Increased automation and sustainability is driving developments for wide web press manufacturers, and with digital technologies snapping at their heels, there is a real need to use the advantages that flexo still holds in the packaging arena. By Neel Madsen.
As the crossover point from digital to flexo continues to work its way up and more supplier announce their intention to reap the benefits of one of the only growing markets in print, wide web press manufacturers are under pressure to come up with new solutions to stand their ground.
Evolution
Flexotecnica SpA is promising to unveil a new ‘flexo concept’ at drupa. It has been developing the ‘Flexo Evolution’ range of presses, the EVOX. This will build on the strategic principles for wide web applications which are already the foundation of its XG and XD press formats, such as the application of innovative solutions aimed at assuring added productivity even with the shortest of print runs, excellent print quality and the eco-sustainability of the converting process.
New solutions aimed at a significant reduction of waste both at print set up and during production include the auto impression setting system AIF, which features an array of ergonomic enhancements and energy saving electric control technologies. These features enable optimum productivity and profitability for short, medium and long print runs.
The new EVOXG format shown at drupa will be based on the existing XG model which is available in widths up to 1600 mm, with an option to increase this to 1800 mm, and a production speed of 600 m/min, whilst the XD format is available in widths up to 1400 mm, with a 1600 mm option, and production speed of 400 m/min. Both feature rigid side frames for high speed printing and fast sleeve exchange solutions, automated or manual, for minimised press downtime needed for short print order lengths. The AIF technology sets impression, without the need for register marks, in a matter of 10s of metres which again maximises profitability.
Both these press offerings can be tailored to suit customer needs by offering flexible solutions, such as shafted or shaftless winders from 800 mm to 1500 mm reel diameters, web inspection or 100% inspection systems, viscosity control to work with the company’s SpeedyClean fully automatic wash up system, which comes as standard on all presses, and other options, such as corona treatment, inline slitting and an array of inline printing, coating and laminating stations, specifically developed for a wide variety of market sectors. Both presses can also be supplied with extended maximum repeats of 1200 mm and 1070 mm respectively.
Other features include the patented Safe Sleeve Change, which has individual print unit access guards and CI shutters to allow safe access to non-printing units for sleeves and unit wash up whilst continuing production on the remaining units, and sleeve pushers to assist in the removal of print and anilox sleeves, especially at wider web widths.
Cost-effective
From Launskroun based Soma Engineering comes the Premia, the latest addition to the SomaFlex range of presses. The company is promoting this as a cost effective combination of high technology and engineering for medium and long runs that is normally only found on more expensive machines.
At drupa, a 1270 mm wide version with 915 mm print repeat and speeds up to 500 m/min will be exhibited with eight printing units, shaftless unwind and rewind, automatic wash up and viscosity control systems, three chip digital camera for 100% web inspection and sleeve ejecting device.
The new press features the latest versions of Soma’s existing technologies, which include direct drive, new generation Inkflow and Inkstorm system, fast adapt, Q-Shield, CDTS, PCTS, sleeved lay-on and spreader rollers, composite mandrels, mono-block, Fast Blade, ink ready, flying anilox sleeve, easy intuitive touch screen, sophisticated machine design and improved ‘energy minimalisation concept.’ The advantages and performance characteristics of the machine will be demonstrated running several different job types on the stand.
The easy way
Since the last drupa, Windmöller & Hölscher has extended its Miraflex, Novoflex and Vistaflex press ranges with new models and features. Under the motto, The Easy Way, the press manufacturer will present a Miraflex CL 10 flexo press at the show along with the established Easy range of options.
The widths and repeat ranges available in the Miraflex and Novoflex ranges cover 90% of flexible packaging products on the market. Detail enhancements along with greater machine performance allow for a real improvement in productivity. The Vistaflex portfolio also grew with the introduction of the CL8 and the CX, which accommodates widths of up to 2200 mm. They feature the ‘smart’ Vista-Port robot system for sleeve and anilox handling, which is an advanced solution for high output that enables quick job changeovers.
The trend for smaller and smaller jobs, and therefore more and more job changeovers, continues and the company’s development team remains focused on improving machine uptime. To this end, it has the Easy range of automation modules, including Easy-Set, Easy-Reg and Easy-Col.
