Drupa 2012 review

Drupa 2012 review

The world’s biggest print show, while not a labels-specific event, continued trends seen at Labelexpo towards digitization of the print process with a new emphasis on automated color control. Andy Thomas reports

Drupa 2012 was in many ways a watershed show in the commercial print market, with the launch of a range of B2 inkjet sheetfed presses and of course the much hyped launch of Benny Landa’s ‘nanographic’ print process.

As there were no live print samples available it was impossible to assess the claims made by Landa, so we must await the first production models in around 18 months time.

We covered extensively the big new launches from HP Indigo and Xeikon in the last edition of L&L, and prototypes of the HP Indigo 20000 label/flexible packaging press and 30000 carton presses were on show, as well as the Xeikon carton print and converting line. Of major interest here was a digital cold foiling application which used a clear toner as the adhesive to bond the foil onto the substrate.

The narrow web single pass inkjet vendors were present at the show, and for a full review of inkjet developments, turn to the feature by L&L technical editor Barry Hunt on page 52 of issue 3.

Durst launched a wider, 330mm press which prints with CMYK+white, with orange and violet to be available later this year for optional extended gamut printing. The speed of the press is 48m/min (157ft) which translates to 950sqm/hour. Durst also demonstrated a new white ink, which is broadly comparable in opacity with a good UV flexo white, as well as an early trial with metallics. Resolution from the Xaar 1001 heads is 720 x 360dpi, achieved by doubling up inkjet modules. The press was demonstrated with an inset capability enabling printing on pre-diecut and pre-printed labels for late stage versioning.

FFEI was showing for the first time a dedicated white print station on the 410mm- wide Caslon hybrid flexo/inkjet press built by Nilpeter. Going forward, FFEI will now sell the exclusively digital version of the Caslon through its global sales and support network, while Nilpeter will continue to sell the hybrid inkjet/flexo press version.

Omet launched its JetPlus in-line inkjet technology, with a 4-color module mounted on an XFlex X6 UV flexo press. The press was demonstrated printing wine labels at 60 m/min. The press line also incorporated Omet’s Monotwin Cut single cylinder die-cut system, where format changes are achieved simply by replacing the flexible die.

Focus announced its entry into the digital print market with the launch of its d-Flex combination inkjet press. The press adds 4-color inkjet heads to the existing Reflex servo UV flexo press.

Heidelberg formally launched its own badged narrow web inkjet press, the Heidelberg Linoprint L. This was otherwise the same machine seen at Labelexpo Brussels on the CSAT stand after Heidelberg acquired the company, with a print width of 210mm and resolution of 600dpi using LED-cured Kyocera heads to print at speeds up to 48m/min.

Daniel Dreyer, head of Heidelberg’s Linoprint program, said most interest had come from Heidelberg’s existing sheetfed customers, both label converters and general commercial printers looking to move into PS labels.

EFI Jetrion were another Xaar user which had increased the print resolution of its Xaar-based inkjet press, demonstrating a new 720dpi mode on its 4900 press – which also includes a dedicated laser die-cutting section. The company also announced a broadening of its qualified portfolio of flexo substrates that need no special coating or overlaminating. This means the Jetrion 4830 and 4900 are now compatible with additional stocks from 3M, Avery Dennison, Flexcon, Raflatac, Ritrama, Spinnaker and Wausau.

Drupa also gave converters a first glimpse at a prototype of Screen’s new UV inkjet press, one part of a major move by the company into the package printing market, which included a carton-optimized inkjet press and a flexo CTP unit.

Stork Prints showed its established DSI UV inkjet press with a new digital primer, enabling printing on machine-coated paper. The press is supplied with four print heads as standard, but an additional six can be added to enable options like the digital primer, digital white and an extended color gamut through orange and violet.

Konica Minolta introduced a successor to its established KM1024 industrial inkjet head. The KM1024i has a printing speed approximately three times greater than the KM1024 and is compatible with a wider range of industrial inks, aqueous, solvent and UV. The unit has 8 grayscale gradations with13 pl droplets.

For label converters, OKI is majoring on its proColor pro510DW roll-fed digital label press – part of the proColor Series of digital printers – launched last year. The press uses using a drum and toner model using LED imaging to fix the toner particles rather than laser imaging. Its consumables are based on OKI dry toner that adheres to a drum roll where the image area charge is neutralized by small LED printheads. The image is then transferred from the drum to the media.

