A label being finished on the Delta ModTech Spectrum finishing system
Recent years have seen considerable developments from manufacturers offering dedicated finishing or converting equipment for digitally printed labels and packaging. Neel Madsen spoke to some of the suppliers.
The fast throughput of digital puts pressures on the finishing process, be it inline, near line or off line. Finishing can present a bottleneck in production if the workflow is not seamless and there is close integration between the printing press and the converting line. Finishing is also where printers can stand out from the crowd by offering value added processes and show their skill.
Tony Bell, sales director, AB Graphic International (ABG), described the situation thus, ‘The need for label and packaging converters to differentiate is crucial. Traditionally with flexo, offset printing, etc, it was easier to differentiate for example by offering better print quality, superior origination, faster production. Digital print can mean more of a ‘me too’ situation where the output from machine A is the same as machine B. Finishing and embellishment can make all the difference.’
David Grenwis, marketing coordinator at Delta ModTech, commented, ‘Label converters using web-fed digital presses are enjoying the ability to produce very short run lengths and handle multiple SKU changes, but can come up short when it comes to providing finishing capabilities that are commonly found inline on many flexo presses.
‘While eye-catching graphics are important, finishing – that last 20 or so feet of label production – are just as important as placing an array of colours on the substrate. Finishing may take up only a small part of your production space, but it is a place where you can add significant value and be a clear differentiator for your business.’
Automation focus
Automation and the tools to enable label converters to differentiate are key for all future developments at ABG, explained Mr Bell. ‘Since the launch of the Digicon Series 3, we have seen a 25% rise in sales value for our flagship digital finishing machine, with particular investment in automation modules to reduce set up times and maximise efficiencies. Our auto die-load, autoslit, iscore auto edge slitting, turret rewinding and laser die-cutting are just a few examples of how we are developing our finishing equipment to complement the fast paced digital print market.’
The company launched its new Big Foot hot foil and embossing stamping module at Labelexpo in September. It uses 50 tons of pressure to lay multiple foil colours and raises embossing to a new level. It has a rotatable foil head that can foil across and along the web, running at speeds up to 65 m/min, in three lanes in the web direction and two across the web.
‘Customers have been very impressed with this module and since launch we are already well into double figures for numbers sold. We also have a healthy number of current enquiries from those customers wanting to increase their portfolio and get ahead of the competition,’ said Mr Bell.
The Digicon Series 3’s flatbed screen-printing module, runs at much higher speeds and has an option of two positions for the UV dryer for total flexibility. It is ideal for relief, super varnish and vibrant screen inks. There is also a Crossover Module is ideal for diversifying into multi-layer labels when combined with variable and personal information from digital printing.
Described as the ideal machine for customers wanting a compact and economic digital finishing solution, the new Digicon-Lite 3 was also launched at Labelexpo. This is capable at speeds up to 150 m/min and can be run inline.
Mr Bell believes the future of the labelling and packaging industry is progressing towards digital, and whilst flexographic still remains the predominant printing method he sees many customers worldwide moving into digital. ‘With more and more inkjet solutions coming onto the market, it’s going to be interesting to see how the industry embraces these technologies in the next couple of years. ABG’s challenge is to continually develop modules that complement all technologies and allow our customers to give a diverse finishing offering to brand owners.’
The last 20 feet
The Spectrum finishing system from Delta ModTech can be configured with rotary and semi-rotary die-cutting, varnish or spot printing, over laminating, slitting and nipping, scoring, hot foil stamping and embossing. The company’s portable Edge laser allows parts to be through-cut, kiss-cut, perforated and ablated by uploading a drawing of the die-cut to the laser cutting station. This station can run inline with an existing finishing press and eliminates the need for and cost of flexible tooling, or the expense and storage of rotary dies.
Mr Grenwis said, ‘Finishing processes all demand precise control of the web, and must incorporate processes that minimise waste while supporting a range of customer requirements. But in today’s competitive landscape, finishing systems should offer still more value.’
Delta ModTech’s systems offer ways to tap into new markets by enabling services outside of label production. The same processing principals used in labelling, such as accuracy, coating, laminating, inkjet printing, cutting and trimming and tight registration, all transfer readily to converting parts produced for consumer, automotive, medical and pharmaceutical industries.
The reliability and easy access to service is also vital in keeping the production line running. The proprietary software used on Delta ModTech machines means that technicians and engineers can remotely diagnose issues and determine which adjustments are needed. This can reduce costs, minimise downtime and helps keep systems running at optimal performance.
‘Not only are Delta ModTech machines the most reliable, Delta has tremendous ability to support us with respect to training, parts and reliability,’ said Darrell Friesen CEO of Jet Label in Edmonton, Alberta. ‘They help us push our machines to the limits, try new projects, and go into new markets.’
The Digicon 3 was in focus at Labelexpo for AB Graphic
Bursting
Spartanics, which is based in Rolling Meadows in Illinois, recently took a step back to look at the overall technology currently being offered to ascertain where digital converting and printing solutions could improve. The answer pointed towards tight integration of digital printing and finishing technology, and developing partnerships with co-suppliers to convert rolls of material into finished labels or parts.
