Italian press manufacturer’s alliance supplies Litografia Fiorentina

Nuova Castagnoli S.r.L. has supplied an in-line UV offset press to Florence-based Litografia Fiorentina. The press includes six UV offset units from Nuova Castagnoli with unwind/rewinds and flexo varnishing. The press is equipped with intelligent register PC interface to control job storage, remote tension control and press adjustments including fully automated inking and dampening functions.

The precursor of the new Xpannd press, currently under joint development by GIDUE and Nuova Castagnoli, the installation at Litografia Fiorentina uses the combined expertise of both companies. The extended UV litho technology planned for the Xpannd is intended to serve the markets where GIDUE has developed a major presence.

Federico d’Annunzio, GIDUE managing director, said: ‘UV offset technology fits in well with our existing product offerings and provides the needed growth opportunities to help us meet our five year plan to double turn over.  We fully believe the offset technology developed with Nuova Castagnoli, will force the label producing industry to radically change its thinking regarding this printing method’s ability to meet their needs when combined with other print technologies available from GIDUE. By combining our existing flexo, screen and gravure printing technology with new UV offset science we come another step forward towards standardization in the label industry while at the same time reducing the production and operating costs of the label manufacturing process. The installation at Litografia Fiorentina uses UV offset units from Nuova Castagnoli adapted with GIDUE technology to meet the requirements of the pressure-sensitive label market.’

Litografia Fiorentina began label production with a German-made sheetfed press then moved to Swiss made letterpress machines where the need was to reduce production costs while maintaining high product quality. The new press consists of six UV offset print units, a UV flexo varnish station with an enclosed doctor blade chamber along with unwind and rewind system, two die cutting units and a matrix removal unit.  The UV curing system is fully integrated with the press and is supplied by GEW (EC) Ltd. of the UK.

Litografia Fiorentina serves the Italian wine, spirits and olive oil industries where the market calls for short run with many jobs as low as 20,000 pieces using expensive antique and specialty paper substrates. Waste and print quality are then key factors for the company. Owner Romano Romoli commented: ‘Traditionally, short runs have been a problem for rotary offset, due to high waste levels and extended make ready times.  What we have found with the offset press technology is that set-up times and make-ready waste are generally the same as for compact letterpress machines. After completing our learning process, we are seeing only 10 to 15 meters of waste substrate during make-ready. Also, offset offers an advantage when printing the textured labels we supply.’

Print results have been reported to be equivalent to that obtained on Litografia Fiorentina’s sheet fed offset presses at a reduced cost. A marked improvement is the absence of ghosting commonly seen with offset printing which Nuova Castagnoli engineers say is due to the 16 rollers used in the ink train.

A key factor in reducing make-ready waste for the offset press is the low idling speed used. Most rotary litho presses have a minimum press speed of 40 m/min (132 ft/min) to obtain job print quality thereby producing significant waste.  This is a particular problem when processing short run jobs on relatively costly substrates typically used on wine and olive oil labels such as produced by Litografia Fiorentina. 

Federico d’Annunzio explained: ‘This slow idling speed is achieved by controlling the water fountain roller with an independent servo motor. During make ready we increase the speed of the press for a short time until we are printing high quality labels at 12 m/min (40 ft/min).  We adjust the speed of the water flow as we ramp-up the press speed. Once we have found the correct operating curve for the color units on each substrate process we can save this ink/water balance setting into the press control computer.  Press operating settings, controls and measurements are stored in the ‘Intelligent’ electronic control program which can be recalled by both production and print managers. The intelligent PC based interface controls all the parameters within the ink train.  Needed adjustments are carried out on the PC main control panel through automated servo controls on the ink ducts, water and inking rolls.  The ink management system logs all data of the inking process which can be called up later for repeat jobs or even used for new orders if appropriate.’