Edale develops AIIR to take flexo automation to ‘new heights’

Edale has teamed up with press control system specialist AVT to integrate its camera-based technology into the Edale range of FL3 and FL5 flexo presses, providing an optimal level of registration not seen before in single pass printing, according to Edale. Bespoke software developed in-house by Edale ensures that five additional motors, individually positioned on each print station, adjust the print impression, inking and cross register.

Registration marks are printed on each station and fed through to an AVT Helios S camera positioned at the end of the press. The camera analyses the relative positions of the marks and sends necessary corrections to the respective print stations. Sophisticated tracking software developed by Edale ensures that no additional corrections are made until the initial corrections have passed the camera.

To minimize waste, the AVT Helios S camera registration implementation is designed to complement Edale’s pre-register and print-to-mark register systems, ensuring that a saleable product can be achieved in no more than two web lengths of the machine. Increased linear and cross registration accuracy can be maintained throughout the print run, without the intervention of operators manually adjusting registration settings which can lead to increased wastage and out of register prints.

Edale said the technology significantly reduces the number of operator inputs and time needed to set-up a job by automatically positioning the pressure settings based on saved job data or material calliper. Print consistency is enhanced through operator defined profiles that adjust pressure relative to press speed.

The addition of AVT’s Helios S system, fully automatic image-based pressure control technology, takes automation and quality to a ‘new level’, according to Edale, by analyzing all the print stations during make-ready and adjusting the plate and anilox rollers automatically. This brings the press to perfect print pressure which further reduces the reliance on operator input by automating the initial setting of inking and print pressure at the start of each new job.

‘As brand owners seek higher quality printing at lower costs, printers are constantly seeking ways to increase superior output whilst minimizing costs,’ Edale said in a statement introducing AIIR. ‘By fully automating print and registration processes, the level of operator intervention can be reduced leading to fewer errors and a more consistent, higher quality final product.’

AIIR is available as standard on all new Edale FL5 presses and can be purchased as an optional extra on the FL3 presses.