RotoMetrics and Omet combine to offer cost effective short run flexo cartons

Leading suppliers of rotary tooling, RotoMetrics, and narrow web flexo presses, Omet, have combined to create a unique installation for the cost effective production of flexo cartons at Base Consulting in Romania.
 
The installation consists of an eight-colour Omet VaryFlex-F1 with a 530 mm web width and full UV capability.  It is the first Omet to be installed in Romania, and was chosen for its capability across different substrates.  The Omet offers flexibility with its facility to run 12-micron PE up to 600 gsm board.  Its web width of 20” and running speed of 170 m/min has doubled output and the company has been test-running cartons at 110 m/min.
 
Two of the flexo print stations have the capability of printing on the reverse of the web, and the Omet has both screen-printing and hot foil units, which can be interchanged with a flexo station.  Fitted with a 1500 mm diameter unwind unit, to cater for carton board, the Omet currently has sheeter and rewind units at the delivery, but it is due to have a stacker added in 2011 to enable Base to up its carton production to 50% of its total output, and eventually to 100% of the Omet’s capacity. 
 
To cope with this volume of cartons, Base needed to find the best die-cutting solution, and the male/female principle of creasing was the obvious way forward with RotoMetrics technology, which devised a bespoke system for the Omet.  It has a two die cassette stations on trolleys for easy mounting, offering the possibility of preparing one unit offline, and uses the latest RotoMetrics flexible dies, fitted to high strength magnetic cylinders.  The tooling, which brings lower costs to rotary die cutting, so long its biggest deterrent, is proving ideally suited for shorter run work.
 
According to James Wellsbury, of RotoMetrics UK: ‘Our flexible dies and magnetic cylinders have brought rotary tooling within the reach of more converters.  Depending on the application and materials, our flexible dies can offer significant upfront production tooling savings.  They are easy to use and quick to fit, and you need only one set combined cut and crease or separate cut in one station and crease in another.’  The new technology has achieved low cost production of high volume folding cartons in one pass, with a complete job change on pharmaceutical job achieved in less than one hour, because the creasing is integrated with the cutting tool.  ‘Flexible die tooling can lend itself to crush cut or RP pressure cut – and both are available,’ added Wellsbury.