The pro510DW digital web press has four color stations and a print width up to 12.9 inches. It runs up to 30 ft/min (10 m/min) with fully variable data where required. A three inch core holds up to 300 feet of material.

The press is equipped with auto insertion hardware and software that allows converters to ‘cut-on-the-fly’, so when multiple jobs are run on a single roll, each can be cut and cored while the material is automatically held and set for the next run.

As well as new wide-web inkjet kit, Roland DG introduced a white ink for the BN-20 desktop printer/cutter, adding to the metallic option for this CMYK unit. Typical applications for the system include textile heat transfers, labels, stickers, promotional material and signs.

Atlantic Zeiser showed a hybrid digital/sheetfed print solution by mounting a Delta inkjet system for serializing and coding onto a KBA Rapida 105 sheetfed offset press.

Inx showed its new NW140 narrow web inkjet press with UV LED curing, part of its Evolve Advanced Digital Solutions line of equipment, which now includes the option of an in-line Spartanics laser die-cutter module.

Isys launched its Edge 850 desktop label printing system at the show. The machine press will print variable data on die-cut or roll substrates at speeds of 8 m/min (25ft/min/ 6ips) on a wide array of media. The company says applications will include beverage, food and consumer product label printing.

Presses

A new press player for L&L readers will be KYMC, which introduced its Moduflex mid-web in-line flexo press with an 870mm (34.25”) web with UV and/or hot air drying for shrink sleeves or cut and stack label solutions with print repeat range of 300 mm (11.8”) to 800 mm (31.5”). KYMC has an impressive track record. The company has over 1,000 installations CI flexo and stack presses in 42 countries.

Soma Engineering launched its Premia flexo press running the new Connection monitoring software. The 1270mm wide Premia press runs at up to 500 m/min and featured ‘Ink-Ready’ job preparation system, which covers wash-up, blade & sealing exchange as well as anilox sleeve changeover, and allows preparation of the next job while the current one is running.

Focus Label Machinery extended its Centraflex flexo press from water- and solvent-based to a new UV model designed for printing and converting a wide range of unsupported substrates including shrink sleeves and casings. The press incorporates a water-cooled CI drum together with air-cooled lampheads on each print station. For textile labels and ribbons, Focus launched its benchtop B4 Letterflex. This new design offers up to four colors, with options for reverse side printing and multiple ribbon printing. A new, halogen lamp drying system enables production speeds up to 60 m/min.

Omet showed a Varyflex V2 press switching between cartons and flexible packaging. The demo moved from high quality cosmetic cartons, including reverse printing and cold foil, to a shrink sleeve label in just six minutes. The press demonstrated Omet’s new Vision-2 control system, resulting in dramatic waste reduction at these high machine speeds.

Muller Martini has significantly upgraded its VSOP web offset press, making access to the print units easier. Sleeve positioning has been improved, reducing wear and tear of the airshaft during frequent size changes and Muller Martini’s own inking system has been integrated into the VSOP. Remote diagnostic instruments are now available.

Lombardi showed a Lexus CI flexo press equipped with a double chamber central drum for cooling when UV drying is engaged. Features include a closed doctor blade with recirculation of the ink and automatic release of the plate roll at machine stop, allowing the anilox roller to rotate. With a speed up to 120 m/min, the Lexus press will handle a wide range of materials, from self-adhesives to flexible film.

UK-based press manufacturer K2 International showed its 6-color FastAction flexographic press equipped with full UV curing and servo drives to enable both label and film packaging substrates to be processed. A digital print head allowed for variable data and barcodes. While the company’s core competence has been in PS labels, 800mm-wide machines are now available for unsupported film shrink and  wraparound labels as well as flexible packaging applications using solvent and water based inks.

Chinese press manufacturer Weifang Donghang is making a major push into the European market with both a new intermittent offset press and a wider web flexo press for film and flexible packaging applications. Richard McGuire, international sales manager at Donghang, is currently busy setting up an Euroean network of agents and a new generation of presses will be launched at Labelexpo Europe, where the company has already booked a stand in hall 11.

Ancillaries

Kocher + Beck branched out into web control systems with the launch of its UR Precision automatic splicer and rewind system, the first of which was ordered at the show by US converting group Smyth Companies for its new Gallus RCS installation.

