As part of L&L's comprehensive preview of new products to be seen at Labelexpo Europe 2015, here the magazine highlights new products related to finishing that will be seen at the show.
The full preview can be read in L&L issue 4, 2015, and online here, while you can read more about the following technologies on the L&L website: digital presses; conventional presses; inks, curing and drying; materials, adhesives and coatings; MIS and pre-press; ancillaries; finishing; inspection; linerless; and package printing.
AB Graphic introduces a heavy duty flatbed hot foil head with rotatable foil feeds to allow for feeding foil along and across the web direction. Male female embossing can be performed simultaneously with the foil process and impression capacity has been increased to 50 tons. Benefits include increased capacity, more efficient use of foil, and the ability to run multiple foils and embossing in the same module. AB Graphic will also launch its new full rotary servo-drive Converter, redesigned to reduce overall footprint and set-up waste on job changes. The Converter at the show will be demonstrated with a fully automatic Vectra turret rewinder.
Barry Wehmiller company Accraply launches Stanford AccraSeam FC, a fully-continuous shrink sleeve seamer. Equipped with a fully automatic table, the AccraSeam FC electronically sets the layflat width and seam location based on the desired layflat. Both the layflat width and seam location can be adjusted while the machine is running. Job parameters can be recalled via 15in touchscreen controls. At 421cm (14tt) long and 182cm (6ft) wide, the AccraSeam FC has a compact footprint. The dual shaft unwind and rewind turrets have flange-mounted pneumatic shafts with electronic core offset, making core size changes easy. The Stanford Layflat Inspector and Ultrasonic Sensor monitor the width of the layflat while running, providing both a digital and printed report at the machine. This monitoring system comes fully integrated into the AccraSeam FC but is available as a stand-alone system. The servo-driven AccraSeam FC incorporates servo-controlled solvent dispense, electronic oscillation, integrated web guide and tension control.
Ashe will show for the first time its automatic core loading facility on the company’s glueless 4-spindle turret rewind non-stop finishing machine. Each core can be loaded individually within seconds and gaps between each loaded core can be set and achieved with the system. The same system can operate core sizes of internal diameters from 25mm to 76mm. A 520mm wide Opal 'glue-less' turret slitter for labels will be operational during the show. The latest design of die station will also be running on a 420mm wide Opal converting line. This form of rotary die station is loaded horizontally and the pressure load is achieved via hydraulic rams, allowing precise and accurate loading of the die cylinders to the material being run. The design also allows for ease of loading and unloading of the die cylinders when fast changeover times are required for blank label production.
Bar Graphic Machinery launches four systems. The 450mm-wide BGM Elite MultiflexG2 is a full servo multiple substrate inspection slitter rewinder for unsupported and supported materials from 11 micron upwards. Fitted with BGM intelligent tension control system, the machine will be demonstrated with E+L’s latest sensor-free MMLD control system. The BGM Ecoflex is a multiple substrate inspection slitting and rewinding machine, demonstrated fitted with a one meter capacity unwind and integral roll lift. It includes a job memory facility. The eDTR re-register die-cutting slitter rewinder and eDSR high speed die-cutting slitter rewinder are both fitted with BGM’s easy load die-cutting station. The weight of the die is supported by the bottom guide rail, improving operator set up time, handling and reducing damage.
Berkeley introduces the Autoflex Excel AS300 automatic high-speed shrink film sleeving machine, capable of converting up to 350m/min.
Shows a workflow for the efficient manufacture of business cards and labels in multiple-up production. The printed sheets are die-cut with the Bograma rotary die-cutter BSR 550 Servo. With the Dynamic Alignment function (auto register correction) each sheet is also aligned laterally. This ensures a consequent cutting accuracy of +/- 0.1mm also with digitally printed sheets. An integrated barcode monitoring allows both and the consistent monitoring of the production. as well as the tracking of the products. Following the die-cutting and stripping process, the products are stacked in piles of identical products, and packed into boxes using a new, clever robot solution.
Brotech shows its SDF finishing system with a new semi-rotary flexo print unit and semi-rotary die-cutting technology. The new CDF Plus includes flexo coating, semi-rotary die-cutting, slitting, sheeting and conveyor stacking in one compact unit. Brotech also introduces the TR in- and off-line turret rewinding system with four quick change expandable spindles, core gluing and end roll closing system with integrated label dispenser and inkjet printer.
