Automation, connectivity and big data are shaping the future of flexo
Flexographic printing has historically been the dominant process in label and packaging printing, but suppliers are designing their latest products with the future in mind. They are not content with the status quo when designing and developing a new generation of machines. Flexo press manufacturers have a keen eye for automation, connectivity, leveraging data and simplifying the printing process. At the same time, suppliers of inks, plates, materials and more are going all out to further shape the future of flexo printing.
The flexo press was designed with robotics and newer CNC machining in mind. As Industry 4.0 technologies continue to play an important role, production workflows and quality control procedures have been enhanced. "Flexo printing is a truly fascinating craft that is constantly evolving, making remarkable progress over the past few years.
The continuation of the new crown epidemic has even affected product development. As converters struggle to find skilled print operators, "doing more with less" has become a mantra for many. Automation will allow processors to achieve this, while also facilitating process improvements for the next generation of workforce. In recent years, flexo printing technology has made great strides, mainly through improved automation.
According to companies across the industry, the quality of flexo press production has never been better. "With servo technology and better tension control, flexo presses are capable enough to compete with offset and gravure presses due to higher print quality and tighter registration. With advances in electronics, presses are very easy to operate, install Faster with minimal waste and less downtime.
Improvements in flexo printing are not limited to printing presses either, but the product offerings that go with it have also improved, leading to more robust processes. “Over the years, the flexo printing process has greatly improved due to new technologies such as inks, anilox rolls, tapes, photopolymer printing plates, UV and LED curing.
Flexible packaging will continue to be a trend in the evolution and transformation of label printers as converters increasingly seek to expand their reach. Flexo press manufacturers have designed wider-format presses to accommodate more printing applications. Flexible packaging is one of the fastest growing markets, especially in mid-width 26"-33", with servo-driven presses and tension control, flexo presses can print a wide variety of packaging products, from shrink sleeve labels. , wrapping labels for roll feed, and pouches, etc.
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Printing press update and development
For Bobst, its latest press technology has been categorized by improved automation. The company ensures seamless integration between digital and flexo, especially in Bobst's all-in-one presses. “Bobst has been providing a high degree of automation on its flexo presses to eliminate any human-related bottlenecks and enable uninterrupted production with minimal waste of time, substrate and ink,” Pasquinelli said.
The latest concept in Bobst's oneLABEL portfolio is an all-in-one platform where digital printing is integrated with state-of-the-art and automated flexo and converting modules for priming, printing, decorating and die-cutting in one pass. "Each module digitally automates dynamic order change, providing maximum press uptime and excellent repeatability, ensuring fast time-to-market for most label products. These are 100% by Bosch The technology is developed and manufactured in-house for seamless integration. This also means that converters only need to contact one company for sales, service and support of digital and flexo parts.”
Gallus is currently developing two new flexo products. The first is the Gallus Labelmaster 570, intended as an entry point into the flexible packaging market. According to Gallus' Nagel, the Labelmaster 570 offers a machine that is well-suited for smooth entry into this profitable segment, with a 22.4" width. This iteration of the Labelmaster is suitable for short to medium runs in the sleeve labeling industry, the company says , the machine has excellent productivity in the field of labeling.
The second addition is the Gallus RCS 570, which offers printers maximum customization and process flexibility. “The stable and modular design forms the basis of this machine,” explains Nagel. “The Gallus RCS 570 is equipped with a separate direct drive for operating units such as flexo, screen and hot iron. The RCS 570 can be ideally Adapt to the necessary requirements required. Customized integration of processing modules and OEM equipment on a two-rail system provides the highest level of customization. A team of experts supports each customer project and provides individual support.”
McAndy offers a variety of options for label converters. The Performance series has more than 1,500 installations worldwide, and the latest press promotes the AI suite to support Industry 4.0's need for enhanced automation. In addition, 360-degree registration adjustment and controlled ink density enable high-quality dots to be obtained in an easy and repeatable manner. McAndy's Evolution series is designed to enable full servo flexo printing at a cost-effective price. Unveiled at Label Expo Brussels 2019, the new Evolution range is the perfect complement to McAndy's award-winning performance range. Built around the fully servo-driven P7 platform, the Evolution is a modular press that can adjust its configuration to the current working environment and be modified if necessary.
MPS recently launched its next-generation EF flexo printing platform, which offers new capabilities in technology enhancements and connectivity for better printing performance and output. As a fully automatic multi-substrate flexo press for 24/7 operation, the EF has provided printers with a high degree of automation, flexibility, connectivity and ease of operation for many years. Building on the successful foundation of the previous six generations of EF platforms, including MPS features such as Crisp.Dot technology, Non-stop Print Change and Ultraflex Rail System, many enhancements have been made to the new generation of EF machines.
These improved features include an MPS-designed slide-out ink drawer, standard on all machines for faster order change, MPS E-sleeve with quick release, advanced job memory, M2M (mark-to-mark) registration, Width extended to 580mm etc. “We recently launched the EF7 press and will be showcasing it at Labelexpo Brussels and Labelexpo North America,” said MPS’ Nagle. “The EF7 press is part of the ongoing evolution of MPS’ EF flexo line, offering the industry’s best automation and connectivity.”
Nilpeter's FA-26 is described as "the 'Swiss Army Knife' for production packaging solutions". Landberg notes that this multi-process and multi-purpose flexo press is designed to take lean printing to the next level. “Flexible packaging has many different substrates with very different properties and specifications, and run lengths are shrinking. As a result, each shift requires more complexity and more setup. We rely on the advantages of the innovative world of labels to target flexible packaging materials New solutions for and structures using multi-process inline printing, lamination and processing, as well as UV LED, solvent and water-based flexo printing.”
At the same time, Omet introduced a medium web press (26") designed around flexible packaging. With a smaller footprint and shorter web paths, converters can operate more efficiently and faster set up, and minimize waste, all with a simple platform to learn and operate. Rotoscreen, gravure and inline lamination are just some of the additional options that can be added to the X7.” For label printers who are considering expanding into the flexible packaging market In other words, the X7 can still run their current pressure-sensitive jobs when entering new markets," Baldwin said.
Omet also offers a hybrid press solution called the XJet. This allows customers to utilize digital inkjet to print short-run jobs while increasing the flexibility of one-off printing for die-cutting, cold foiling and other decorations. “For heavier ink coverage using white, varnish, etc., adding flexo stations can help reduce the cost of more expensive digital inks,” Baldwin added. use both technologies in the context of