Martin Automatic demonstrated its range of narrow web automatic butt splicing unwind systems as well as web transport systems for delicate webs. The company is currently working on a comprehensive evaluation of automated splicing and rewinds in terms of sustainability profile as well as ROI.

Swiss company Berhalter featured a demonstration of its web-fed in-mold label die-cutting system. Handling thin IML substrates through die-cutting and stacking has long been a challenge, particularly the elimination of static charge, and this dedicated machine is an increasingly popular solution according to the company.

Machinery from AB Graphic was converting the full range of packaging materials. A Digicon 2 with an HP Indigo WS6600 was shown capable of converting short run flexible packaging and well as PS labels, while a joint demonstration with flatbed die-cutting and creasing equipment manufacturer Kama illustrated the effectiveness of printing and finishing small orders of highly decorated digitally printed folding cartons. This Digicon solution incorporates a large diameter unwind with in-line flexo unit for applying both UV and water-based varnishes. The company demonstrated the latest Saber Xtreme laser die-cutter in line with UV flexo and overlaminating units.

Cartes was also majoring on laser die-cutting of PS labels with the launch of its new HS series, fully configurable with hot stamping, silk screen printing, varnishing, embossing, flat die-cutting, laser and/or rotary die-cutting.

The line is fully modular. Cartes’ automatic Multi Head Positioning System the line to register pre-printed materials. Each printing unit is automatically centred in order to be precisely positioned on the label and, reducing waste when starting a job.

The HS line incorporates a regenerative braking system, which allows energy generated by the motors during the braking phase to be reused by other modules or even returned to the network to power other devices in the factory.

Atlas Converting Equipment showed for the first time its Titan SR9 Series Dual Turret (DT) slitter rewinder, demonstrating reel set changes of less than 30 seconds. The SR9 platform features three separate machine modules of unwind, slitter and rewind sections.  The converter need only change the rewind section of the slitter from a Duplex Shaft (DS) to a Single Turret (ST) or Dual Turret (DT) configuration, to meet changing production requirements, without the need to change the existing unwind and slitting modules. Atlas also announced a global technical support package for all its machines.

The new Soma Venus III flexible packaging slitter rewinder, available in web widths from 1100mm to 1850mm, is optimised for food and pharmaceutical packaging applications. Also shown was the Lamiflex E solventless laminator.

One of the most useful troubleshooting strategies when print quality starts to deteriorate is to check the setting of nip rollers. Nip Control is a company dedicated to developing these solutions, and at Drupa introduced its Pressure Indicator, which shows the peak pressure level inside a nip in Newton/cm2. This is done by inserting an extra-thin nano-technology sensor blade into the nip. This makes it possible to understand if cylinders are parallel or not, or if there are differences in pressure between different print units. This looks like a perfect instrument to use for trouble shooting print problems such as poor ink transfer, ink build up, plate wear, web wander or web breaks.

Turning to web treatment, Vetaphone demonstrated the Quick Change System on its updated VE1C corona treater, enabling tool-less cleaning and changing of the complete set of electrodes in a matter of seconds. Also on show was the new iCorona generator series with features including auto power density control, auto quality reports and auto maintenance schedules all controlled via an intuitive touch control panel.

Inking and drying

GSE Dispensing was demonstrating a very interesting software interface which integrates seamlessly with the printer’s MIS. The MIS interface provides real-time information such as ink availability, ink recipes and an immediate overview of ink costs per order, enabling a more responsive print value chain.

On the inks side, Marabu introduced its UltraJet DUV-F UV-curable inkjet ink for flexible substrates. This product is part of a comprehensive portfolio that includes the UV-curable Ultrajet range, TexaJet water-based sublimation inks, and the mild solvent-based Marajet series. A new low-migration ink was also launched, the UV-curable Ultrapack UVFP range. Further highlights included graphic screen printing inks and UV-LED-curable inks for container and label printing. Marabu's UV-curable special effect inks were shown on the new Sakurai Maestro cylinder screen press.

IGT introduced a new printability tester for the low end of the market, a replacement for manual proofers and hand rollers.

