Gallus has developed a new inkjet-based digital label press, with a compact footprint and high-level automation to ‘drive the digital transformation’.
Gallus One has a print width of 340mm, can achieve a resolution of 1200 x 1200dpi, and prints CMYK at 70m/min. White can also be printed at 70m/min with 85% opacity. Gallus One prints using proprietary inks developed by Heidelberg. By size, the press is a little over 6.3m in length and just shy of 2m tall – closer to 3m with exhaust air duct – and the body is 1.76m deep/3.35m including cabinet.
The inkjet printing system is stated as being ‘highly automated’ by Gallus, to ensure precise ink application with high process stability. Unique to Gallus One, the system printheads are firmly attached to the machine to increase print quality. Automated ultrasonic cleaning of the printheads is said to deliver a consistent cleaning process for improved print quality and minimises manual cleaning for improved press availability. Printhead capping is integrated. A newly designed ink management system streamlines ink replacement, even while the press is running, with the ink cabinet easily accessible from the operator’s side.
Once printed, a proprietary vision system ensures high levels of print quality at all speeds and on a wide range of substrates. Registration can be adjusted easily, with the ability to perform live visual quality checks. Automatic compensation of missing nozzles avoids white lines and automatic compensation of density variations avoids rainbow effects. Sensors on the press automatically detect splices, letting them pass all printbars without loss of register and speed.
Engineered to combine Gallus’ expertise from the 1200dpi Labelfire 340 with the platform and components from Labelmaster, Gallus One and all its key systems have been designed to ‘operate seamlessly together’. Operation and control of the press is done using Heidelberg Prinect, from creating ISO profiles for enhanced colour management to quality assurance, and calculating ink usage offline and in advance. For additional flexibility, Prinect is compatible with third-party workflow systems, meaning Gallus One can be integrated into existing set-ups.
In-built predictive system management allows issues to be identified in advance, using the Cloud to communicate the performance status of the press as well as maintenance issues directly to Gallus and action a response as necessary. According to the company, such steps help ensure ‘reliable and continuous operation’, minimises downtime and production stoppages, and allows effective scheduled maintenance. Predictive system management strictly complies with the EU Data Protection Regulation, with no personal data or order content shared.
According to the company, Gallus One, ‘removes the TCO barriers to profitable digital labels, with the highest level of reliability, productivity and price performance.’
Dario Urbinati, chief sales and service director at Gallus, said, ‘With the launch of the Gallus One, we are doing more than just bringing a new press to market – we’re providing a unique solution that has the capability to drive the next big opportunity in labels.’
He examples the Cloud capabilities in-built within Gallus One, saying, ‘You can not only enjoy remote set-up, but transparent performance monitoring and standardisation across your press portfolio and manufacturing sites. In conjunction with the sophisticated press design the Gallus One offers a complete reel-to-reel digital label solution, including all the software and hardware necessary to produce high quality, profitable digital labels. All this, with the highest level of automation available, and the most competitive TCO.’
