Narrow web presses offer multi substrate ability

Label converters are seeking extra avenues and flexible packaging converters are keen to add narrow web presses to their armoury. So it came as no surprise that the trend at Labelexpo was towards presses that allowed quick change, speed and reliability, and waste reduction plus an ability to run a variety of substrates and several printing technologies and additional processes.

Comco stole the show on this front with the launch of its next generation of multisubstrate presses - the attractively styled C2. Claimed to be the most advanced servo motion equipment on the market, it is completely shaftless and gearless. It is aimed at the label and tag, flexible packaging and carton converter. Vice president sales and marketing Greg Palm said: ”At the heart of this press is the new I-Drive (Intelligent Drive System). This brings together state of the art servo technology and advanced controls focused on simplifying operations. It enables print quality, productivity and flexibility never seen before in a web flexographic press.”

I-Drive is not a single technology. It is the complete integration of a variety of advanced technology features found on the line press, says the company. Features include specialized programming, continuous tension management, pacing profile tailored for film type, anilox and plate roll sleeves which change out in one smooth move and instant “on the fly” change-over. Waste is said to be “dramatically reduced”. “It also features in-line cylinder design for each print station and anilox/plate/impression cylinders are of direct in-line geometry,” said Greg Palm. There is a patented fully automated registration system - automated pre- and re-registration.

Available in widths of 406, 457, 559, 660,and 813mm, the press can handle a variety of substrates from films to thin board at up to 305m/min, depending on substrate. Print technologies are interchangeable (flexo, UV flexo, rotary screen, gravure), and hot and cold foil processes and lamination are offered.

New from MPS is a wider width EF (effective flexo) press designed to handle a full gamut of substrates from selfadhesive labelstock, selfadhesive or non supported film, paper and cartonboard to flexible packaging and shrink sleeve films (20-350 micron). It is available in 20 and 26in widths and is claimed to operate at speeds up to 900m/min.

The press also features the company's latest NPC technology (non stop print change). MPS claims that its servo drive makes it possible to switch designs without stopping the press. “So a design change with zero waste is possible,” said director Eric Hoendervangers. With NPC the machine processor speeds up idling units until its speed and register position matches with the running of other printing units. On an operator instruction, the machine processor lifts the printing cylinders from their printing position. Then the idle printing units, fully engaged, but not printing yet, are put into print position. Typical applications for NPS are split-run labels and packaging jobs, varying text (language), bar codes and series information.

The company also demonstrated on an EF 16in flexo module technology that allows the flexo converter total flexibility in using print sleeve technology or standard printing cylinders. The company showed how print can be achieved from original steel print cylinders or from exchangeable fixed diameter mandrel bodies for sleeve mounting on the press. In addition it demonstrated the EP in a 22in width showing the walk-in platform technology offered by the company in presses with widths over 20in. Five orders were taken for UV flexo lines.

Servo drives were the order of the day at Nilpeter. All its label and packaging presses are now servo driven. Unveiled was the redesigned modular FB, now servo driven. Operating was the FB-3300 S equipped with eight hot air flexo units and UV curing on the last station. Described as “no longer a workhorse, but a race horse” the press is capable of operating at 750ft/min. It was sold to a converter in Spain.

“Today every Aquaflex press is film capable - offering customers the ability to diversify into flexible packaging,” said vice president Mac Rosenbaum. It was a goal established by F L Smithe when it acquired the company in 2004. “With the introduction of the new ELS Servo that has been achieved. Replacing the DBX as the entry point to our line, the groundbreaking press makes servo technology affordable and available to tag and label printers everywhere.

“We wanted to make servo technology accessible to the smaller shops and provide a viable upgrade path for them to diversify into flexible packaging. Priced similar to mechanical presses in its class, the 10in and 13in ELS Servo prints on traditional label substrates as well as on film at speeds up to 750ft/min.” The ELS Servo's Intuitive Register Control monitors speed changes, anticipates variations in tensions, and holds registration reliably, claims the company.

There are six ELS presses in the field since it began shipping the commercial version in March. “One is in Europe and a few more will be going there next year,” he told Converting Today.

Gallus is the only major narrow web press manufacturer to offer screen printing know-how from prepress through machine design to a wide range of screen printing plates. Latest from Gallus Rotascreen is the Gallus Screeny S-Line, which is designed to extend the durability of the screen mesh for longer runs and repeat orders. In addition the company announced a digitally processed Screeny printing plate, which for the first time will allow screen printing to be integrated into the industrial workflow. Said Heinz Brocker: “The S-Line will be available at the end of this year. It is designed to increase the run length up to 50,000m - 20,000m more than the current Screeny can achieve.” On the digital front he says the product should be available in the middle of next year. “A lot of people are operating digital flexo and want digital screen too. Field tests will begin at the beginning of 2007.” The company has already invested SwissFr12M in the new facility near to St Gallen.