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Fax: Enter the corresponding product numbers into the Reader Reply Form in this issue. Fax it toll-free to 800/334-2812.

Phone: All Reader Reply items list telephone and fax numbers. Many include Web site addresses. Call suppliers directly and mention Converting.

Indicate precise tension values

A new line of TS Load Cells meet converter needs for accurate tension measurement in any unwind, rewind, or intermediate web-processing application. These sensors combine extremely accurate tension measurement, flexibility, and ease of use. The new MAGPOWR TS line features a low-profile design, minimizing space requirements inside machine frames, maximizing the potential for web width. Mechanical overload stops in both force directions eliminate sensor damage and the need to recalibrate even after extreme overloads. All TS tension sensors incorporate a dual-beam construction to insure linear output under all loading conditions. Inch and metric models are available. TS sensors also offer the flexibility of a variety of mounting styles and coupling options.

Magnetic Power Systems, Inc., 636/343-5550, fax: 636/326-0608, www.maxcessintl.com/magpowr

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Fits CI-flexo presses

The PRIME FLEXfilm Advanced UV-curing system can be easily installed after the last color unit on CI-flexo presses and reportedly guarantees complete cure of Sun Chemical's UniQure UV Inks. This new Wet-Trap UV-curing system is said to be the most cost-effective solution to the drying of ink on flexible film substrates. It ensures the complete cure of heavy coverage UV inks and is controlled by the SMART 2100 Control Platform for consistent cure, deep penetration of the UV-light waves for Sun's Wet Flex EC™ process, as well as cool processing of the film substrate. FLEXfilm UV requires less than 3 ft of space in the web direction and can be installed as a retrofit on all CI-web presses running flexible films, or can be installed by the OEM manufacturer on new CI-flexo or in-line flexo presses. FLEXfilm UV gives the flexible film converter a cost-effective alternative to heat-set ovens for the drying of inks on flexible film at speeds over 1,000 fpm.

PRIME UV Systems, Inc., 630/681-2100, fax : 630/681-0022, www.primeuv.com

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Remove unwanted dirt

Cleaning rollers used to remove dust and particulates in card printers, film systems and manufacturing equipment are available in custom sizes. The rollers eliminate dust and dirt at critical points in converting systems. Available in diameters from 1/2 to 5 in. and lengths from 1 to 10 in., the rollers' degree of tackiness can be modified to meet the needs of specific applications. Molded to aluminum hubs, these custom cleaning rollers can be produced to specific outside diameter and run-out tolerances.

Hiawatha Rubber Co., 763/566-0900, fax: 763/566-9537, www.hiawatharubber.com

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Cuts material costs

The FOX Matrix® system, engineered for tag, label and other narrow web press matrix removal, handles web widths to 22 in. at speeds to 700 fpm. Waste matrix material can be transported up to 60 ft. The system is effective with nearly any shape and size material. Designed to be easily fitted to existing lines, it can be mounted to a 3-in. rewind shaft and be fully operational in about 15 min. The FOX Matrix eliminates the need for rewinding matrixes and thus eliminates production interruption for roll changes. Elimination of matrix rewinds also helps reduce web-tension fluctuations caused by increasing matrix-waste roll diameters. An important feature of the FOX Matrix removal system is that it is "dry" and does not require the use of lubricating powders or oils that can have a negative impact on adhesives and pressure-sensitive labels.

Converter Accessory Corp., 800/433-2413, fax: 610/863-7818, www.handleyourweb.com

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Handle range of sizes, styles

Co. offers a new range of high-speed bagmaking machines. New models are said to be able to replace up to three older machines and can produce up to 800 bags/min with a changeover time of 15-20 min. New models handle a full range of bag sizes for flat or gusseted, glued, heat-sealed flat bottom bags, or oriented polypropylene/biaxially oriented polypropylene plastic bags.

Holweg, 630/681-9900, fax: 630/681-8225, www.novaflex-inc.com

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No electric components

For applications that do not require automated closed-loop control, a new robust, manual pneumatic brake controller operates on 0-100 psi filtered shop air. It has no electrical components. Its three pneumatic solenoids channel air flow to one, two or three brakes or brake cylinders. Two-position toggle switches turn each output channel on and off. An adjustable regulator knob and air pressure gauge let the operator change output pressure to a desired level in real time.

