Product category:
Labelling and Packaging (including Cans, Cartons, Labels, Flexible Packaging, Sleeves, etc.)
News Release from: Skanem | Subject: MPS UV flexo and screen-printing presses
Edited by the Printingtalk Editorial
Team on 09 November 2004
UV Flexo And Screen Combo Presses In
Label Upgrade
Improvements in productivity and output have been achieved by Skanem's Willich self-adhesive labels factory, which has just completed a modernisation programme to replace 13 older presses.
Improvements in productivity and output have been achieved by the Skanem Group's Willich self-adhesive labels factory in Germany, which has just completed a modernisation programme to replace 13 older presses with just five UV-flexo combination machines The Willich (Germany) plant began the changeover in 1999 with the adoption of a mid-term strategy to become Skanem's European centre of excellence for UV-flexo printing
This article was originally published on Printingtalk on 21 Jun 2004 at 8.00am (UK)
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MPS, a relative newcomer to the techniques of UV-flexo printing and screen-printing, was chosen as the preferred partner and the first MPS press was installed in 2000.
Skanem's managing director at Willich, Thomas Gottenstroeter, said: "They have been a great partner since our first meeting in 1999.
They understood our technological needs and were quick to offer us a screen and combination solution with their UV-Flexo technology." The MPS machines lets the printer run either UV-flexo or rotary screen operations at any station on the press without having to change print modules.
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Hot foiling can also be included.
The MPS technology was one of the first narrow web machines to make extensive use of servo motor technology and incorporate double tooling in the same print heads said Skanem.
To change to screen-printing from UV-flexo means sliding out the flexo inking system and exchanging the squeegee and ink pump.
A single set of press controls operates both print processes.
Within the print unit design is a solid lock feature where the plate cylinder and impression cylinder are locked together in a cradle.
The print pressure is adjusted by moving the whole assembly, without unlocking the gears, so avoiding gear marking.
The ink assembly - anilox, doctor blade and meter rolls - moves automatically as the pressure changes and the anilox can be changed without losing doctor settings (pressure and angle).
A plate change takes about a minute and there is no web break or re-threading required added Skanem.
Special features of the new equipment includes multi-drive technology, with the web transported independently of the printing and converting process with separate servo drives for all print and converting functions.
Each printing and converting function has it own register control with preset capability independent of web transport.
The independent servos allow web speed and the speed of the plate cylinder surface to be perfectly matched, regardless of the thickness of the substrate being run it is claimed.
That avoids barring marks - particularly noticeable on vignettes, which are caused when the web and the plate cylinder are running at different speeds.
That happens when the circumference of the plate cylinder changes as the press operator uses different tape combinations to compensate for substrate thickness.
The speed of the dot must be identical to the web speed for all substrates, both thick and thin and for this reason the gears are locked together with their own motors.
Among other issues that critical to the printer that the new systems achieve is a reduction in waste, wide width standardisation, shorter run lengths and short set-up times at the lowest set-up waste said Skanem.
The printed result is claimed to give minimal dot gain with a full round dot and good ink coverage of solids, with sharper printing of smaller fonts.
There is said to be the capability of printing one per cent dots up to 200 lines per inch (lpi), matching offset quality in most applications, with savings in comparison to former UV flexo systems.
Skanem also added that make-ready time is reduced by 25 per cent and waste is reduced by 30 per cent.
Thomas Gottenstroeter said that the complete change at Willich, which is one of Skanem's 10 European factories, has come about as market trends have changed, which has enabled the factory to meet the new demands.
Customer run lengths have decreased by 20 per cent to 25 per cent as more variants have been introduced and stock holding reduced.
Not many jobs now run up to 20,000 linear metres - 4,000 linear metres is now more normal - which means average running time on the presses is reduced to two hours instead of 10-15 hours.
Each shift now averages four changes and there are three shifts a day.
That is helped by reduced setting-up times - now ranging from 30 minutes to two and a half hours depending on complexity.
A streamlined approach meant that while one job was running, the next was on the bench ready and the third was in preparation.
When the first press was installed in 2000, the Willich workforce began to develop its new UV-flexo skills and give added value to both products and customers said the company.
Continued investment led to more new technology, which in turn led to more sophisticated products and satisfied customers, he said.
It also enabled Skanem to streamline the factory's workforce down from 130 people to 85, whilst increasing output by 50 per cent.
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