Cartes introduces the Gemini 360 (GE360) series of converting machines configured from entry-level upwards. The GE360 series incorporates the following modules: fully-/semi-rotary flexo unit; semi-rotary die-cutting unit; and Cartes CO2 Semisealed laser with no factory refilling needed.
Launches the Taurus laser die-cutter and laminator, capable of converting pre-printed media to die-cut labels and powered by an air-cooled CO2 30W laser source. The system support vector-based files and operates at up to 30 linear m/min. The unit laminates, removes matrix, slits and rewinds. Another new product from DPR is a wide-format digital label finisher capable of handling media up to 14in (355mm) wide, matching today’s wider digital presses.
Enprom & Vela, a new player in the narrow web industry, shows a solvent applicator for shrink sleeve seaming machines, improving both speed and seal quality compared with the current Vela system. The seaming machine adds in-line cross perforation to the shrink sleeve using a new module developed from an IML technology. A high speed magnetic roller system has been modified to work in semi-rotary mode, so one cylinder will be enough for all the jobs. The machine also includes a new system to apply in-line hotmelt onto the internal face of the shrink sleeve.
Introduces the system grün converter, which allows slitting and rewinding of narrow, 3mm ribbons. The specified line width is 300mm, which results in 100 slit and wound rolls. A double-sided axial friction winding shaft allows replaceable spring assemblies to be used on both sides, allowing pressure to be applied to the winding cores and the spacer rings. The spacer rings are co-rotated by the winding shaft, thus transferring the frictional power to the adjacent cores in each case.
Introduces a range of new measurement devices. The FAG Creasy measures and controls the heights of embossing and 3D metallic surfaces; the FAG Flex Pro checks elements printed with ultraviolet security inks; FAG Flex³ Pro has new functions to compare the dot on the plate and dot on the printed result.
Launches a flatbed unit for hot stamping and embossing for integration into narrow web label presses. Gietz also shows the unit as a modular off-line version with an unwinding and rewinding unit.
Launches the entry level GFSR Compact 1300 slitter inspection rewinder with 760mm (30in) unwind, dual 14in rewinds (355mm) – all with automatic tension control – and pneumatic rewind spindle options down to 1 inch (25.4mm). Speed is 200m/min (750ft/m). There are shear/crush/razor knife options.
Launches a combination print and converting machine with flatbed hot stamp and screen modules. The machine measures only six meters and has semi-rotary die-cutting and a flexo graphic printing station. Also new is a compact version of GM’s laser. The LC330 Laser Compact is equipped with registered flexo varnish, cold foil/super gloss and a knife box. GM’s established ‘mini’ series of in-line converting systems for digital presses has been upgraded with cold foil/super gloss capability. The unit now supports the HP6600 in-line calibration modes (web reversing). GM also launches a new inspection slitter rewinder.
The new DCL-series is a fully modular digital finishing machine which includes a non-stop system, flexo printing and combined semi-rotary/rotary die-cutting unit. Each module is servo-driven and works independently. The updated Servo R-series is a pharma machine for 100 percent re-inspection. The compact machine has a high speed servo buffer that allows re-inspection at 200 m/min. Grafotronic also shows its established Hi-series 100 percent inspection system with a new automatic knife positioning system. The CLD-series is a modular die-cutting machine with new quick change features on every part from unwind to rewind.
Presents the latest in the company’s VDC coding equipment range, the VDC 350 module, incorporating double coding with Inkjet Domino K600 high resolution inkjet heads and with laminating. The RF 250 module is designed for RFID converting and coding. Also on display is the VDC 80 module (thermal transfer + RFID), and the VDC 125 with Domino K600 Inkjet heads.
Launches the LC340S sheet-fed and LC330R roll-to-roll laser cutting and engraving machines. The LC340S uses a CO2 laser in a 340mm x 483mm format, while the LC330R has a web width of 330mm and roll diameter of 500mm. An optical tracking system allows accurate cutting positions for through-cut or half-cut options.
Launches a narrow web inspection slitter rewinder. Machine speed is up to 300m/min. The machine features airshafts on the unwind and rewind, splice table, pre-slitting web aligner, a servo-positioning nip, rotary knives with pneumatic throw and an edge slitting system with Venturi trim extract. Options include clear label count, missing label detection, inspection system integration, inkjet coding and dual shaft rewind, along with remote system diagnostics. The servo control system is manufactured by Tesla Controls, a subsidiary of Hyden. Hyden sources components from ABB, Siemens, E+L, Optex, Festo and P+F.
