The first part of our preview of converting exhibits at the world's biggest printing show (Düsseldorf, May 6-19, 2004). A separate guide to the USA companies' stands also appears in this issue
Moving into mid web
Gidue will give the “world’s first 730mm wide, in-line, mid web packaging press” its official European launch at the show. To be demonstrated as a full packaging press using print cylinder sleeve technology, the Unipro is said to print and convert virtually any kind of substrate from PE, BOPP and PET to paper, aluminium and laminates, and cartonboard up to 450g/m2 without changing configuration.
The printing head is an enhanced version of Gidue’s Flower flexo head with two new features – the UNI-Lock for non reversible printing and the Spider for full automatic print unit wash-up.
The UNI-Lock is optimized for larger format printing cylinders and the high performance demands of mid web printing. It clamps the print cylinder within the press frames, where it becomes an integral part of the print unit. Any press vibrations are “totally absorbed within the print head”. This permits the use of solid cylinders or printing sleeves. Sleeves of any diameter can be inserted into the Spider head and are immediately print ready. Plate pressure and register and pre-register control are pre-set for reduced set-up and consistent print quality.
The latest version of the E-Combat shaftless press with new IML-EDL delivery system for in-mould labels will also feature. It uses servo driven controls for all press functions and is available in web widths of 280, 370, 430 and 530mm. With the benefit of electronic drives, the E-Combat will print and convert substrates ranging from 15 micron film to 350g/m2 cartonboard without changing the mechanical configuration of the press. The IML-EDL delivery system is equipped with a batch counting and final long ‘buffer’ delivery table where the stacked piles of in-mould labels printed face up can be easily collected.
The company will also demonstrate its HHS hologram deposition system for use with most makes of printing and converting machines. The HHS unit is designed for simple integration onto both rotary and intermittent printing systems. Fully servo driven, it allows for speeds up to 100m/min. Set-up time is greatly reduced by a job and program memory.
On each individual HHS application head, multiple lines of holograms and foils can be positioned – each having a variable graphic configuration. The system includes an unwind and rewind unit, a foil transport and a dancer cassette, together with a power gain rack for the console. Cassettes are available in widths of 40, 60, 100 and 150mm. Hall 10, stand C40.
Birthday presents innovations
In addition to celebrating its 25th anniversary, BST will introduce new products across a wide range of printing and converting applications.
Drupa will be the official launch for the Super HandyScan 3000 – the sixth generation of what is claimed to be “the best selling video web inspection system of all time”. Another innovation to see is the PowerScope 3000, which combines a high quality PAL image with a 75mm x 100mm field of view, 17in monitor and 38x magnification. It also offers a simplified control design, improved icons, and two new productivity enhancing features – Quick Zoom and Dynamic Image Update.
For web guiding, BST introduces the ekrPro Series of devices, said to feature superior performance, ease of use, maximum versatility and network connectivity. These compact units are designed for simple integration and use over a wide range of printing, converting and OEM applications.
CCDPro ProLogic/ProTouch integrates the CCDPro camera into a web/process management system capable of complex automated functions such as web width measurement and splice control in applications for extruders, slitters, printing presses, and a wide range of converting machinery. Hall 10, stand D57.
Xaar has expanded
For the first time, Xaar will present its complete and expanded range of services: printhead and ink products, integration expertise, a new range of peripherals and licensing of its patented technology. The company will also display its latest inkjet printheads, the OmniDot series, along with three OEM industrial printers.
Sales director Hugh Baker-Smith says: “This drupa, Xaar will be demonstrating how, like its technology, the company has evolved over the past few years. From pure research and development beginnings, we have now also proven ourselves as a leading inkjet manufacturer. Today we are offering our customers a ‘one-stop shop’ which provides the solutions, service and support required to produce successful and competitive inkjet printers.”
He continues: “Looking back at drupa 2000, inkjet was still very much a newborn technology. Four years on, digital inkjet components, media and machines have evolved at an extremely fast rate, enabling printers to produce high quality prints on a variety of substrates. Digital print is now a strong participant in the graphic arts industry and its current market is predicted to continue to grow at a rapid rate.”
Xaar will also be showing Kappa’s board packaging printer, which uses its XJ500 printheads and oil based ink. This machine prints variable information on both sides of a box simultaneously – one side in colour and the other in monochrome. Hall 07, stand C28.
