the Plastic Line/Screen class. Recognized for its technical difficulty, this entry was produced using a combination of UV flexo and Stork rotary screen requiring nine printing units. In addition to specialist effect inks and a metallic silver filmic material, a tactile effect was created to complement the blind embossed outer packaging.

Royston majors on the use of combination UV flexo and screen, supported by letterpress and rotary foil blocking. Working from digital repro, the winning prints were produced on Nilpeter presses, using ANI inks and Fasson labelstock.

Elite aims to extend quality

The new FlexoElite 10 ES 32 10 colour gearless sleeve press from Italy's Converting Technology features a number of patented innovations claimed to make it "a landmark flexo press".

Foremost among these is the LinearSet patented print deck design - "probably the most extraordinary innovation ever appearing in the flexo market", boasts the manufacturer. Claimed to provide the most accurate deck positioning in the market, it moves the print cylinder and anilox roller into the printing position using linear motors that are connected directly to the cylinder supports to eliminate backlash.

LinearSet is claimed to enable "unmatched deck positioning precision, which will open new horizons to flexo quality". According to Converting Technology, it provides positioning precision to 0.1 micron, set-up time of just one second for 10 colours, zero or negligible print overpressure and zero or negligible dot gain.

The EasyLock patented motorized system locks and unlocks the printing cylinder and anilox roller mandrels at the operator side, to change the sleeves automatically. The change-over sequence is controlled entirely by the PLC; all the operator has to do is move the sleeves in and out.

CT Phaser is a patent pending automatic register control system that allows register pre-set when the new job is being prepared, and maintains it continuously within the required tolerances.

Suitable for using both solvent and water based inks, the FlexoElite 10 ES 32 is available with printing widths up to 1,800mm and repeats to 1,300mm. Top speed is 450m/min. The press has a 2,500mm OD CI drum, carbon fibre doctor blades, a high efficiency, patent pending drying system, and a PLC controlled wash-up system.

Converting Technology is currently building two machines for US customers - one 1,650mm wide, the other 1,350mm. From April 27 to the end of June the company will show the 1,650mm model in open house demonstrations at its plant in Verona.

The first machine has been sold to Eastern Packaging of Lawrence, Massachusetts, for the production of printed packaging films.

Geo Label streamlines with Instaprep

Aquaflex has supplied a 13in Instaprep press to Geo Label in Ontario, California.

"Our focus is on pressure sensitive labels for supermarkets," says George Contreras, president and owner of Geo Label. "In that business, we must respond quickly and deliver excellent quality. The Instaprep allows us to streamline our change-over process for faster job turnaround and it consistently produces an exceptionally high quality product."

The Instaprep press features the patented ITC quick change system that enables off-line job set-ups and clean-ups. Change-overs are accomplished by the simple exchange of print station cassettes — no tools are required.

George Contreras continues: "We purchased the Instaprep because it was easy to set up and operate. The ITC system has literally cut our set-up time in half. As a result, we have increased our production levels significantly every shift."

Further proof

RK Print Coat Instruments has supplied several FlexiProof 100 systems to Degussa, a multinational manufacturer of formulations used in goods as diverse as toothpaste, construction products, 'green' tyres, and yogurt.

The FlexiProof 100 can be used for a variety of purposes, from achieving flexo colour consistency across a range of differing packaging media to R&D, printability testing, computer colour matching, preparation of customer samples, and for the determination of performance properties.

Foray into US repro

German packaging prepress house Flexicon has established a subsidiary in the USA. Flexicon Corp, based in Florence, Kentucky, will offer a complete portfolio from artwork through to the finished flexo plate.

CEO Gabriele Kison comments: "By setting up operations on location, we can provide our American partners with flexo plates of German quality even quicker. Our workflow is so standardized that we can achieve the same quality anywhere in the world from the same data." Technical ceo Gerrit Sander adds: "The technology will be the finest the world can offer prepress package printing".

Hybrids offer flexibility at low costs

While flexo technology has improved considerably in quality over the past few years, says Drent Goebel, the quality requirements of the market are developing even more rapidly than flexo technology. The company believes that hybrid web presses that combine different printing technologies are the answer to the increasing demands of the market.

Drent Goebel offers its hybrid VSOP press as the answer to these increasing demands. With its "affordable size variability", fast makeready and change-over capabilities, the VSOP is designed to offer high print quality and high efficiency - especially on short runs - and user friendliness. The press is available in 520, 850, 1,120 and 1,250mm widths.

Janus Technologies now represents Drent Goebel in the UK and Ireland. Janus is creating a Flexible Packaging Division which will focus wholly on serving the needs of companies in this sector.

At a stretch

The "longest press ever installed in a UK flexo plant" is now operating in Leeds at the new £8.74M factory of flexible packaging printer Roberts Mart. The 10 colour Fischer & Krecke Model 26S press has a total length of 27m.

Accommodating widths up to 1,300mm and reels of 1,000mm diameter, the F&K press can handle all types of packaging material from 10-120 micron, films, foils and papers, at 460m/min. Roberts Mart is involved in the household, textile, retail and healthcare industries, and hopes its latest addition will attract blue chip companies, particularly in the food and drink sector.

The press configuration allows the company to print either up to 10 colours on one side or eight plus two on the reverse. Alternatively, the downstream units can be used for coating or overprint varnishing. Print repeat range is 400-1,350mm.

The press also features automatic print unit wash-up, a video monitoring the web, and a print register control system.

Colpak's Combat clinches quality

South African Machinery importer Ipex Holdings has supplied an eight colour, in-line UV flexo press from Italian press manufacturer Gidue to Colpak, Cape Town. Equipped with servo driven motors, the 530mm wide X-Combat press features automatic reel-to-reel production with a non stop, unwind and rewind system.

