Bradford converter installs first FA-Line press in the UK

The installation of an eight-unit, servo-driven Nilpeter FA-4 UV-flexopress with a maximum web width of 410 mm (16,5 inches) is expected to greatly extend the services offered by The Label Makers Ltd of Bradford in West Yorkshire, UK. It is also the first FA-Line modular press for labels and packaging to be installed in the UK.

Besides eight UV-flexo units, the configuration includes two drop-in rotary screen units for positioning anywhere within the press line, and a cold foiling device for metallic printed effects. Other ancillaries include a delaminating and a relaminting unit for producing reverse-side printing of primary labels. With a total cost of 600,000, the new press joins several other Nilpeter narrow web presses, including three offset-based MO-3300 Servo, all with 330 mm web widths.

Like all FA-Line models (available in four web widths), the FA-4 can reach speeds of up to 175 m/minute (575 feet/minute). The unwinder and rewinder have the same 40-inch diameter, while a taper tension control on the latter ensures uniform tension for all types of substrates. Direct servo drives are used for the web infeed, print cylinders and die-cutting stations. Eliminating gear wheels on the printing cylinders avoids the risk of gear marking while allowing greater flexibility with repeat lengths. Servo drives also facilitate multi-substrate printing, from un-supported films and foils to carton board.

Founded in 1963, The Label Makers Ltd remains a family-owned company and has currently 54 employees. Pressure-sensitive labels for the cosmetics/toiletries and industrial sectors make up some 80 per cent of the annual turnover of around six million pounds, with labels for dairy and various food products accounting for most of the rest.

David Webster, managing director, says the FA-4 is the widest press installed by the company. 'Those extra three inches on the web allows us to print one extra label across the width for certain large-format jobs, such as margarine tubs. The fact that we can achieve repeat lengths of 24 inches also gives us more flexibility. Also, the
quick set-up features and low materials wastage means we can handle quite small runs, down to 1,000 linear meters, whereas the average run on cosmetic labels is 2,000 to 6,000 linear meters.'

The press line includes 13-inch chill drums positioned at every print station to augment the GEW UV-curing lamp modules. David Webster says this feature will allow the company to examine new types of packaging  markets involving heat-sensitive films, laminates and foils, such as sachets and pouches for toiletries for example. The FA-4 prints with either conventional flexo plates or the new type of light weight polymer sleeve constructions now becoming available. The company produces all its flexo and offset plates, using an Esko Spark CDI digital platesetter and DuPont's Cyrel FAST solventless plate processing system.