Dover Flexo Electronics, 603/332-6150, fax: 603/332-3758, www.dfe.com

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Digital singular drives

The SYNAX200 shaftless system solution delivers shaftless-driven technology to more than 1,000 printing and paper converting machines, replacing mechanical-drive elements with high-precision digital singular drives for greater flexibility and efficiency. User-friendly software tools for fast commissioning, diagnosis and PLC programming simplify the implementation and maintenance of the automation system, while synchronized, highly precise drivers reduce production and assembly costs in printing, folding, winding and embossing units and in draw rollers and cross cutters. Electronic gears reduce the need for mechanical re-tooling and enable operators to set machines for a change in format or product and adjust longitudinal registers quickly and easily. Additionally, the elimination of torsional elasticity and gear backlash improves register accuracy to ensure product quality and reduce paper waste. Integrated tension, dancer, register, winding controllers and electronic cams eliminate the need for auxiliary drives and external electronic controls.

Bosch Rexroth Corp., Electric Drives and Controls, 847/645-3747, www.boschrexroth-us.com

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Fit narrow-web applications

A new photopolymer printing plate, Flex-Light® ULT 5.0 for the narrow web market, can be used for a broad range of applications including labels, folding cartons, flexible packaging, and multiwall bags. ULT 5.0 is available in 45-, 67-, 107- and 112-mil thicknesses, and in sizes up to 52 x 80 in. It processes in most safe solvents used for flexographic platemaking. ULT 5.0 can be used with conventional and point-light imaging processes. Its rapid dry time and shorter light-finishing time provide substantial improvements to platemaking productivity.

MacDermid Printing Solutions, 800/348-7201, www.macdermid.com

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Uses Platinum™ anilox roll

The Echocel Junior precision hand proofer for flexographic printing is now available with co.'s Platinum anilox roll for better ink release and easier cleaning properties with high durability. The unit comes with laser-engraved anilox roll (1 in. diameter x 4 in. face), a Swed/cut® doctor blade and a transfer roll to act as the engraved plate. The 2.5-lb proofer is easily maneuverable by the operator when making color matches. Several packages are offered for traditional water, solvent and UV-based inks.

HarperScientific.com, 866/588-5656, fax: 704/588-8172.

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High-gloss facing

New Kromekote® Extragloss label stock offers converters a flexible substrate for applications requiring superior graphics and a high-gloss facing for on-the-shelf product differentiation. The 6.3-mil construction combines Kromekote face stock with co.'s RP51 permanent adhesive and a 2.5-mil kraft liner. The white, high-gloss product is said to have a smoother print surface compared to other cast-coated products, as well as yields a better overall printed image. It meets print needs for high-screen, four-color processes, particularly in holding difficult vignettes.

Raflatac, Inc., 800/992-3882, www.raflatac.com

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For digital photopolymer plates

The ThermoFlex™ 5280V, the largest member of co.'s flexographic CTP devices, achieves a maximum imaging speed of over 60 sq ft per hour—a 38 percent increase over the F model. When combined with efficient load and unload sequences, the ThermoFlex reportedly exceeds all of the competition in productivity. A second CTP device, the new ThermoFlex 4048, images plates up to 35 x 47 in., making it a perfect solution for converters using standard plate sizes. The 4048 is said to provide unmatched plate quality and consistency to flexo customers. ThermoFlex uses co.'s thermal-imaging technology for digital photopolymer plates.

Creo America, 781/275-5150, www.creo.com

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Solvent presses run faster

A new purged-station corona-treating system meets the needs of solvent-based printers by ensuring optimal substrate surface energy. Materials with higher surface energy may require a secondary (or bump) corona treatment for proper ink adhesion. The system allows solvent presses to run faster and at lower cost because of the improved adhesion, while it reduces pinholing in solid colors and gradients. The unit's pressurized system features positive pressure air flow for safe operation in solvent areas. Doors allow operators to access system components when the line is not operating.

Enercon Industries, 262/255-6070, www.enerconind.com

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Creates no sawdust

The Double E Core Cutter is available in semi-automatic and manual models. Each cuts cardboard cores efficiently without creating sawdust. The machines accept cores with diameters ranging from 1.5 to 8 in., and wall thickness up to 3/4 in. A simple modification allows the machine to switch between various core IDs. Cut lengths range from 3/8 in. to over 40 in. on the standard model, but the machine can be custom manufactured to accommodate various lengths. To operate the manual model, operators must lower the circular blade by pulling its handle down, while the semi-automatic model automates this process with the push of a button.

Double E Co., 508/588-8099, fax: 508/580-2915, www.doubleeusa.com

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For rotary label printers

The MBS Minicure UV unit offers rotary label printers the ability to move their UV-curing units to accommodate the various processes used in combination printing. The unit can be fitted to printing presses with chill-roll assembly and presses featuring a straight web path.

IST America Corp., 630/771-0590, fax: 630/771-1190.

