In label production, laser cutting is becoming increasingly common with many suppliers selling precision narrow web laser finishing modules to cut complex shapes. Sean Smyth explores the advantages of lasers.
It is a truism, but worth repeating. All packaging and labels are converted after printing, except for some unsupported films although they may be coated or laminated. Largely the finishing methods being employed are analogue, mechanical processes of slitting, die-cutting, creasing, folding and gluing. The situation is starting to change, however, as manufacturers explore new methods to digitise the finishing processes.
Laser cutting is available either integrated with a digital printer or as part of a complete finishing line. Most suppliers offer the laser cutters as options to boost the response of label production as a more flexible alternative to mechanical die-cutting. They highlight that tools are not required, saving cost, time and storage, which are increasingly important as converters handle more short run jobs. The systems are generally simple to use, the shape and cutting power set in a simple control file that can be loaded automatically from a mark printed on the web. The laser can cut very intricate designs accurately, using kiss or through cutting and micro-perforation on most materials although a chiller and fume extraction is recommended.
Laser cutting is a non-impact digital technology that has the potential to radically change the analogue finishing processes. For most materials the quality of a cut is as good as the traditional mechanical alternative but there are potential advantages that are impossible using a fixed die. The shape of every label may be varied to provide design flexibility. The laser can burn a security code or pattern into each label and the flexibility means users can finish ultra-short runs economically, opening the possibility of customers using web-to-print portals and create new business models.
Converting revolution
Spartanics, located close to Chicago, sells a range of laser finishing equipment for labels, the prosaically named Laser Die Cutting Station. This is available in widths from 140mm (in the NW140 UV inkjet press) up to 350mm, as seen on the Durst Tau LFS 330 finishing line. Danish manufacturer GM (Grafik Maskinfabrik) has the small footprint LC330 Compact Laser Finishing system, with laser power from 100-400W, offering different power levels on the same label to create special effects. The system can include a barcode reader to automatically load jobs on the fly.
Delta ModTech, headquartered in Minneapolis, sells a range of precision engineering equipment, including label finishing with the Edge laser cutting system that combines the Crusader rotary converting platform with a servo-controlled laser module. There are several versions available with the portable Flex Edge that may be used inline or offline with various configurations to allow for production and development in roll-to-roll or sheetfed mode. It can be bolted onto an existing machine or run as a standalone unit, and uses galvanometer-controlled lasers, running at a maximum speed of 91m/min.
LasX supplies laser equipment into many industries and is partnering with a range of label equipment companies including Aztech Converting Systems, Coherent Inc, Colordyne Technologies for an integrated printer/finisher, FlexPak Services for laser scoring and micro-perforating solutions for easy-open, breathable and microwaveable flexible packaging, RevoLaze, Shiki Corporation and Sohn Manufacturing, which sells tabletop flexo printing equipment.
AB Graphic International has the Digilase Series 3 featuring two 200W CO2 sealed laser heads with the bespoke Digilase workflow. It can run at up to 100m/min, with continuous mode cutting across a 330mm web. Back scoring and slitting knives can be automatically set too, enabling changeovers to take place on the fly.
Italian provider SEI Laser sells the Label Master with a format up to 350 x 600mm for papers, PET, PP and BOPP. It is its fastest laser system for cutting and finishing of labels featuring a top speed of 100m/min with a modular system comprising up to four laser cutting stations. Systems may be customised at purchase or later with upgrades that can be retrofitted.
SEI is pushing the concept of the ‘Digital Converting Revolution’ in labels, graphics and cartons that is being driven by new applications that are opening new markets. This moves into a totally digital workflow and business process that changes the production processes which are increasingly digital up to the finishing stages. Digital cutting systems and plotters are digitising some converting processes to eliminate bottlenecks, important as run lengths fall and demand for fast turnaround rises, eliminating delays for cutting dies.
The company sells into the graphic arts sector where web-to-print is commonplace, opening new markets and reducing time from the supply chain and it sees opportunities to move the concept into labels and packaging. According to SEI sales manager Ettore Colico, ‘We want to integrate our laser systems in a digital production workflow, the machines involved in the production process automatically exchange the data to start their production phase. This, along with laser application in converting, means the only limit is the designer’s imagination. Our concept of digital revolution will be applied to packaging and label printing, following the lead in commercial print.’
And beyond
Digital finishing is moving beyond labels. Laser cutting technology has greatly improved to allow clean, accurate cutting of paper, films and carton board, and even corrugated. Most flatbed die boards in cartons are laser cut, and in other sectors, lasers are used to cut plastics, leather, even metal and ceramics, or to engrave glass.
Highcon is a pioneer in digital carton finishing, launching the Euclid cutting and creasing system in 2013. This re-engineered the process, splitting mechanical creasing from laser cutting and the company has sold more than 50 systems across the world.
The technology has developed since the launch with larger formats and faster operation. The B1 Highcon Beam is the flagship machine in 2018; it has a 15 minute set up and speed of up to 5000 sheets per hour depending on the complexity of the cuts. An early adopter is US carton and commercial printer Boutwell Owens & Co, which already had one of the previous Euclid machines. According to Bill Lorenz, VP operations, ‘The Beam will take our existing capabilities to new heights. With the Euclid, our customers are already reaping the benefits of production flexibility in terms of supply chain support and the ability to order just what is needed, when it’s needed, not to mention the highly creative designs that were impossible before. With the Beam we will be able to extend those advantages to longer run lengths, and bring these capabilities to market segments and customers that were beyond the Euclid’s reach.’
Founded in Minneapolis during 1998, LasX Industries also has a base in Europe in Frankfurt. It manufactures high-performance industrial laser systems for on-demand converting applications in labels, flexible packaging and folding cartons with over 500 systems installed. It is looking at innovation in inline digital finishing for cartons with the ‘CartonsInMinutes’ (CIM) system. This features sealed CO2 laser units, power either 400 or 1000W, with a format 350 x 350mm or 500 x 500mm linked to a cut-sheet digital press with inline folder/gluer and total robotic material handling including automated stripping. There is a camera inspection system for precision print-to-cut registration, and the solution promises a complete digital workflow with instant job changeover, optimising production workflow and output of folding cartons.
As it expands there are new distributors, namely TLM Laser for the UK and Dr Wirth in Germany. William Dinauer, LasX president, said, ‘Our operation in Frankfurt will be installing two very large LaserSharp Digital Finishing Systems in Europe this year. Both systems feature complete digital finishing of printed rolls or sheets into their final form including robotic sorting and stacking.’
These systems, built around precision laser cutting technology, show how finishing is developing. Integrating printing and finishing into a fully digital production line will provide much greater flexibility and open new applications to packaging and label manufacturers. There will be operational benefits as the speed increases while costs fall. More significant is the longer-term potential to re-engineer supply chains and business models, opening new routes to market and eliminating stages in the complex packaging manufacturing processes. Today printing can be digital, in the future it will be complete converting processes, very high quality and very high speed.
