Abbey Labels has implemented three new finishing options from AB Graphic International into its label converting workflow. The investment includes a Digicon Series 3 line dedicated to peel and reveal and multilayer labels, an automatic Vectra turret rewinder for faster changeovers, and a flatbed screen-printing unit for added-value embellishments.
As the fourth Series 3 finishing line for Abbey Labels, the new ABG Digicon has been configured with a re-registration lamination unit to produce multi-ply labels. The 330mm-wide machine also features a corona unit, two flexo stations, semi-rotary die-cutting, and auto-slitting with label gap sensor. “We are experiencing a constant and high demand for peel and reveal and multi-layer labels within our digital department. To better serve our customers, we decided to invest in a new finishing line from AB Graphic dedicated just to this purpose,” commented Chairman Tom Allum.
The new flatbed screen-printing module is perfect for shorter run label jobs due to the lower set up costs compared to rotary screen. With faster changeovers and 48m/min speed, the next-generation module will help Abbey Labels accelerate the embellishment and finishing of digitally printed labels. ‘We already have rotary screen-printing in our flexo department, but it is better suited to longer runs,’ said Mr Allum. ‘We needed to add flatbed screen capabilities to make further headway into the beverages, vape and supplements markets, plus existing customers in other industries have been requesting it for a while.’
The third new piece of equipment is a Vectra SGTR330 Autoset turret rewinder, which comes with glueless technology for automatic job changeovers. Mr Allum explained, ‘We bought the ABG Vectra to minimise downtime and have seen great results already. For example, it was taking around one hour to change core size on our old turret; now this same task takes just 15 minutes. The running speed has also improved by up to 50%, so this is a big jump in productivity, which means we can get the finished rolls of labels out the door much quicker.’
These latest investments at Abbey Labels have been made on the back of a 50% increase in digital printing capacity gained through the successful installation of two Xeikon CX300 label presses. The ABG equipment has been put into production in the company’s new finishing hall, which was constructed last year as part of a £1 million overall investment plan to support growth for the company.
Altogether the three new pieces of kit and the newly constructed finishing hall account for more than £600,000 and is projected to add another £350,000 to Abbey Labels’ turnover. Commenting on the process, Mr Allum concluded, ‘We worked closely with AB Graphic and the whole project ran very smoothly. Despite a lot of upheaval, it has been business as usual here at Abbey Labels, and I don’t think our customers experienced any drop in service or extended delivery dates; and now they are enjoying the benefits of our new and improved finishing capabilities.’