Together with INX International, the company has developed a bursting converting option for the NW210 UV Inkjet Printer which enhances short run, roll to part production of digitally printed and laser cut products. The inline bursting operation is more flexible than guillotine or traditional rotary die sheeting solutions. It allows the printer to run faster than traditional sheeting operations and separate products in a variety of sheet lengths while running jobs ranging from 1 to 500 sheets.
Another advancement for inline converting of digitally printed material is a traditional rotary sheeting function that turns rolls into sheets. This traditional technology is not new to the industry, however, the company has taken it a step further to feed perfed sheets of laser die-cut labels into folding machines for sets of labels that are dispensed by hand in a variety of applications. Medical and pharmaceutical labels along with direct mailers are now being digitally printed, laser die-cut and folded into finished products. The converting tolerance for laser cutting and traditional sheeting is +/-0.2 mm while the folding device eliminates hours of manual folding.
In addition, Spartanics recently introduced a roll to part technology for its L350 series of offline laser finishing equipment. The Universal Parts Extractor (UPE) provides customers with the ability to remove through cut parts from rolls of material. Laser cutting technology offers unlimited flexibility when cutting shapes, however, traditionally this was used for roll to roll converting. The UPE takes any shape and extracts the part from the web and places it on a conveyor for further processing. Applications range from stickers to fare tickets to folded cartons.
Finally, Spartanics developed the X350 Laser Cutting Module for SMAG Graphique to be fully integrated into two traditional lines of converting equipment, the E-Cut and Digital Galaxie. The modular X350 is equipped with a 400 Watt that offers flexibility in cut designs, reduces turnaround time to the customer while averaging a throughput speed of 50 m/min. The X350 can be integrated at the beginning of the system build or added in the future.
Bespoke and modular
Printum GmbH was founded in 1990 by managing director Bernd Leising. The company designs and produces modular converting lines and high precision equipment for unwinding, feeding, gluing, ultrasonic welding, laminating and foiling, die-cutting, embossing, braille, inspection, sheeting/stacking and rewinding for inline and offline configurations in both conventional and digital printing.
At Labelexpo, it showed a converting machine running inline with a Durst Tau 330 digital press that had been developed to produce multilayer labels. Mr Leising said, ‘Labelexpo Europe 2015 was a great success. The configuration on display at the Printum stand generated great interest and attracted many visitors. The press on show is already up and running at a client’s facility, producing multilayer labels, such as high quality booklets and sandwich labels, smart labels with RFID and EAS, clever security features and more.’
The company is seeing a high demand for special configurations and customised solutions in the production of smart labels, which is one of Printum’s specialities. Label design is becoming more and more creative, with added features and functionalities, very short runs with high flexibility and variable data. Thinking out of the box (or label) is alive and well. And for that exact purpose, advanced digital printing presses, and Printum’s modular, multilayer machines, is a great combination.
Mr Leising concluded, ‘Whether customers need a large, complete converting line, an integrated converting line with a digital printing system, a compact converting unit or even a built-in upgrade to an existing machine, Printum has the solution. Built to match customer’s exact, unique requirements, from very close working relationships.’
The Spartanics L350 offline laser finishing unit
Laser cut
With the establishment of LasX Europe GmbH in Germany, LasX is marketing and its LaserSharp brand of industrial laser equipment throughout Europe. It launched the Matrix converting system at Labelexpo.
Available in web widths of 255, 350, 510 and 610 mm, the Matrix system enables off line modular label finishing for conventional or digitally printed labels at speeds of up to 100 m/min. It uses a bar code registration system to register the laser cut pattern to the print and automatically change to different patterns. In addition to paper face stocks, the Matrix can process PP and PE films using the LaserSharp digital converting technology.
The base model is a roll-fed system that unwinds, kiss cuts and rewinds both the label and waste roll. Extra modular customisation options include lamination, varnishing, magnetic die station, second laser module and slitting station.
Cold foil
Labelexpo saw a new collaboration between Spilker, Industrial Inkjet (IIJ) and Kurz demonstrating digital cold foil applications. The cooperation was initiated by Jochen Renfordt, IIJ’s representative in Germany.
Germany-based Spilker’s cold foil solution uses Kurz’s metallic foil to provide a high quality finish, which also enables the use of security and decorative holographic images within the foil. The company has been running successful trials at 25 m/min using IIJ’s 142 Colour Print system and Konica Minolta latest printheads for variable data.
Paddy O’Hara, IIJ’s director of technology, said, ‘We were delighted that the show gave us the opportunity to launch Spilker into the digital cold foil market for label production with help also from Kurz. Results have been extremely impressive. The process is giving a higher quality finish and enabling new applications such as the use of security and decorative holographic images within the foil.’
Labelexpo was also IIJ’s launchpad for the 600 dpi monochrome units, which included demonstrations showing 2 point fonts, barcodes and variable printing. Mr O’Hara said, ‘The show was a great success for IIJ, which has a fast growing reputation in the label markets as well as further afield. Visitors flocked to our stand and we’ve taken away many good quality leads. We’re also expecting to confirm the sale of the actual machine we had on our stand to a UK customer who wants installation before Christmas.’