UV curing manufacturers were demonstrating how energy efficient and compact these systems have now become. UV Ray showed its newly developed Atom compact dichroic reflector, which can be supplied with water cooling. Atom adopts UV Ray’s latest PF technology to enhance its reflector characteristics. The company also showed a compact and lightweight chill roll with a dual chamber system designed to allow semi-rotary presses to handle heat sensitive materials.

Uv-Technik Meyer introduced its new eStar UV curing system with reduced energy consumption. It operates in combination with the company’s new EB 60 high efficiency electronic lamp ballast. Also new was the UV Spectro, which combines a spectrometer for measurements in the 200-440 nm UV range and a probe for measuring the intensity profile under a medium-pressure UV lamp or UV LED. The dose can also be measured.

IST showed its MBS-6 range of energy efficient UV lamp systems and on-line energy measurement, covered in great detail in the last edition of L&L.

UV LED is the current buzz word in energy curing technology, and Phoseon is at the leading edge of these developments, showcasing both air and water cooled products based on its patented Semiconductor Light Matrix (SLM) technology. Uv-Technik Meyer showed its lightweight and compact EDcure air-cooled UV-LED units designed particularly for ‘pinning’ and final cure in inkjet applications.

Vision systems

This Drupa will be remembered for when in-line spectrographic measurement came of age. These systems measure true color values, not just density and register, using l.a.b color space standards and delta E deviation. AVT introduced its SpectraLab module for both color and density measurements as an optional add-on for the PrintVision/Jupiter, PV/Argus II and the new PV/Argus Elite system. SpectraLab can be set to automatically measure user-selected points anywhere on the web, and on clear films can measure color printed on either side of the web.

BST International launched its own inline spectral measurement system, QCenter.Spectral, developed in close cooperation with instrument specialist X-Rite to allow inline and handheld color measuring systems to deliver comparable results.

Eltromat was also demonstrating a new spectral inline color measurement system.

There was also further progress in ‘conventional’ camera systems. QuadTech introduced a high-definition dot viewing system able to compensate for movement of unsupported film as an add-on for its SpectralCam color measurement system.

Tectonic International showed its K3WiFi digital camera system with features including video streaming, iPad connectivity for improved quality control via multiple locations and live print inspection. An enhanced CIELab color monitoring tool includes alarms for color error notification.

Nikka Research demonstrated on a Prati Saturn rewinder its Alis L1C-330 high resolution camera system, with modular apps for 100 percent print inspection, color measurement, PDF to print verification, barcode and 2D code verification, ISO grading and statistical data collection. Offline PDF-to-print and PDF-to-PDF verification was demonstrated with the ODRI A2 scanner system on a variety of substrates. Nikka also demonstrated its workflow solution where on-press camera defect data is used to control a rewinder via a central defect analysis database

Working with industry partners, Apex launched a flexo Pantone simulation guide based around the company’s GTT (Genetic Transfer Technology) ink metering technology.

Pre-press

Kodak has gathered together an impressive suite of package print-related hardware and software systems, and at Drupa was focused on the launch of its Flexcel Direct plate and sleeve engraving system, including both imaging equipment and elastomer sleeve material.

Also of great interest to label converters is the Spotless flexo system for replacing spot colors with accurate recipes for 4-color process printing. Spotless takes advantage of the expanded color gamut and wide tonal reproduction possible using Kodak’s Flexcel NX plates.

Workflow automation using Prinergy Powerpack software, as well as Brand asset management and product visualization solutions were also shown.

DuPont majored on its Fast Round technology with a complete workflow including a Cyrel Fast Round 1450 FR thermal sleeve processor and Esko CDI 1450 Cantilever digital imager incorporating UV Inline 2 technology. The Fast round workflow was supplemented by a Microflex Multiple Sleeve mounting system which allows the mounting of multiple round sleeves to register on one single print adapter. 

DuPont has now commercialized its DigiFlow system, a low cost workflow enhancement which vies digital Cyrel and digital Cyrel Fast the capability to create different dot shapes plate by plate.

The company also launched two new digital plates, the DuPont Cyrel solvent-process DSP and the Fast DFP, designed for flexible packaging printers requiring high densities, good minimum dot size and low dot gain. The DuPont Cyrel DFR, meanwhile, is a high durometer digital Cyrel Fast plate capable of holding high screen rulings and a wider tonal range. DFR is well suited to both a standard digital workflow and DigiFlow.