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Runs foils, films, papers

A new range of EMB cross-cutting systems, which can be used in inline or in offline operations, is said to handle the tight tolerances of cut-foil segments at high line speeds. Unwinders feature pneumatic brake or servo/magnetic-powder brake and foil-edge control or manual foil-edge correction. Roller devices may be oscillated upwards or be fixed to bridge the space between winding idle shaft and cross-cutter in inline operation. A longitudinal cutter produces two or more stacks, and edge trimming with edge tab winder or edge tab ejection by vacuum is available. All drives are equipped with AC servomotors and clearance-free precision gears. Foil stacking is done on an elevating plate or on an elevating shear-table for removal of the foil stack at ground level. The EMB cross cutter is movable between two or more calenders or extrusion lines or can be parked at a winding operation. Materials width between 500 and 2,000 mm can be handled. Linear speed is preset in inline operations as a guiding signal coming from the calender or the extruder. In unwinding operation, the speed can be selected freely at the operator panel.

Emmendinger Maschinenbau GmbH, 49/7641-92420, fax: 49/7641-942470, www.emmendinger.de

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For tag & label printing

Polyart®, a printer- and converter-friendly synthetic paper, is now available as a non-pressure-sensitive product directly to narrow web converters. Currently used in food labels, luggage tags, children's toy labels, bar-code labels, and horticultural tags, environmentally friendly Polyart has high tear resistance, is water-resistant and has excellent chemical resistance. Available in a full range of weights from 3.2 to 12 mils, Polyart is dimensionally stable and can withstand temperatures of -60 to 165 deg F. It complies with FDA direct food contact regulations for all three food categories (fatty foods, aqueous food and dry cereals).

Arjobex, 800/POLYART (765-9278), ext. 825, www.polyart.com

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300% harder than chrome

A new class of metering rods features a titanium nitride coating that reportedly provides a surface hardness of Vickers 3000 (approx. 85 Rockwell C). These metallic yellow rods are said to be three times harder than chrome-plated materials and are ideal for severe-wear problems that occur when coating today's highly abrasive materials. The rods' benefits include significantly longer rod life, wear-resistance to most abrasive coatings, virtual corrosion and chemical resistance, and a selection of 58 wire sizes and 14 core-rod diameters.

Industry Tech, 813/855-5054, fax: 813/891-9904, www.industrytech.net

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For blister cards

New Everest® Seal-Pak bleached packaging board is said to provide superior performance for converting blister cards for pharmaceuticals, cosmetics, toiletries, food and hardware products. The patented, extrusion-coated board is designed specifically for fold-over heat-sealed blisters. It seals to all blister materials such as PVC, PVdC, PETG and Aclar. Available in 10, 12 and 14 pt calipers, the board has reduced mottle and texture for better printability. It reportedly offers consistent ink laydown with fewer surface defects, good stiffness and high brightness.

International Paper, 888/815-4873, www.ipbleachedboard.com

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Web-management tasks

The CxView-WMS system is a specially engineered hardware/software combination for converting that features enhanced technology to perform many web-management and process visualization tasks. It was originally designed as a diagnostic tool for troubleshooting web systems. CxView-WMS is user-configurable and written in Visual Basic™ language. It includes a 15-in. touchscreen; tension, speeds and motor loads; complete drive and motor controls; color-coded fields for data entry and display; and graphical indication of dryer air flows.

Circonix, 201/327-7410, fax: 201/327-7406, www.circonix.com

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Runs films to laminates

The new Model 281 slitter/rewinder handles a wide variety of converted materials from 23-micron polyester films up to heavyweight paperboard laminates. Web widths from 3 to 81 in. can be run at speeds of up to 1,300 fpm. The system also provides powerful torque to unwind parent rolls of material weighing 3,500 lbs and slice through heavy 1-mm board laminates. The 281 also rewinds after slitting to the same 49-in. diameter as parent rolls and is capable of log winding the 81-in. wide web without slitting. Heavy rolls are unloaded onto a scissors-lift trolley as the rewind mandrel is automatically withdrawn.

John Dusenbery Inc., 973/366-7500, fax: 973/366-7453, www.dusenbery.com

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Efficient operation in compact size

The new ModulAir™ dryer unites economical design, robust construction and easy operation into a high-performance web-drying system. Its modular engineering offers a choice of air bars and options for flexibility to meet requirements for a wide range of web-processing applications. Lengths of 10, 13 or 16 ft are offered to run web widths of 33 to 95 in. Design nozzle velocity is rated at 7,874 fpm. Standard 4-in.-thick insulation ensures thermal efficiency. Gas-fired units feature 5-min heat-up and enhanced turndown functions.

