Which one would you choose for your current entry-level flexo press?

For whatever reason, some companies must invest in flexo presses that are considered "entry-level", such as start-ups or simply need to upgrade presses to increase capacity. Clearly, these presses are now quite sophisticated equipment.

Phil Baldwin, UK sales manager at MacAndy, said: "Entry-level presses today are almost completely different from those of a few years ago, far from the simple monochrome, two- and three-colour stacked presses that were mainly used in typical self-adhesive labels. Advances in technology, especially the drivetrain now equipped with servo motors, and higher expectations from label processors and customers have created a modern and cost-effective line across a range of jobs that is easy to use."

Interestingly, while many press manufacturers readily identify "entry-level" presses in their portfolios, they believe these machines stand out in the market in terms of design and performance. For example, Bost said that when asked about the advantages of their entry-level models, the Nova M1 and Vision M1, their answers were ease of use, compactness, and reduced maintenance and operating costs.

"The reduced footprint is probably the biggest advantage - even with eight colours and two die-cutting stations, the Vision M1 is less than seven metres long," notes Bost. Bost's presses are all available in 370mm web-width versions, and the Vision M1 is also available in 430mm web versions. The maximum operating speed is 180m/min. "They have all the basic features, while also including some optional accessories, such as printing on rubber surfaces or decoration," concludes Mr. Pasquinelli. "In addition, since these robust presses are designed for heavy-duty applications, their output capacity is quite high."

01 Extensibility

02 Functionality

Omet cites the functional design of its iFlex entry-level press as its main strength. The press has a width of 370 mm, a top speed of 190 m/min, a print repeat range of 140-457 mm, and a die-cutting repeat range of 203-609 mm in-line.

Regarding the functional design, market coordinator Massimo Bellingardi said: "The iFlex has a short coil path that minimizes boot waste. Due to its compact and ergonomic design, maintenance and spare parts costs are very low, making it a truly cost-effective solution. The iFlex also has a unique smart application specifically designed to make the entire printing process simpler and more intuitive."

These smart features include iLight, an innovative pre-registration system with a laser pointer on each flexographic printing unit that uses a beam of light to point to the registration of the printing cylinder, enabling faster job changes and registration settings. A second laser system is installed within the die-cutting unit to help operators accurately locate the flexographic die. iVision is a registration adjustment system that sets color-to-color registration in real time through a set of smart cameras, which is available in every printing unit.

The iDrive is a new type of direct-drive drive on impression rollers that Omit says can improve printing accuracy. Bellingardi says: "This is the only narrow-format rotary press that requires only one gear per printing unit, so it has better performance and greater stability without any gear marking issues."

03 Customization

From Focus Label Machinery's perspective, the key to standing out in the entry-level market is through bespoke products. The company's Proflex SE is an entry-level press using servo drives, offering 250 and 330mm print widths. Antony Cotton, the company's technical sales manager, said: "Each machine we produce is designed and built to meet the unique requirements of our customers. We believe that versatility, modular design and the ability to easily upgrade and expand our presses are a major USP and key to business success."

In addition to different drying systems (all UV, LED, IR) and an optional combination of cooling rolls with heat-sensitive substrates, Proflex SE's printing stations feature an open construction, with Focus Label Machinery saying ink cartridges and printing rollers can be easily installed. Other options include automatic print register control, and a rail system that can be mounted along the top of the press to allow equipment such as rotary rods, peeling, cold blanching, laminating, scrap rewinding turrets, and scanners to be installed above the rails. Due to the modular design of the press, additional printheads and options can be added, such as a digital print engine.

Modularity seems to be the watchword for Edale, which offers the FL1 Prime flexo label press as an entry-level system. The 350mm format press can handle substrates up to 350 microns at a speed of 220 m/min. The modular design allows options such as the EZ Reg autonomous registration system, EZ Die replaceable in 60 seconds and LED UV curing.

The Future of Hybrid Printing

Going forward, the development and application of hybrid printing technology will make the entry-level flexo press market somewhat confusing. Phil Baldwin of MacAndy says demand for these presses is already very strong, with its Digital Pro hybrid print range recently upgraded to the third generation, the DPro Max. He says: "The press features a toner-based engine that adds flex print units before and after the digital print section, while offering a variety of machining options for producing on-line single channels. It's simple to use, capable of printing high-quality labels at commercial print speeds, and is an excellent entry-level product."

Bobst also expects hybrid printing technology to continue to evolve. Pasquinelli predicts: "In the next few years, we are likely to see more entry-level, all-in-one (hybrid) flexo presses entering the market, reflecting trends in mid-to-advanced press technology." Printers are likely to use some surveys to find high-quality solutions that meet their needs, such as increasing capacity, increasing versatility and entering new markets.