More enterprise for MIS
DiMS!, a supplier of management information solutions for the printing and packaging industry, will launch its 640 software release. This complements the company’s workflow tool, which allows printers to connect internally to other individuals or remote entities within the organization, and externally to valuable customers and suppliers through a centralized, web enabled system.
Highlight of DiMS! 640 is its extended enterprise functionality. Adding to the existing enterprise focused structure, which encompasses the breadth of processes (such as enterprise planning, production, purchasing and inventory management, and accounting) across multiple plants, divisions and even international borders, it offers a simple way in which to manage complex, often disparate financial transactions across the entire organization.
The new release includes a set-up table enabling the user to link profit centres, company profiles and financial companies to each other. The Estimation Desktop is a tool for managing complex alternative estimates including sales prices in a project. The user can also selectively add, remove and manage favourite orders to gain quicker access to the desired information. Hall 09, stand A25.
Cameras in control of accuracy
The Overlay Module from AV Flexologic is an ActiveX control mounter/proofer system with a Windows interface for ease of use and improved accuracy and efficiency. Each colour is mounted using computer controlled cameras that provide digital screen shots for operator guidance.
The pictures can be edited for external light influences – brightness, gamma, sharpness, shutter, white balance, and gain, as well as optical zoom. A digital zoom is also available. AV claims time saving of at least 50 per cent. Stand A17, hall 10.
Innovations in curing
GEW (EC) will launch the NUVAplus system for UV curing of heavy lay-downs of both traditional and cationic inks and coatings on thermo-sensitive substrates at high press speeds. The NUVAplus features a ‘clean cool’ airflow system with an integral filter in the lamphead that is said to eliminate dust or ink mist contamination and any disturbance from airflow to the web. Power ratings up to 230W/cm for print widths up to150cm can be supplied.
The NUVAplus FILM is available for the most heat sensitive materials, such as sub 40 micron film or shrink film. This model has a water cooled chill roll integrated into the dryer housing. GEW will also be launching the Jetcure UV curing system, designed specially for the needs of the inkjet market. This is billed as an ultra compact, light weight unit with adjustable power up to 200W/cm, and with an integral fan in each lamphead.
Also featured will be the latest version of the VCP ‘cold UV’ curing system. It is said to combine compact size with a high cure rate, and cool running and modular construction with low capital and running costs. Available in power ratings up to 160W/cm, it can be supplied for print widths up to 45cm and is also offered in a FILM version.
GEW now has a sales and service facility in Auerbach, Germany, to support customers in Germany, Switzerland, Austria and Eastern Europe. Hall 10, stand E78.
Wide web sleeve ups performance
Flexotecnica will be showing the printing section of its new 8NG eight colour CI sleeved gearless flexo press. With a 1,300mm print width for a printing repeat range of 330-850mm, it is designed to run at up to 500m/min. The printing section features rugged cast iron frames 120mm thick for greater stability with a 2,000mm diameter, Hastalloy coated CI cylinder, whilst maintaining a compact profile for easy operator access to each print deck.
A new development is double linear guides supporting the print bearing block on either side with increased diameter of the anilox sleeve mandrel to ensure better performance at high speed with the sleeve system on a wide web. The 8NG series will be available in print widths of 1,000-1,600mm (optional up to 2,000mm), in eight and 10 colour versions.
Each print deck incorporates tool-free quick change-over of print and anilox sleeves, as well as easy handling of intermediate adaptors on the press and a new doctor blade chamber design which provides on-press blade changing. The Speedy Clean automatic ink wash-out system is said to allow efficient washing of all print decks in a few minutes with minimal solvent consumption. The air drying system has high efficiency inter colour dryers and a final drying bridge to allow printing of both solvent and water based inks on various substrates at 500m/min.
The gearless 8NG features consolidated direct drive technology with digitally controlled brushless servo motors. It also has the FNC-3000 computerized print monitoring and management system to provide rapid auto registration, with storage and control of all print parameters. For troubleshooting, there are diagnostic pages, modem connection, and integrated video and audio assistance systems to monitor and view on-line all press functions and communicate directly with operators worldwide. The Smart Ride System facilitates makeready on idle print units while the others are running, and a sleeve ejector eases extraction of print sleeves and adaptors on the wide web configuration.
