Gallus system targets niche carton markets

At drupa Gallus demonstrated its KM 410/510 folding carton converting system, designed to print, process and finish complex cartonboard packaging jobs in a single pass. The modular in-line system is claimed to be especially cost effective for short to medium runs of small format cartons. It is said to improve workflow and simplify materials handling, as well as saving time and increasing efficiency.

Gallus Group vp sales and marketing Klaus Aarestrup says the equipment is particularly suited to the healthcare and beauty care industries, in addition to certain food and other non food products. He explains: “We are targeting specific folding carton products and blister packs that require high added value elements such as reverse-side printing, effect printing with screen inks, hot foil stamping and hologram insetting – as well as laminations, creasing, die cutting and embossing.


“The KM is an industrial based, single purpose machine clearly complementary to Heidelberg’s sheet based packaging solutions,” he stresses. “Sheet-fed offset is the prime technology for folding carton printing and at Gallus we do not see this changing any time soon. What we do see is an additional approach for folding carton printers to optimize their capabilities to produce cartons more economically with several in-line processes.”

The KM line is said to offer a high degree of production flexibility coupled with ease of operation. It can print water based or UV flexo and reverse side on board up to 450g/m2, at 508mm maximum width. Top speed is 150m/min. In-line operations include hot foil stamping/hologram insetting and laminating, rotary or flat bed window punching, creasing, die cutting and embossing. The platform format provides for quick and easy exchange of modules to perform up to 16 operations.

The 410mm width version is combined with the FSM 410 flat bed folding carton die cutter, while the wider KM 510 is available with rotary die cutting. A flat bed die cutter will be available next year.

At drupa Gallus demonstrated a job change from a healthcare to a beauty care application including substrate, ink and processes. The press was configured with eight platform units, six for UV or water based flexo printing and varnishing, one screen printing unit, a hot foil stamping with foil saving and hologram insetting devices, a laminating unit on a rail system, a dual rotary processing unit and a flat bed die cutter.

Next month Gallus will demonstrate its EM 260/410/510 S multi substrate press in a series of open days (June 7-9) at the Arsoma facility in Langgons, Germany.

Capable of converting self adhesive and monofoil labels, as well as other substrates up to 300g/m2 cartonboard, this model’s web transport uses servo drive technology “to ensure optimal multi substrate flexibility, operational efficiency and print quality”. It also offers a modular, platform design concept, and a wide range of printing, processing and storage units from the Gallus EM 410 family can be integrated.

Quick change

Front loading of the sleeve system print cylinders and anilox rollers is now standard, with chambered doctor blade units and additional pre-setting functions to simplify the workflow and minimize set-up and change-over times. Flexo and screen processes can be changed without breaking the web – and reverse printing without web turning.

A servo motor directly drives the printing cylinder. There is also a movable master control panel with touchscreen to facilitate easy operation at any point along the press. New units are available for water based and UV flexo printing (front and reverse), rotary screen printing, hot foil stamping, varnishing and laminating.


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