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New Technology

Mark Spaulding, Editor in Chief -- Converting Magazine, 11/1/2002

Chill rolls

For curing

These chill rolls provide a solution to web overheating that is often inherent in the UV curing process. Chill rolls located at the UV curing site on a film-based flexo web line can control web temperature and eliminate web stretching and distortion, allowing the web to run at optimal speed, without waiting for ink to dry. But, these chill rolls offer precise temperature control to within +/- 1 deg F across the face of the roll. Each custom roll features a double-wall, spiral-wrap design that helps the fluid flow over the entire inside surface of the roll. A precisely calculated space between the inner and outer roll allows fluid crossover, evening out temperature differentials between the spiral channels. Straight-pitch and gain-pitch heat transfer roll designs are available for optimal performance, reports co. Webex, Inc., 920/729-6666, fax: 920/725-9992, www.webexinc.com Enter 304 or Inquire Online

Controlled powder brake

With tension control

The Double E/Re "Eleflex" magnetic particle brake provides precise, quick-response tension control for light tension applications, reports co. The brake is an alternative to friction brakes, and is said to be ideal for clean environment situations. Low voltage (24V DC) operation presents no safety hazards and makes installation and use simple. The compact unit is available with an integral fan or radiator for added convenience. The Mega Controller can be connected to the powder brake without a current regulator. The three push-button keyboard on the controller allows easy programming of its 40 available functions. Three independent PID settings allow this controller to have different set-ups for the running, acceleration and deceleration modes. Double E Co., 508/588-8099, fax: 508/580-2915, www.doubleeusa.com Enter 313 or Inquire Online

Knife arrangement

For splicing thick material

This new high-speed cut-off knife arrangement is suitable for flying splices at unwind or for automatic transfers to a new core at rewind, and is considered superior to traditional pivoting style flying knife designs, says co. These materials will no longer need to be spliced or transferred manually. The high-speed knife will allow flying splices and transfers of tough films and papers to be cut. Faustel, Inc., 262/253-3333, fax 262/253-3334, www.faustel.com Enter 302 or Inquire Online

Screening technique

For flexo plates

A new imaging process for photopolymer plates is said to improve flexo-printing quality on smooth, non-porous substrates, such as those used in flexible packaging applications. The patent-pending process, named NuDot™, uses high frequency "imaging granules" to break down conventional screen dots into smaller units and rearranges the units to form new dot shapes, or shorelines. The shorelines exploit the natural beading and "rivering" characteristics of ink on high holdout materials. Phototype, 800/304-7989. Enter 301 or Inquire Online

Slot die

Improves quality

With a new generation of Ultracoatw slot dies, web converters are able to apply consistent, distortion-free fluid coatings even at very low coat weights or onto very thin substrates. As in standard dies, the wet or wiping lip (the lip passed by the substrate after coating has been applied) is on the upper section of the die; the profile and surface properties of this lip play a critical role in coating quality and consistency. Unlike standard dies, however, this new Ultracoat V die has the flexible lip and lip-adjusting system (used to change the size of the exit gap) on the lower section. Extrusion Dies, Inc., 715/726-1201, fax: 715/726-2205, www.extrusiondies.com Enter 311 or Inquire Online

Hot-air welding machines

For coated fabrics

These automatic-welding machines UNIMAT and UNIPLAN were developed based on intensive welding tests under real operating conditions. The new range will replace the existing type UNIVERSAL. The high operating speed is an outstanding feature of the new machines, as is the low-noise operation. The UNIMAT hot-air welding machine can reach running speeds of up to 12 meters a minute during overlap welding (with a welding seam width of 20 mm). Welding seams of 40 mm in width can be produced at a rate of up to 10 meters a minute. In the case of tape welding (40 and 50 mm in width), welding speeds of up to 8 meters a minute are attainable. The small and compact UNIPLAN can produce welds up to 7 meters a minute, with widths of 20 and 30 mm. Leister Process Technologies, 41/41-662-7474, fax: 41/41-662-7416, www.leister.com Enter 305 or Inquire Online

Edge strip

With more cutting teeth

The Eco-Edgee is an edge strip for kitchen film and foil dispensing cartons with 50 percent more cutting teeth. This new profile has 40 cutters per in. The Eco-Edge mini-profile is based on the co.'s unique Scalenee paper cutter with teeth angled outwards at each end of the pack to give clean cut for both left and right handed action. The patented paper material cuts like metal but makes the pack fully recyclable. There are now six Eco-Edge profiles to suit different materials and international requirements. All are produced in paper, aluminum and plastic on reels up to 600 mm wide and applied by hand fed or automatic carton edge machines at speeds up to 15,000/hr onto pre-printed, die-cut cartons or fine flute corrugated boxes. Carton Edge Systems Ltd., 44/24-7642-2221, fax: 44/24-7642-2223. Enter 316 or Inquire Online

