Digital finishing showcase at Labelexpo

The rapid adoption of digital printing in the label industry has created the requirement for finishing systems efficient enough to economically handle short runs of pressure-sensitive labels. In the early days of digital print, the slow speed of the presses made it more efficient to finish labels off-line, with one converting machine often handling the output from multiple digital presses.

As today’s digital presses reach speeds of 50-75m/min, there has been growing interest for in-line configurations that more closely resemble the traditional narrow web model of single-pass printing and converting. In response, more finishing manufacturers are offering systems capable of both in-line and off-line configuration with the addition of a buffer and timing systems.

The requirement for finishing short runs means semi-rotary die-cutting – where different formats can be handled without changing cylinders – has become a standard, with full rotary sometimes offered for managing longer runs. The industry has seen the development of laser die-cutting for instantaneous change of cutting format, albeit with some substrate limitations.

The drive to automate as many processes as possible also has seen the development of automated slit and back scoring knife positioning, all tied into a unified pre-press workflow based on JMF and JDF file formats. Similarly, more manufacturers now offer semi and full turret rewinding stations for non-stop operation. Another key trend has been the development of the finishing system from basic varnishing and die-cutting format into a self-contained value-added converting system, with modules available to add a wide range of decoration techniques including hot foil/embossing, cold foil, semi-rotary and flatbed screen and inkjet numbering/marking.

The decision of which of these options to take or leave is an increasingly complex one, and will require consideration of the degree of automation and added-value decoration required, as well as the benefits of an off-line versus in-line configuration.

This Labelexpo Americas special feature will demonstrate the wide range of technology solutions available. In the Digital Finishing Experience at the show, visitors will have the chance to see digital finishing machinery from Delta ModTech and Xeikon.

Delta ModTech

Delta ModTech will showcase its Spectrum Finishing System in the Digital Finishing Experience Delta ModTech touts the Spectrum’s tight tolerance semi-rotary die-cutting, high-speed output and on-the-fly changeovers as just some of the capabilities. This finishing machine does automatic changeovers on a continuous printed web through the use of Delta’s Intelli-Mod control system, multiple semi-rotary die-cutting stations and auto-adjusting slitting knifes. Through the use of barcode reader, the Spectrum can detect the incoming product change and automatically load a new program.

The Spectrum, which boasts maximum speeds of more than 500ft/min, features total servo control for tight tolerance digital registration. It has full rotary, semi-rotary and specialty cutting abilities and under cutting with registration to a kiss-cut, and is modular, allowing users to add new options at any time.

Xeikon

Xeikon will showcase its flatbed die-cut unit at the show. The Xeikon Flatbed Die-Cut Unit was launched at drupa and will make its North American debut at Labelexpo Americas. Developed to aid end-to-end printing and converting for folding carton printers, the Flatbed Die-Cut Unit is designed to fit in any digital production of carton, tags and sheet-fed labels.

This 2,000-sheet-per-hour flatbed system handles sheet sizes from 400 x 400mm up to 530 x 1000mm and a maximum die-cut size of 490 x 700mm. Substrate thickness can range from 160 to 890 micron for paper and carton board and also microflute corrugated board can be finished.

This article appeared in L&L issue 4, 2016, as part of the publication’s preview of Labelexpo Americas 2016; the full preview can be read online here