The company said that customer needs and feedback received on hundreds of systems on the market have inspired targeted, hands-on improvements and that more than just increasing the cost efficiency of flexible packaging printing was addressed. Its guiding principle of all development is sustainable production, eg reducing waste and ink residue with all developments focused on quick, safe and reproduced job changeovers, in which the print job is analysed at the beginning of the printing process and can be used as the master for automatic register and colour optimisation.
Crystal ball
Italian manufacturer Uteco Converting has developed the Crystal 808, a CI press aimed at the food packaging industry, although the company points out that it is equally suitable for other applications requiring a high level of automation.
Due to be launched at drupa, the press can reach a speed of 500 m/min and the standard machine configuration includes front rewinder and unwinder enabling easy loading. With its fast changeover and compact design, it is well suited for short runs, and changeover operations can be carried out while the machine is running in complete safety for the operator. In addition, its quick start up, doctor blade tightness, automatic cleaning system of the central drum and LED lights help make all machine operations easier, while the rigid construction eliminates vibration when printing heavy jobs.
The company’s patented Kiss & Go system for automatic impression setting and Click & Drag for register setting up ensures minimum waste at the start of each job. The new press can also accommodate a wider assortment of anilox rollers and formats. With an enhanced drying system achieved by the reduction of friction and better air canalisation as well as the application of variable speed fans, the press promises significant energy savings. High efficiency brushless motor drives increase performance by 20% to 30% offering still more savings.
Green features
Comexi Group said that it is committed to leading the flexible packaging converting industry into a sustainable and environmentally friendly setting and that sustainable innovation is its the goal.
Along with partner BASF, the company will present the Flexo F2 press at drupa. This new press comes equipped with Cingular modules developed for managing pressure adjustments and registration, which can offer significant reduction in waste.
In order to achieve important advantages, such as accessibility, easy maintenance and energy savings, the company will introduce the latest technology in water-based inks with BASF resins. These inks offer improved sustainability and reduced cost in use while maintaining a high level of printability and print quality.
The press will feature an automatic reel unloading system which is part of the Enviroxi product line that is dedicated to developing solutions for logistical management in production plants and reducing environmental impact in the graphics industry.
On the stand will also be a demonstration of a fully compostable package printed on the F2 using Ecovio substrate from BASF, with Flint Group’s PremoFilm SXS certified inks and laminated on a Nexus EVO with Epotal ECO compostable water-based adhesive also from BASF. Comexi has joined up with partners Flint Group, Actega-ColorChemie and Chimigraf, which will be present on the stand.
Small and efficient
The new Fischer & Krecke 20SIX press, which will be launched by Bobst at drupa, is a compact machine aimed at the small and medium converter looking to win new business from brand owners. With its small footprint and modular platform, it cuts down on waste and changeover time as well as energy consumption. This has been achieved by optimising drying systems, integrating the automatic wash up system, redesigning sleeve mounting and optimising ink consumption.
The basic model is an eight colour press with integrate loading function. Options include an updated version of the company’s trademarked smartGPS (Graphic Positioning System) technology, which was first introduced in 2009.
Sustainability and efficiency are the main driver behind this new press. Bobst defines these as less production waste, the ability to print thinner films, an increase in machine up-time, less energy consumption, less manpower needed on the press, less dependency on operator performance, and reduction in inks, solvent and adhesives consumption.
Business director of the web-fed business unit, Eric Pavone, said, ‘Converters are looking for a stable machine that can produce the high quality of print that their customers demand. Our machine eliminates guesswork and operator dependency by minimising the variables and offering a high level of automation and stability.’
The press is 3 to 4 metres shorter in length than comparable machines. The eight colour model is lower and all decks can be reached easily while the larger 10 colour version only requires a small step ladder for the top decks. A further option is the new smartCol, an offline colour matching system which can map the whole job and specify anilox requirements for the customer. It promises considerable reduction of wasted substrate (a max waste of 50 metres of substrate is guaranteed), ink (reduced by 50%) and time (full speed achieved in 20 seconds).
Printing width ranges from 800 mm to 1700 mm and printing speed for the eight colour base model is 400 m/min. An HS (high speed) version for very long runs will also be available and Mr Pavone said it would be running at speeds up to 600 m/min.