Options for the new press include a gravure station for cold/hot seal, or downstream coating or over-lacquering flexo stations, as well as rotary and platen die cutters for folding carton work. Hall 16, stand B03-04.
Accurate control of UV
The new IPC Inline Process Control developed by Arccure Technologies is said to enable real-time monitoring and control of the UV intensity and UV doses in the company’s pure UV systems. The drying process can be monitored continuously during each print job. Claimed to be more reliable than the ‘Teach-In’ function, with IPC the printer now adjusts the process directly in keeping with curing performance.
The spectral monitoring of intensity and dosage can take place in up to three freely selectable spectral spheres. The spectrometer used facilitates a resolution of up to 1nm. With these three control areas, curing processes for different printing techniques combined in a single machine can be monitored. At the same time, the UV output of the lamp can be precisely adjusted to suit the respective requirements of the inks and lacquers used; and that UV output is then supplied consistently during the entire printing process, it is claimed.
Dosimeters are not capable of this, says Arccure. Freely selectable measuring cycle times of between 1 and 180s make it possible to co-ordinate monitoring precisely with the respective process. Furthermore, the measuring process can be triggered off either by internal timers or external triggers. This guarantees that the monitoring function is activated only during the production cycles of the plant.
Whether highly pigmented lacquers or flexo inks are used, the IPC monitors and regulates the UV output and dosage. Shifts in the relevant UV peaks in the spectrum are detected at an early stage and the process readjusted optimally at any time by means of the closed loop. An integrated shutter minimizes the aging process of the optical measurement optics.
The user is therefore said to receive reliable and precise measured results, which can also be recorded and archived. An integrated circular buffer provides space for over 6,000 data records. Hall 03, stand A69.
The flexible packaging and converting division at David Hulme Machinery specializes in reconditioned flexo and rotogravure printing equipment, film production, coating/laminating and converting machinery. The company regularly carries out the installation of machinery in companies around the world. It claims to be able to handle the most complex machinery with skill.
An eight colour Rotomec 2001 is currently fully assembled in the company’s works and available immediately. It has a web width of 1,200 mm and has been print tested at maximum speed. Hall CP, stand A41.
Washing and cleaning
DW Renzmann will show a type HA high pressure cleaning machine for anilox rollers, the new type 80 washing machine for label and narrow web printers, a Roto distillation unit, and a type 340 washing machine.
Renzmann’s range includes spray, brush and ultrasonic cleaning systems, all washing with solvent, aqueous medium, or caustic products. The Roto distillation machines are able to recover expensive waste inks and solvent and distil them back into useable solvents.
They feature a self cleaning rotor and a nitro-cellulose safety package designed to prevent an exothermic reaction inside the machine.
All systems are said to comply with current safety regulations and meet VDE and EN standards. When using solvents, all systems supplied are explosion-proof and conform to the new European ATEX 100 regulations. Hall 17, stand A70.
Slitters from Bimec
Bimec will show the latest models making part of its range of slitter rewinders for films, paper and laminates.
The model TCA/64.C duplex turret slitter rewinder is a compact model featuring automatic change and a shaftless unwind stand. The machine unwinds mother rolls up to 1,000mm diameter and rewinds finished rolls up to 600mm diameter. It will be displayed in a ‘full optional version’, with differential rewind shafts, computerized control system through touchscreen operator panel, laser core positioning and a pushing system for finished roll unloading.
The model STB/45 duplex slitter will be in its renewed version. The machine – having unwinding and rewinding on the same side – is suitable for mother rolls up to 800 mm diameter and finished rolls up to 450mm diameter. Hall 11, stand E68.
Ko-Pack covers special cases
Latest specialist machine from Ko-Pack is the Euroflex 250 artificial casing press, a 12 colour flexo system for non stop printing of polyamide food casing at up to 150m/min. With 12 print units located on two temperature controlled central impression drums, 360 degree printing with six colours each on the face and reverse of the casing will be demonstrated.
Configured for UV curing, the Euroflex is available with up to 16 flexo print heads and uses specially formulated FDA approved cationic inks. Three automatic web guide systems, coupled with a servo controlled web tension system are said to ensure excellent web handling.