Clutch brake

For material handling

This new shaft-mounted clutch brake (LSCB-44) used for repetitive start/stop conveying applications. This compact, single piston clutch brake utilizes the clutch disengagement springs as brake actuators. The splined hub design of the LSCB-44 assures full brake torque to the system. Both clutching and braking components use the same piston, which eliminates simultaneous engagement. The clutch release springs also serve as the brake engagement force, the brake automatically engages as the clutch releases for fast, dependable stopping and holding. Nexen Group, Inc., 800/843-7445, www.nexengroup.com Enter 315 or Inquire Online

Compact system

For narrow web

This co. announces a new compact system for the narrow web industry—the 16A anilox cleaning system. It is designed with a small footprint, for restricted space. This new compact design allows the narrow-web converter to clean anilox rolls, using the same well-proven method as with wide-web. The 16A is an off press, computer controlled, automatic system, utilizing plastic media in a clean controlled blast chamber with the capabilities to accommodate up to 16 in. face, 32 in. total length, and up to 4 in. diameter anilox rollers. Absolutely Micro*Clean Intl., 800/474-8489, fax: 916/635-4654, www.microclean-intl.com Enter 300 or Inquire Online

AC drive

With low voltage

The new ACS 800 drives are available in NEMA 1 or NEMA 12 enclosures (without de-rating). All units are designed in a bookshelf style, and range from 6.5-in wide low-Hp designs up to freestanding 600-Hp units that measure only 13.78 in wide. The freestanding enclosures of the drives in the range from 150 - 600 Hp turn easily to fit into deep, narrow spaces, or wide, shallow spaces. Designed with integral EMC filters and chokes and rated at supply voltages of 230V to 690V, the ACS 800 is backward compatible with the co.'s previous ACS 600 family. ABB Inc., 262/785-8363, fax: 262/780-5120, www.abb.com/motors&drives Enter 307 or Inquire Online

Thermal transfer coating

With strong bond

This co. introduces product #8067, a UV-curable thermal transfer imprintable coating with the unique ability to slightly soften under the heat of a thermal print head to form bond between the tape and substrate. Coating 8067 allows the substrate to accept a wider range of wax/resin tapes than conventional and UV-curable coatings and varnishes, providing printers with an expanded array of printing options, says co. The coating provides a strong bond because it was created using a proprietary formulation. The unique formulation allows 8067 to be used on paper and most treated synthetic substrates. It is part of the co.'s extended line of coatings formulated for all methods of applications, including flexo coaters, letterpress, offset, dry offset, gravure, and roller coaters. UVitec Printing Ink, 800/478-6330, fax: 973/778-5981, www.uvitec.com Enter 303 or Inquire Online

Base film

Added to release film

This co. has added a new base film to the various Clearsilw release films already offered. Produced by Valéron Strength Films, this is a flexible, UV stabilized, high-performance polyolefin release liner. Initially available on 3 mil white base with the co.'s cleanroom coated UV10 silicone release, it's printable, easily convertible, tear-resistant, durable, and impervious to air, heat, vapor, water and chemicals. Originally developed for applications requiring a high strength base, Valéron is suitable for outdoor usage, or final applications such as top printed, pressure sensitive self-wound labels. This liner offers consistent, "easy" release for use with pressure sensitive adhesives, in addition to low silicone transfer for backside printing. CPFilms, Inc., 888/273-4567, www.cpfilms.com Enter 312 or Inquire Online

Flat pack machine

For crepe paper

The new model ACR-500 machine is designed to automatically produce retail packages of flat crepe paper at speeds up to 50 finished products/min. or five 10-count piles/min. Working from a single 39.3 in. master roll, the ACR-500 automatically slits, folds and stacks finished products. A programmable logic controller continuously monitors machine functions to assure final product quality. A touch screen interface allows for easy set up of cut length, machine speed and other parameters by the operator. Servo drives eliminate gear trains and provide accuracy in operation. The unit features automatic edge guiding and rotary shear center slitting. Elsner Engineering Works, Inc., 717/637-5991, fax: 717/633-7100, www.elsnereng.com Enter 317 or Inquire Online

Mounting machinery

With top & bottom feeder

This new Lamina fully-automatic mounting machinery features both a top and bottom feeder and works with a variety of substrates, including corrugated display board, paper, plastic, chip board, and card stock. This compact system offers +/- 0.02 in. registration accuracy. The gluing using works with PVA/water based glues and keeps thickness consistent to ensure that mounting boards are stable and flat. The Lamina is capable of mounting up to 3,000 sheets per hour. Liberty International Technology, 903/667-5584, fax: 903/667-5583, www.libertyiti.com