Drupa was also the first opportunity to see Xeikon’s new ThermoFlexx flexo CTP system – a rebadged version of the FlexoLaser technology which Xeikon acquired recently and which forms a key part of the company’s digital strategy: servicing converters with mixed digital and conventional press operations. Workflow is provided by Kodak’s Prinergy.

DigiFlex showed its Flexojet1725 inkjet CTP system for flexographic, dry-offset, letterpress plates, and optionally for rotary silk screen. The system jets DigiFlex Bi-component ink onto an analog plate, creating a mask for subsequent ablation.

MacDermid extended its Lux Platemaking technology with ‘Lux in-the-plate’, which incorporates the flat-top dot benefits of the Lux process into the plate itself, eliminating any extra steps in the platemaking workflow. Field testing of Lux in-the-plate is expected to begin later this year, with the goal of commercialization in 2013. MacDermid recently created a Lux Certification program and has certified 19 of its 100+ installation sites at both printers and tradeshops.

Lüscher launched its 8-page XDrum! UV CTP system, targeted at package printers using mid-format offset plates. It uses a new external drum system to process plate formats up to 930 x 1050 mm and achieve plate through-put of 25 plates per hour. Also new was the large-format MultiDX! 240 flat-bed CTP system, processing print forms in formats up to 1300 x 1100 mm and capable of exposing flexographic, offset and letterpress plates as well as photoresist plates for use in hot foil, embossing and punching applications. Resolution is up to 5,080 dpi.

Visitors also saw the launch of the Accent coating plate, a joint project undertaken by Lüscher and plate manufacturer MacDermid and targeted specifically at packaging printers. Accent coating plates for spot and surface coating can be imaged on an inhouse XPose! UV-CTP system.

Stork launched a new range of light-weighted gravure sleeves and adapters. The re-engineered sleeves are based on a single metal technology – directly engraveable nickel – while Apex previewed its X-Sleeve project,  lightweight and durable plate-mounting and bridge sleeves.

An interesting launch from Recyl was the Sleeve trolley cabinet (STC) for protecting, transporting and storing anilox and plate sleeves. Available for narrow, medium and wide webs, STC models are designed for six, eight or 10 sleeves. They fit all sizes and diameters of cylinders. Made of aluminum, the STC trolley is robust. Various options can be added to these standard models like individual opening for sleeves, marking company logo on trolley and special location for files plates.

Intelligent inspection

The new Spectral measurement camera forms just one part of BST’s very interesting QCenter ‘intelligent’ quality assurance system.

Rather than the operator selecting a camera – linescan or spectragraphic for example – Q-Center automatically chooses the appropriate hardware and software tools depending upon what part of the web the operator wants to look at, and at what level of detail. The operator uses a large Quad HDTV touch screen monitor wall to control functions such as zooming, selecting fields of view, overview of the entire web width, and other quality assurance tasks. QCenter both selects a camera and automatically positions it to bring the selected web viewer onto the screen.

QCenter is fully modular, and can integrate multiple cameras, image analysis functions and additional lighting, all operated by the central user interface.

Don’t touch!

tesa demonstrated its SecuritySeal products which undergo a physical and visual change when they are opened. Such changes are irreversible, meaning that any attempted tampering is clearly evident. When the seal on the tape or label is opened, a warning appears and remains visible when closed again.

SecuritySeal labels can be printed with logos, serial numbers and item-specific barcodes, allowing use in track and trace systems.  

The company was also showing its StretchSeal and SecuritySeal security closure tags for reusable containers, which can be quickly attached and easily removed without leaving residue.

MIS augments reality

New features in Sistrade’s ERP/MIS system for the printed packaging industry, included an Augmented Reality tool which enables 3-D visualization of the final printed and converted piece, sent to the end user along with the usual technical information.

Other additions included a flexo plate management system, defining the imposition for each job as well as managing stock control of the photopolymer plates and generating a specification file for EskoArtwork or other plate cutting machines.

An enhanced scheduling module now allows for dynamic, multi-user interaction and allows management of both machinery and operator resources.

Sistrade also unveiled a program to incorporate security printing elements into its MIS.

Pictured: Berhalter demonstrated a system for automated handling of in-mold labels

This article was published in L&L issue 3, 2012

Andy Thomas

  • Strategic director