Other features include an AC servo driven unwind and rewind shafts, and semi automatic accumulators on the unwind and rewind for continuous production. The press is also available with a 400mm web width, and can be configured for label production.
A 12 colour 650 film press will also be shown. Using hot air drying and water based inks, it is configured for high speed (300m/min) non stop printing of food packaging films. Hall 03, stand E16.
Closer inspection urged
New from AVT will be an enhanced PrintFlow optional tool for use with any of the company’s PrintVision automatic web inspection solutions. With a versatile, standard SQL database platform, PrintFlow has been reconfigured to provide comprehensive job information including the ability to study defects by type, frequency, duration, and even view images of the master and defect images. Operators can edit the report, accepting or rejecting detected defects, print the report and keep it as a file for further use.
A new PrintFlow Manager extends the benefits of PrintFlow to supervisors, quality assurance managers, and production managers, enabling them to view and process information from the databases on each PrintFlow-equipped PrintVision solution on the site’s network. Production can be monitored and comparisons made between jobs, job histories, presses, inks, substrates and other criteria. Reports can be created using all the information from the database(s) to provide both printer and customer with the most useful information.
WorkFlow Link is an add-on feature that links the press and the rewinder in a PrintVision production environment. It integrates with PrintFlow and PrintFlow Manager and is said to enable increased control over waste removal from a printed roll while reducing the time of preparing a finished roll. Used with a PrintVision system on press, WorkFlow Link will place a mark on the web at pre-determined intervals. These marks can be numbers or bar codes printed in the trim area, or on the reverse of the web or self adhesive labels that are applied to the web.
When the printed roll is delivered to the rewinder, the WorkFlow Link information is sent to the rewinder. A reader here ensures the physical web is synchronized with the defect information contained in the roll report – even if sections of the roll have been removed as a part of the quality assurance process. Using the markings on the web, WorkFlow Link controls the rewinder, slowing it down and stopping the web at the beginning of the defective area on the splicing table, ready for removal.
In label printing, the closed loop option for PrintVision/Helios is used during makeready to verify that the job in preparation is the correct one, and to shorten the makeready time. This is done by comparing on-line the printed image to a previously captured or produced reference, such as an image from a previous run of the same job or information (file) from the prepress. Hall 03, stand F9.
Gravure and flexo debuts from Uteco
Uteco will launch a gravure press offering different levels of automation to suit different budgets. Top of the range will be a gravure unit incorporating the shaftless technology used in the company’s flexo machines, coupled with quick sleeve change, automatic cylinder wash-down and doctor blade positioning.
Uteco claims its Programm presses have done much to address the perception that gravure is only suited to long runs. In-line operations such as cold seal, varnishing, laminating and sheeting can all be undertaken on the presses, which are available in widths from 500-1,900mm and for speeds in excess of 650m/min.
Also new will be the Amethyst GL gearless flexo press, featuring a sleeve change system for both plate cylinders and ceramic anilox rolls. Innovations include an optional wash-up system, and a doctor blade allowing both blade and end seal change without the use of tools .
A patented feature is direct drive of the CI drum by a motor installed on the drum axis coupled to the direct drive of the printing sleeve. This is said to eliminate backlash and ensure perfect dot and print resolution.
The Amethyst is available in 1,050, 1,250, 1,450, and 1,650mm web widths, and speeds of 350m/min. Hall 03, stand CO4.
Improvements in treatment
Vetaphone will show its latest ‘open designed’ treater stations, which can be fitted with the new corona quick change electrodes. The complete electrode is mounted in a pull-out/push-in cartridge designed to enable quick and easy cleaning or changing of the complete set of electrodes in seconds, without the use of tools and ensuring minimal downtime. Automatic disconnection and reconnection is incorporated in the design, as is electrode realignment and air gap settings. An added bonus where pattern treatment is used is that pattern set-up can take place quickly and easily while the cartridge is out of the station.
Available with segment, profile and ceramic electrodes, the quick change electrode cartridge is aimed at film lines with widths from 100-2,500mm.
The Corona Plus TF415 control module can be mounted either locally or remotely. A graphical overview of the complete treatment system is designed to make troubleshooting easier. The TF415 can be switched between readout modes, displaying either the actual generator output power in kW or the energy delivered to the substrate in Watt-min/m2. Both the power and the energy can be adjusted directly from the module. When the Watt-min/m2 value is selected, the generator automatically adjusts the power to-line speed ratio to ensure identical treatment on each square metre of film, independent of actual film width and line speed.
