Smart technology for flexo printing

The modern flexo press has advanced from manual setting by the printer for print register and correct impression, but nevertheless all these settings are traditionally carried out whilst the machine is running, and this takes time and energy and generates a lot of waste.

This waste is substantially increased on the modern high speed machines which use faster drying inks resulting in increased set-up speeds in order to avoid ‘drying in’ and other problems.

The flexo industry has been striving to automate this process by duplicating and enhancing the orginal manual steps with various forms of optical automated technology; however, as mentioned, this occurs whilst the press is running with the consequence of significant waste.

Alternative solution

Fischer & Krecke has found a way to generate the print register settings and impression settings data off the press in such a way that the final optimum results can be entered and set in the print decks without actually running the machine.

The company’s initial studies were conducted in different package printing industries, using different inks, different plates, different plate thicknesses, different sleeves, different shore hardnesses for plates and sleeves; and different ‘sticky backs’, etc., at worldwide facilities.

From these extensive studies came advanced impression-setting algorithms to provide choice of optimum impression settings for millions of variables. These algorithms were beta tested many times to determine that their accuracy would provide the required results under all circumstances.

In the ‘graphic positioning process’ a new measuring system is integrated into a specially engineered mounting machine that enables the topography of the print ready package (i.e. bridging sleeve + sleeve + tape + plate) to be scanned to an extremely high precision level. An antenna transmits the calculated data to an RFID chip embedded into the sleeve. Similarly a datum registration position is read and downloaded into a second chip in the sleeve. The register information comes directly from the plate micro dots. Impression data from complex software takes into account all information relating to each module of the built-up package from sleeve type and hardness, tape type, plate type etc. This measuring sequence takes place rapidly.

The special mounter is also used for measuring the anilox and its TIR, which also provides a quality control check. Such a quality control check is made on the finished mounted package highlighting any defects such as high spots, etc.

In the actual printing machine, each ‘graphic positioning print deck’ includes an RFID antenna and positioning sensors. Once the mounted sleeves are installed in the machine the reading of the stored data from the sleeve chips is then transferred to the machine computer controls so that all the processes from racking in, registration and impression setting are now automated and synchronised for all print units engaged for the job. This takes place while the machine is completely still.

Cost savings

Such precision pre-setting results in substantial elimination of waste such as:

¦¦ Substrate needed during set-up

¦¦ Ink/solvents consumed during set-up

¦¦ Energy used during set-up

¦¦ Hourly press time

¦¦ Wasted labour hours

¦¦ Additional waste disposal costs

¦¦ No register marks are required therefore additional material width is eliminated

¦¦ No damage due to over-impression and longer plate life

¦¦ No premature evaporation in impression setting, good ink transfer

Works on any substrate

The register and impression setting is consistent irrespective of ambient conditions and works whatever the colour or type of ink or coating, even optical coatings, which are difficult to see. The system is suitable for any substrate including metallised films, papers and foils of any thickness or type.

All print data remains with the sleeve until new plates are mounted. The system provides the correct impression settings independently of ink drying characteristics and machine speed.

With this new F&K smartGPS system, the print adjustments and impression parameters are known in advance of loading the job in the press and as such the first impression is a saleable print, increasing the ‘uptime’ of the press with minimum waste resulting in a ‘greener’ and more profitable solution.

Like all of Fischer & Krecke’s presses, the latest model, the FP 15-S is smartGPS ready.