Introduces the new ComPress LF4 digital label cutter, a finishing system for the ComPress LP4 LED dry toner label printer. Features include contour cutting, waste removal and a slitter in a single compact device.
Launches non-stop K5 Seamer with a new QC Package that includes the new Automatic Solvent Application Positioning System to tie the solvent application to the film edge. The lK5 model will work with finished sleeve widths from 18mm to 350mm and runs to 500m/min. QC options include solvent detection system, splice detection system, lay flat measurement detection system with reporting, automatic solvent application positioning system and automatic flagging systems.
Launches Mustang-series turret rewinder with a smaller footprint and increased production speeds. The machine automatically loads cores, allowing for faster turret cycle times and permitting shorter rolls to be run at higher line speeds. The rewinder has four spindles and is available in web widths up to 20in (508mm), roll diameter up to 12in (304mm), speeds up to 750ft/min (228m/min) and can run cores ranging from 0.75-3in (19-76mm). Optional features include a roll label closure system, automatic core loading, slitting module and touch screen HMI mounted on a pendant arm. Customers can choose from two types of core gluing: automatic spray glue system with a hot melt tank and spray nozzle or the traditional core glue pot with an optional refill system.
Introduces the LDW-360S2R laser cutting machine in formats 269 x 227mm and 400 x 350mm. The laser is a sealed CO2 with an average 250W output and a peak 800W, making for a cutting speed of 7.62 linear cm/sec. Cutting width is 150 micron.
Presents the new Eiger330 die-cut to register machine, a full rotary unit that works in-line with the Labeltech rewinder to convert digital jobs. The gearless die-cut station, the matrix rewinder and the nip roll have three dedicated brushless motors. With its compact size, 1.2m, it can be transformed into a simple slitter/rewinder in a finishing machine. Also on display is the Labeltech IT450 series 5 with dual rewinder and 100 percent inspection camera.
Demonstrates the new Discovery MaxScan inspection system, which uses a sensor array to produce an image with true 600DPI resolution. MaxScan is available in three widths: 309mm(12”), 619mm (24in) or 929mm (36in). MaxScan has a working distance of just 12mm (0.5in) and with a maximum headroom requirement of less than 130mm (5in), the Discovery MaxScan can be integrated within the transport system of a press without the need for additional rollers, redesigned web paths or complex optical assemblies. MaxScan captures reflection-free images of holograms and foils across the full width of the web. The MultiScan Manager pulls together images and data from a multiple cameras to create QC reports.
Shows the Sprint 420 quality inspection system able to inspect defects of 0.1 sq mm area at a speed of 300m/min. The LabelRoll 330+ (vertical) inspection system inspects 3D printing defects such as excessive glue and bubbles. It Inspects a defect area of 0.06 sq mm at 200m/min.
Launches the MA350 label finishing unit designed for converting runs printed on digital or rotary lines in 350mm web widths. The MA350 can combine flatbed and rotary units in a single semi-rotary platform with a short web path without requiring a buffer. Modules include flatbed silkscreen, flatbed hot foil stamping, flatbed embossing, rotary die-cutting, rotary laminating, flexo units for varnishing, printing or coating and cold foil stamping. Use of flatbed screen, foiling and embossing units greatly reduces tooling costs.
Will present its new ‘light’ smart label machines, which include all processes in one system, including reel-to-reel antenna web handling, label or ticket lamination, die-cutting as well as output testing. The system has a throughput of up to 10m/min for semi-rotative cutting and of up to 30m/min for rotative cutting. The CL light is targeted at applications with smaller lot sizes and start-ups entering the RFID converting market. PL light is targeted at entry-level RFID applications involving personalization, following increasing demand for RFID and NFC products that include special printed features, serialization printing and unique encoding. The system operates at up to 18,000 units/hour. The process includes UHF chip encoding as well as printing variable data for graphical personalization. Both reel to reel as well as ticket to ticket usage is possible. A maximum width of 110mm can be processed. Thanks to its modular design other processes can be integrated on request.
Launches the Newfoil 3534 Servo flatbed hot stamping, embossing and die-cutting machine, compatible with 330mm-wide digital and flexo presses. The machine has a top speed of 75m/min, maximum web width of 340mm, and platen size of 310mm x 270mm (web direction).
Introduces new multi-screen interface for Alis camera line allowing up to 12 apps for web-viewing, color and register measurement, trend analysis and defects to run simultaneously. New camera models offer higher inspection speeds. The entry-level M1 camera product line has been extended with 520 and 630mm wide models. The ODRI product line with print-to-PDF and PDF-to-PDF verification now offers multi-artwork support, color consistency check and optional barcode grading.
