Flexo gets faster

6 May 2008



Successful introduction of new eltromat flexo technology at Skymark


The Scunthorpe, UK, plant of Skymark Packaging International has proved a successful pilot installation for eltromat’s new Fast Flexo Auto Set technology, which is claimed to offer important production benefits to CI flexo printers.

The Fast module is part of eltromat’s Web Video 3000 web inspection system installed on an 8 colour Fischer & Krecke Flexpress 6S CI flexo press at Skymark Performance Films. It is designed to automate the printing pressure setting process “quickly, precisely and safely”. The F&K press, installed in spring 2007, was supplied with the Web Video 3000 plus optional modules CI Register Control, SIS Detection of Print Faults, BC Bar Code Verification and Image Lock Sensor.

The new auto set module was installed in September, after successful production trials.

According to eltromat, whereas the set-up process of a CI flexo print job normally results in several hundred metres of waste, the Fast feature saves up to 70 per cent waste and time. It automatically controls the printing pressure between the anilox rollers and the plate cylinders, and between the plate cylinder and the printing substrate. At the same time, the CI module, adjusts the length and side register with an accuracy of 1/100mm.

The combined modules control all ink decks simultaneously. Unlike other systems, set-up of Fast is done when the press is out of action; no manual intervention is necessary during the machine run.

Pressure and register adjustment are combined in a “one touch” operation. The web inspection system’s HQ 3-chip camera collects all necessary data about printing pressure adjustment, and length and side register. The measuring field for the Fast module consists of marks with variable area coverage, said to offer a more precise adjustment of the printing pressure than with conventional full tone marks. The result is said to be an absolute minimum production material waste and a maximum of valuable machine time during each job change.

The successful introduction of the new technology is part of a partnership between Skymark and Fischer & Krecke, who has now delivered three CI presses to Skymark in six years. The latest Flexpress 6S installed at Scunthorpe – one of Skymark’s three production centres of excellence in the UK – followed two 8 colour 16S models at the company’s Leominster site in 2001 and 2006. Both of these are also equipped with eltromat print quality control systems.

The latest press has a 1,300mm web width and is capable of 400m/min. Designed for quick change-overs, it has increased the Scunthorpe site’s capacity from 300 to 430Mm/year - and is said to be a major factor in boosting Skymark’s group turnover. The press provides infinitely adjustable print repeats and is specified to process all types of films, laminates and lightweight papers.

Skymark Performance Films specializes in the production of cast embossed PE back-sheets for the hygiene and personal care markets, speciality embossed films for the toilet tissue and tyre industries, speciality blown films for the adhesive industry and EMA films for the medical industry.

Managing director of Skymark Packaging International Group John Turner sees the investment in the Flexpress 6S as a logical progression in the strategic partnership with F&K and eltromat. “As this is our third F&K installation running with eltromat print quality systems, we saw no risk being a development partner for the new auto set technology. The installation performed very well within a very short time and was extremely useful to convince our customers about our improved capabilities as a premium printer.

Leeson Potter, site manager at Scunthorpe, confirms: “Eltromat was able to develop and present the innovative Fast system in a very short time. Installation of the system took only four days to make it running and to meet our expectations very well. There was only minimal training necessary to make our printers well prepared to use all of its potential. In view of the continued increase in the number of job changes and reduction in order run lengths, the reduction of set-up costs becomes more and more important. The new auto set technology is an important step towards solving this problem in a professional way.”

Due to the excellent results achieved at Skymark, eltromat says it has already been able to sell more than 10 Fast modules worldwide. n


Leeson Potter, site manager at Skymark, and Richard Warnick, general manager of eltromat UK (from right) watch the function of eltromat system eltromat system

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