MEGTEC Systems, 800/873-8458, fax: 920/339-2784, www.megtec.com

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For extrusion coating/laminating

Ozone generation is said to be an inexpensive way to promote adhesion of flexible-packaging materials during extrusion coating and laminating processes. By generating ozone on extruded materials, reliable adhesion and maintenance-free operation is improved. The generators are mounted to ensure the operating position is deep into the nip area.

Pillar Technologies, 262/367-3060, www.pillartech.com

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Winds core, coreless rolls

The new Model V-5-30 automatic rewinder produces consumer-size retail rolls—with or without cores—for a wide range of materials. It features several new enhanced features that ease setup, operation and productivity over the previous V-4-30 system. Servo-drive technology eliminates gear trains and precisely monitors cut length, speed, product characteristics and other parameters for high accuracy and finished-product quality. Cut lengths are totally adjustable from 3 ft to an infinite length, which will fit the maximum 3.5-in. finished roll diameter. Web widths from 12-30 in. can be run, and production rates up to 50 rolls/min or 600 fpm are possible.

Elsner Engineering Works, Inc., 717/637-5991, fax: 717/633-7100, www.elsnereng.com

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Automatic preparation

The Gravostar 2215 features automatic engraver preparation, which downloads job specifications from the engrave controller. It also includes automatic engraving-head positioning and direct cell-size entry with the Easycell® Calibration System. Screen range is 40 to 200 lines/cm, depending on cylinder circumference.

Max Daetwyler Corp., 800/627-1011, www.daetwyler.com

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Cantilevered design

The ZC series butt splicer offers an extremely small footprint, one-piece cantilevered design and zero gap splicing. The splice unit allows for easy splice preparation that is not dependent on special techniques or operator finesse for splice reliability.

Keene Technology, Inc., 815/624-8989, www.keenetech.com

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For heat-shrink PVC labels

Aqua HS water-based inks deliver high-impact color for PVC heat-shrinkable labels. Formulated for reverse-printing, the inks withstand sharp creasing, scratches and rubbing and shrink with the PVC film as the label is applied. Process colors are available for low-volume high line-count aniloxes.

Environmental Inks and Coatings, 828/ 433-1922, www.envinks.com

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Compact actuator

The BD Model caliper brake, an expansion of co.'s Air Champ® line, is spring-applied, and its compact actuator is hydraulically released, with mounting capabilities on either side of the brake. Ideal for rapid start/stop applications, its simple design with very few seals and moving parts is said to make installation and maintenance easy. The brake shoes mount with detent pins for quick friction-facing replacement, and all pivot pins have life-lubricated pivot-point bearings.

Nexen Group, Inc., 800/843-7445, www.nexengroup.com

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Single-control station housing

Reducing downtime during job changes is a top pressroom goal. The co.'s new IF-NW system automatically supplies ink and flushes the system via a PLC. The system is based on the PPS Peristaltic Pump and consists of a single-control station housing a PLC with graphic interface from which the press operator can control all print stations at once, or individually.

Graymills Corp., 773/477-4100, fax: 773/477-8673.

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Displays, analyzes results

TestLink™ software automates the process of acquiring, displaying, analyzing, storing and printing test results. It lets anyone with a test instrument or sensor with a serial data output to send data to a PC over RS-232, COM port, TCP/IP or FTP. Converters can automatically collect test data and compare results to test plans and previous results. Users can create customized test plans and export data to SPC software and popular business applications such as Microsoft Office and Crystal Reports.

Testing Machines Inc., 800/678-3221, fax: 631/439-5420, www.testingmachines.com

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For HDPE-film converting

The Saturn Titan air ring is designed to process high molecular weight, high-density polyethylene (HMW-HDPE) resins on most blown-film systems. It reportedly develops the best possible airflow distribution to create a specific combination of volume and velocity to suit the extrusion of HMW-HDPE film. The single-lip design maintains the control necessary to produce a wide range of stalk heights, gauge control and bubble geometry; it can be retrofitted to any system with or without internal bubble cooling (IBC), producing maximum capacity and exceptional quality to exceed the demands of HDPE film extrusion.

Future Design, 905/361-9978, fax: 905/361-9985, www.saturn2.com

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High-voltage power supply

The new 8004 control module and 8011 high-voltage power supply are the newest additions to the patented Virtual AC™ line of static neutralizers. The 8004 module allows remote activation of the system's static-neutralizing bars without turning off the monitoring circuitry. This new system circuitry can also provide malfunction alarm and maintenance signals to the control panel. The 8011 power supply can be used with standard or computer interface to turn bars on or off via a main operating control panel or remote computer.

Ion Systems Industrial, 888/310-3334, www.ion.com/industrial

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