One Box Vision introduces ImageFlow, a modular vision system which can be used to proof, inspect and serialize. The package includes Image Match, used to verify what’s on the press is what is in the customers design file; Print Master, used to guarantee that no defects will be printed during the job; and Code Flow, a complete serialization system that includes an interface to the leader in cloud based EPCIS compliant repositories and brand protection.
Launches the SRFD3030 finishing line for wine labels, incorporating a silkscreen printing unit with a faster, patented squeegee design, and hot stamping and die-cut stations. Also new is the DGCON350 digital label converting machine with continuous spot varnishing and semi-rotary/rotary die-cut station.
Launches the Digifast One digital label finishing line. With speeds of 80m/min and cutting waste to just 18 meters per job, Digifast One requires just over eight minutes for set-up, says Prati. The company also introduces the versatile Saturn Omnia processing line, able to handle PS labels, IML and flexible packaging. Thanks to its modular concept, it’s simple to switch from one label type to another, handle sample runs, or stack different shaped wet-glue labels or in-mold labels together at the same time. The new Jupiter WF is dedicated to labels and unsupported films.
Precise Graphic India shows its high speed rotary die-cutting machine Precicut–330, which runs at up to 150m/min with web width of up to 330mm. The die-cutting station is capable of cutting labels in the range of 8.5in to 18in repeat. It incorporates an electronic web guide with ultrasonic sensor and in-line razor blade slitter (rotary shear slitter optional). Unwind/rewind and waste matrix rewind shafts are of 3in core size. All machine functions are controlled with a PLC and interactive touch-screen HMI.
Displays for the first time a modular converting line in an in-line configuration with a Durst Tau 330 digital press. The line includes as flexo printing or varnishing, semi-rotative die-cutting, length slitting and rewinding. The line also demonstrates further options including production of sandwich labels, digitally or conventionally printed and combined using Printum’s multiweb capabilities; the option of booklet labels; feeding of individual or smart labels in full register; and complete cut-through features in order to deliver single labels or single carton products. The multiweb converting line can also function in a stand-alone configuration to process pre-printed webs.
Launches next generation DT-series for processing and finishing digitally created labels. New features include flatbed screen printing, in-line finishing with digital presses, and increased speed to 67m/min in semi-rotary mode. The DT-series is equipped with an automatic knife positioning system and integrated with the FC-series FastChange fully-automatic 4-spindle turret. Standard with a fully integrated flexo printing station and a semi-rotary die-cutting unit and register control, the DT-series is suitable for varnishing, die-cutting in register, slitting and rewinding of printed or blank labels.
Introduces to the European market the Labelmaster laser die-cutting system, available with between one and four laser heads. Additional finishing options include semi-rotary die-cutting, full and semi-rotary flexo varnishing, semi-rotary hot stamping, overlamination, self-wound/liner lamination, sheeting and slitting.
Smag introduces a variety of new products including a high speed screen station (SP model) integrated on Digital Galaxie Systems, with running speeds of 30 m/min, large format size, flatbed technology, and using standard ink and frames. Automatic length slitting adjustment is now available for the Digital Galaxie: E-Cut and Sirius, including automatic workflow adjustment, save positioning set-up knives and eliminating potential dimensional errors. A new laser die-cutting station (powered by Spartanics USA) on Digital Galaxie uses new 400 Watt laser technology with its own workflow software. 3D Jet varnish and digital foil are presented in cooperation with MGI, including electronic screen, electronic foil and laser die powered by Spartanics. Other new systems include an RFID tag insertion system and fully automatic turret rewinder, powered by Errepi.
Launches a 500mm-wide laser die-cut system fully integrated on the converting line and online with any MIS/ERP system. New jobs are identified by a barcode printed by the digital press, with the system adjusted on the fly without stopping the line. Also launches an automatic slitting system, meaning job changes can be performed on the fly without stopping the line. The Werosys automatic turret ‘knows’ when a new job arrives and automatically cuts the web and changes the rolls automatically without stopping the line. The close integration between all modules means that the line will take care of separating the jobs and perform all adjustments. The line doubles as a 350m/min slitter rewinder (faster as option).
Launches the RSDS6 Plus TTR slitter with ribbon saving. The jumbo roll returns automatically to add the leader foil, and the company says this saves around 0.8m of material. Machine speed is 400m/min and maximum web width 600mm.