Preprint workflow

JDF-based

The Prinect Printready System allows prepress to map all its tasks in a freely configurable, digital workflow and thus to automate them. The new solution is fully modular in line with the basic principle of Prinect, so that individual components can be selected and added to the overall system rapidly and easily in line with specific requirements. It is therefore possible to unlock the trapping module and automate trapping simply by inputting a license key. The open system concept is also suitable for companies using products from other vendors. Heidelberg, 800/437-7388, fax: 770/419-6665, www.heidelberg.com Enter 308 or Inquire Online

Sensor system

For label, tapes & films

This co. introduces further improvements of its Slot Die Coater Gap Sensor System. This new and improved system achieves coater gap uniformity better than 10 microinches across the full length of the coater die, reports co. The new thinner non-contact sensor wands will allow coaters to access die slots down to 0.004" extending the range of the system. The dual sensor wand also compensates for the non-centered position of the gap. The capacitive gap measurement solution includes sensor wands, special wand holders, and signal conditioning electronics and software. Capacitec, 978/772-6033, fax: 978/772-6036. Enter 309 or Inquire Online

Dancer roll

Reduces down time

The latest Dancer Roll features a non-contact dancer position sensor with analog output, thus eliminating mechanical position sensors, such as a potentiometer. Downtime and inaccuracies associated with potentiometer failure and wear are eliminated with this new technology. They have proven especially effective contributing to quality production in high-end printing, laminating and coating applications, reports co. They offer closed-loop tension control for unwinds, rewinds and nips and may be supplied with clutches, brakes and drives. These dancer roll systems are offered in two standard models, one for 8 in. of material storage and another for 16 in. of storage. Converter Accessory Corp., 800/433-2413, fax: 610/863-7818, www.handleyourweb.com Enter 310 or Inquire Online

Troubleshooting kit

For adhesive & coating problems

A collection of quick comparative tests and 30 tools comprise a new kit designed to evaluate adhesive and coating problems. Suitable for packaging labeling, converting, lidding, bag making, and other applications. This kit works with PVA's, VAE's, acrylics, caseins, starches, dextrines, hot melts, lacquers, polyesters, urethanes, epoxies, cohesives, 100% solids, solvent-based adhesives, and gel lacquers. The kit helps user determine speed of set, clarity, size level, open time, clean up potential, water resistance, filler level, and assess bonding properties. Conlor Corp., 905/472-1282, fax: 905/472-9030, http://members.rogers.com/dickduff Enter 314 or Inquire Online

Moving equipment

For rolls

The ergonomically designed Adjustable Rollmaster utilizes AeroCasterw technology to safely float heavy paper rolls on a cushion of air providing omnidirectional movement. This roll handler allows one person to handle and position heavy paper rolls of varying diameters. It features precise positioning, reduced risk of strain injuries, and the versatility for one operator to move multiple paper/plastic rolls of varying sizes. AeroGo, Inc., 206/575-3344, fax: 306/575-3505, www.aerogo.com Enter 318 or Inquire Online

Laminating/die-cutting system

With PID loop

This new sheet-fed laminating/die-cutting system uses a PID loop to precisely control tension by oz. per linear in., sheets of foam are fed by an automatic sheet feeder module through a water-heated laminating station. Two layers of adhesive are laminated to the top of the material while a substrate is laminated to the bottom. The sheets are then fed to an optically registered diecutter, cutting out the final product at extremely close tolerances. The product is then removed from the matrix by a knockout station onto a side-exiting conveyor, the matrix is sheeter-cut to conveyor for waste disposal. Contech, 800/961-6449, fax: 316/722-2976, www.contech-usa.com Enter 319 or Inquire Online

CTP system

With laser-image

This is the first complete, laser-imaged computer-to-plate (CTP) system for water-wash flexo plates, reports co. Specifically designed for narrow web applications, the FlexoLaser system includes Pix Flow software workflow package, a laser imagesetter and an in-line system for automatic processing of Cosmolightw water-wash flexo plates. Available in a range of sizes, the FlexoLaser system is also compatible with solvent-wash plates used throughout the narrow-web industry. Anderson & Vreeland, Inc., 866/282-7697, fax: 800/223-6869, www.andersonvreeland.com Enter 320 or Inquire Online

Coating & cleaning system

For flexo printing

This co. is now offering its DynaFlexe Coating SB and DynaFlexe Cleaner 1 SB as part of the DynaFlexe Coating and Cleaning System for anilox rolls used in flexographic printing. These new products are said to help printers using solvent-based inks to reduce downtime relating to cleaning as well as making cleaning easier, says co. The coating remains the same, only now it is in a solvent base. It has been shown to decrease ink-residue build-up, as well as the frequency of having to clean the roll. Dynaloy, Inc., 800/669-5709, fax: 800/671-9583,www.dynaloy.com Enter 321 or Inquire Online

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