Heidelberg-Gallus launch digital converting system

Gallus and Heidelberg have jointly unveiled the prototype of a digital press that uses FujiFilm 1200dpi inkjet heads to print at speeds of 50m/min in up to 7-colors plus white. Conventional modules are only used for web preparation, embellishment and finishing.

The Gallus DCS 340 press was shown at Gallus’ Innovation Days event, which also included key announcements about future conventional press developments.

The DCS (Digital Converting System) 340 is built around a Gallus ECS 340 ‘granite’ press frame. The DCS 340 press is fully modular, and at the launch event was configured with servo unwind, web cleaning and corona stations, two UV flexo print heads, DOD inkjet module, flexo UV varnish, semi-rotary die cut, slitting and rewinder.

Up to 64 Fujifilm Dimatix printheads, each delivering a drop size of 2 picoliters, are deployed in the inkjet module. These are the same heads used in the FujiFilm Jet Press 720 B2 sheetfed press, but adapted to handle UV inks. The prototype Gallus DCS 340 was configured to print in up to six colors (CMYK, Orange, White), but will show its full gamut range with additional Green and Violet, when the press is launched at Labelexpo Europe 2015. It combines LED-UV inter-color pinning with a combination of both LED-UV and mercury lamps for final cure.

The DCS 340 press is driven by Heidelberg’s Prinect digital front end, which will be common across the new generation of Heidelberg digital press systems developed with FujiFilm. The DFE will handle workflow automation and color management, including spot color matching.

AVT demonstrated a new quality assurance technology integrated into the Gallus DCS 340 press control system. Features include real-time print quality monitoring and continuous detection of missing, deviating or weak printing nozzles. The AVT system can be expanded to include color control, verification of geometric parameters like color-to-color registration and image placement. It can monitor both static and variable content, classify possible print defects and initiate corrective actions.

Rapid prototyping

The Gallus DCS 340 short-circuited Heidelberg’s usual lengthy development process, moving from concept to prototype in less than a year, guided by Jason Oliver, Heidelberg’s recently appointed senior vice president Digital Print. As former leader of EFI-Jetrion’s European operations, Oliver has plenty of knowledge of the requirements of the digital label and packaging markets.

The final version of the Gallus DCS 340 is expected to launch at Labelexpo Europe 2015 at a price around €1.4-1.5m in this configuration.