Italian label converter, Grafiche Amadeo, is producing labels with intricate designs using a double die-cutting shape without backing removal on a specially configured Omet XFlex X2 370.
Omet designed a tailor-made solution for the production of dual-shape labels based on the addition of a die-cutting station in-between the flexo units and with the an accurate use of the glues.
The machine was designed with a layout that enables the removal of the internal part of the label, by cutting and removing it before the stripping unit. The die-cutting unit installed between the last two printing units cuts the shape meant to be removed, without touching the backing, thus preventing the support from being punched.
Andrea Delfino, head of the label sector at Grafiche Amadeo, explained, ‘After the cutting process, we use a Cold Foil and a flexo unit to apply a layer of UV glue on the shape already die-cut, to facilitate its removal. The label and the filmic substrate are coupled by mean of a nip roll, the UV lamp activates the glue and the removable shape sticks to the plastic film that strips it away. The following steps consist in traditional die-cutting process and matrix rewinding to obtain a special label with both internal and external die-cutting shapes.’
The application of a layer of glue killer under the part of the label to be removed is a crucial step for the job. When the adhesive material is separated from the backing, this particular substance is spread onto the area corresponding to the removable shape, weakening the strength of the glue in order to facilitate the stripping process. Without this special glue killer, the maximum printing speed would be dramatically slower than the working speed of 130m/min capable now.
Omet had already integrated this special configuration with the die-cutting unit between two printing units on an XFlex X6, fully automatic and high-performance machine. Yet, Grafiche Amadeo’s X2 is the first machine to implement this very application on a completely mechanical platform.