The remote control module is compact and can be mounted conveniently at the main machine, or line control panel, while the remote controlled generator can be installed in a suitable position, if necessary, with other control cabinets. Hall 12, stand E11.
BHS builds for in-line board
New from BHS is the Flexoline Intro in-line flexo press for printing paperboard and folding cartons, as well as for flexible packaging materials. Its machine configuration is said to be “ideal for the cost conscious entry into the mid web range for printing from reel to reel, reel to cut blank or reel to sheet.
All common ink systems – water, solvent and/or UV can be used, and high productivity is said to be ensured due to short makeready using change cassette and sleeve systems. The highest flexibility is also promised, with a gearless drive system on the printing cylinder. A full range of in-line finishing modules can be integrated, including gravure and screen printing, lacquering, laminating, and hotfoil stamping.
Working widths of 560 and 670mm are available. BHS will show the 670mm version in combination with a flatbed die cutter.
Also new from BHS is the Auto Set Pro flat bed die cutter for working widths of 560-1,400mm. It is said to employ state-of-the-art in-line cutting and creasing technologies for the highest productivity. Short change-over times and reduced start-up waste are achieved by automation and machine pre-settings with servo technology and networked machine controls.
The display will feature a complete flat bed die cutting line with shingle delivery of 670mm working width, designed for an output of up to 350strokes/min. Hall 10, stand B39.
Carint creates Cybers and Skorpions
New CI flexo presses from Carint are the Cyberflex, with its ‘cyber-technology’ gearless system, and the Skorpion – said to represent an important link between the Cyberflex and the company’s SLP configuration – a mechanical transmission and double printing system enabling the use of integral plate cylinders and sleeves.
According to Carint, the Skorpion “is sure to meet operators’ expectations” in terms of quality printing results and quick job change-over, thanks to the use of sleeves for both anilox and plate, an operator friendly sliding block, and “efficient operating conditions in the printing group area”. Both presses incorporate a data management system operated by the Teckman Industrial PC interfaced with the Siemens computerized control system. This supervizes press data management and functions, and enables machine adjustments and automatic control of operating parameters during run time .
The presses can also be equipped with the KD system, which carries out automatic inking and washing cycles of all colour units, either simultaneously for all printing decks or individually – and at high speed. It is controlled by a PLC that can also be interfaced with the data management unit. Hall 10, stand A24.
GretagMacbeth is introducing colour management solutions said to provide price/performance advantages tailored to the requirements of specific market segments, including package printers.
The new ProfileMaker Packaging solution includes a module said to support a limitless n-colour multi colour profile generation capability for up to 10 channels – with and without CMYK inks, and in addition to Hexachrome and CMYK+Red/Blue profiles. It also features a patent pending generic output profiling technology with which users can replace inks in existing profiles instead of making new test charts. This is said to reduce the need for remeasuring/profiling when changing inks, “significantly decreasing time and cost” associated with recreating plates and cylinders for new test charts.
New solutions for the pressroom include DensiEye densitometers for CMYK and spot colour measurements; and an economical ink formulation package that addresses the specific requirements of small to medium sized printers.
An entry level version of the iCPlate plate reader for conventional and CTP plates will also debut. Hall 05, stand D40.
Inks shine out strongly
Wolstenholme International’s new Mirasheen metallic inks are said to offer exceptional mirror-like metallic brilliance, and “a design and printing flexibility that is usually denied by the use of foil and metallized substrates”.
Harry Bowyer, Wolstenholme’s business development director, says that while the cost of Mirasheen is understandably higher than traditional metallic inks, “printers are taking the cost at face value. They are not making accurate cost and design flexibility comparisons with foil and metallized paper and board. Instead, they’re simply comparing ink prices.
“Regrettably, printers are unaware of some potentially significant cost savings. As a general guide, Mirasheen inks are most cost effective where the metallic feature represents 25 per cent or less of the overall design, he affirms”.
The Mirasheen inks are claimed to provide new benchmarks for brilliance, printability and cost effectiveness in high quality packaging applications. They are formulated on vacuum metallized pigment technology and can be applied on conventional printing units without the need for special press modifications. Hall 06, stand B76.