The press has already demonstrated its ability to produce high quality work for the launch of Sensations of Fruit a new fresh juice from Parmalat. The packaging quality got the thumbs-up from the Flexo Print Excellence Awards 2004 judging panel when Parmalat won top honours in the Shrinkable Label category. The first prize was awarded to Parmalat 1.5 litre Tropical juice. The judging panel took note of the "superb" half tone print quality, dot clarity and colour balance.

Comments Colpak ceo Bob Jones: "We run high quality, eight colour halftone work on the Gidue press and our operators like the simplicity of operation and very quick change-overs. The press is ideal for our short run jobs, and the high print quality achieved will eventually enable us to compete in markets that are traditionally gravure".

Gidue has added a 500m2, Graphics Technology Centre to its headquarters in Milan. Managing director Federico d'Annunzio says: "It will provide increased showroom space and better R&D facilities to enable us to accelerate our product development programme".

Doctor goes to college

One of the USA's premier print technology colleges, Fox Valley Technical College, at Appleton, Wisconsin, has upgraded its new PCMC Avanti press with the latest carbon fibre ink chamber doctor system from Absolute Engineering.

"Safety, easy clean-up, and ease of use were just a few of the many reasons we decided to use Absolute Engineering to upgrade our new Avanti," says FVTC's Steve Utschig. Because of their light weight, the chambers are easily handled by one person. They are also easy to clean, and allow quick blade and seal changes without need of tools, says Absolute.

Easy-Set earns technical innovation award

In the USA, Windmöller & Hölscher's Easy-Set automatic impression system has won the FTA/Flexo Market News Technical Innovation Award. Claimed to take flexo "another step closer to competitive processes such as gravure, where there are fewer variables", Easy-Set provides fully automatic and precise adjustment of the anilox and plate impression settings using the actual printed job as data input. No additional printed marks are needed.

According to W&H, this previously operator skill dependent process now requires just pushing one button to assure precise print impression settings on all decks reliably and quickly. It is estimated that with Easy-Set, impression setting times are reduced by more than 60 per cent.

Additional machine production time available is said to increase by up to 300 hours/year (based on three-shift operation seven days a week).

Introduced at drupa 2004, the Easy-Set system is available as an option for all new Astraflex, Novoflex and Primaflex flexo presses. It can also be retrofitted to existing machines of these types.

W&H has also sold its first Novoflex CL press in the US. The Robinette Co, of Bristol, Tennessee, has ordered a 10 colour configuration, 53in wide and with a maximum repeat length of 49in. It will be equipped with Easy-Set, the new Port-A-Sleeve sleeve handling system, and a Procontrol TS Windows based touchscreen control panel.

New orders from North American customers for W&H equipment of all types over the last three months are said to total over $75M – the highest order entry period since the German manufacturer established its US subsidiary in 1977.

DSS makes Mini driving debut

Trade repro house DSS (Liverpool) is believed to be the first UK company to drive a new Lüscher ZEDmini flexo sleeve engraving system through a NexusRIP from Artwork Systems. A long standing user of ArtPro, the company has installed a NexusRIP, along with DotSpy and FlexoCal software from Artwork Systems, and has upgraded its ArtPro seats to the latest version.

"The Artwork Systems equipment has played a key role in our development and certainly the NexusRIP has been vital in enabling us to drive the engraver effectively," says technical manager Tom Keaney. "All the engraving work we handle goes through our two seats of ArtPro and the new Version 8 software provides us with even more functionality."



Contact

MPS Tel: +31 (0) 316 291260


Contact

Mark Andy UK Tel: +44 (0) 1625 500964


Contact

3M Industrial Adhesives & Tapes Tel: +44 (0) 870 6080050


Contact

Royston Labels Tel: +44 (0) 1763 212020


Contact

Converting Technology Tel: +39 34077 12731


Contact

Aquaflex Tel: +1 877 247 6627


Contact

RK Print Coat Instruments Tel - +44 (0) 1763 852187


Contact

Flexicon Tel: +49 5201 87190


Contacts

Drent Goebel Tel: +31 (0) 313 671 776 Janus Technologies +44 (0)161 236 4977


Contact

Fischer and Krecke Tel: +49 521 3048 0


Contact

Gidue Tel: +39 02 9668181


Contact

Absolute Engineering Tel: +44 (0) 1484 868366


Contact

Windmöller & Hölscher Tel: +49 5481 14 3669


Contact

Artwork Systems Tel: +44 (0) 1527 592550




External weblinks
Converting Today is not responsible for the content of external internet sites.

Absolute Engineering
Aquaflex
Artwork Systems
Converting Technology
Drent Goebel
Fischer and Krecke
Flexicon
Gidue
Janus Technologies
Mark Andy UK
3M Industrial Adhesives & Tapes
MPS
RK Print Coat Instruments
Royston Labels
Windmöller & Hölscher

"Gidue press will enable us to compete in markets that ...
Flexo labels fulfil Astral aspirations Flexo labels fulfil Astral aspirations
EFTA winners for Royston EFTA winners for Royston
Absolute chamber system on Fox Valley's Avanti Absolute chamber system on Fox Valley's Avanti


Privacy Policy
We have updated our privacy policy. In the latest update it explains what cookies are and how we use them on our site. To learn more about cookies and their benefits, please view our privacy policy. Please be aware that parts of this site will not function correctly if you disable cookies. By continuing to use this site, you consent to our use of cookies in accordance with our privacy policy unless you have disabled them.