KPL to debut converting trio
For the first time, the companies in the Körber PaperLink Group will be assembled under the same roof, presenting system solutions for sheeting, converting and packing paper and tissue.
In the paper converting business, the group is planning three world premieres in the entry level for cut-size sheeting and packaging, in further converting, and in the mid range segment for folio size sheeting. It also will demonstrate remote control maintenance of machines for a customer in the Düsseldorf area, and will offer attendees in the tissue field the opportunity to visit a local customer.
The group also plans to stage an open house event in Hamburg at the same time as drupa. This will have other new products on display. Travel will be organized by KPL for visitors to the stand. Hall 11, stand A62.
Improved flexo proofing
As a result of its “resounding success” in the packaging industry, GMG will launch the FlexoProof 04 proofing system – “to answer the particular needs of this market segment with specific features, such as an out-of-register and a printing substrate simulation. The product also includes DotProof, GMG’s system which allows users to generate contract quality half tone proofs.
Another new highlight at drupa will be the InkOptimizer. This application, which has been successfully field tested at several large printers, is said to automatically reduce the amount of chromatic colours, thus promising ink savings of up to 25 per cent on the press, whilst maintaining quality, and improving printing conditions. Hall 09, stand D74.
Entry level slitters line up from Laem
Laem System will present its ‘renewed’ range of compact dual-shaft slitter rewinders, the models RB1, RB2, RB3. These versatile, ‘entry-level’ machines are said to offer an outstanding price-performance ratio. In addition, the new RB4 will be introduced as a high performing single turret slitter for paper and non extensible materials.
The new RB3 has a double turret rewinding system to obtain better productivity compared with the simple, dual-shaft RB1 & RB2 models. This machine has a built in back-to-back unwinder with automatic lifting of jumbo rolls (up to 1,000mm) from the ground. Rewinding features Laem’s differential shaft technology, said to have shown excellent results in the higher-end TR 400 series. The slitting device has been designed to work with shear cut or with razor blades, while the tension control is obtained by a dancer roller and servo – diameter.
The TR 425 double turret dual shaft slitter is a high productivity system often used for precision rewinding of ‘pancakes’ (narrow web). Available with a web width between 1,000 and 1,600mm, with a working speed of 600m/min, it features computerized positioning of the cores and slitting devices, for the quick (within 60s) and automatic unloading of the finished reels, user friendly pre-setting of the operator panel and easy maintenance. Hall 11, stand D26.
It’s all about roll handling
The Roll Handling branch of Metso Paper, based at Delémont, Switzerland, offers integrated solutions for roll Handling to the printing and converting industries. It supplies both mechanized and fully automated systems for roll storage, roll stripping, paste preparation and for loading of reelstands.
The company’s RoAd roll administration and inven- tory system is said to tracks everything “up to the expired core”. Hall 12, stand B14.
MDC on a mission
“Your Vision – Our Mission” is the motto for MDC Max Daetwyler’s display of innovations for gravure and flexo printing form preparation.
For engraving, there will be Vision3, claimed to be the world fastest and most universal engraving system offering “ideal cell geometry for increased volume and colour quality”. The system also delivers detailed reproduction of letters and line work which has not been achieved until now, the company boasts. The Gravostar HS high speed engraving machine is equipped with the Vision 3 head and can be upgraded from semi, to full automation for integration into a fully automatic line.
Also on show will be the Laserstar laser engraving machine for automatic imaging of gravure cylinders for the highest level of quality. Besides perfect reproducibility and an engraving speed of up to 140,000 cells/s, this technology is said to offer “tremendous” colour savings on the press.
The new DisCoP copper plating technology for gravure cylinders is said to reduce the plating time up to 20 per cent, while maintaining ideal copper structure. This also greatly reduces the processing time after the plating process.
Also displayed will be information on doctor blades, consumables and handling systems. Hall 3, stand A17.
Tackling short runs – the KBA way
One of the many attractions on KBA’s 3,500m2 stand in hall 16 will be a ‘short run factory’ demonstrating the speed, versatility and quality possible in waterless offset with new inking technology. The ‘factory’ comprises a 74 Karat press with Gravuflow inking units and integrated coater, a B3 Genius 52 five colour for printin
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