Fact-finding mission accomplished

A status report on Earth's label and narrow web converting industry reveals a wealth of high-tech machinery and material advances.

By the Crew of the Starship Labelco -- Converting Magazine, 11/1/2000

Stardate 11-01-00. Mission accomplished. Our long voyage to Planet Earth for the Labelexpo USA 2000 show was certainly worth the trip. We will be able to incorporate many of the new machines, equipment, materials and supplies unveiled at the Stephens Convention Ctr. in Rosemont, Ill., Sept. 12-14, into our next label-converting expansion project.

Summarizing the offerings of the 493 exhibitors that filled 210,000 net sq ft of display space is not easy, especially when we had to fight for room among the 14,841 registered attendees and nearly 600 humans at the successful conference program. However, we'll do our best. We hereby submit this status report to the Planetary Council for its review, as well as offering it to the readers of Converting for their professional benefit.

Presses go high-tech

Digital, UV ink-jet, multisubstrate and servo-driven were the talk of printing presses at Labelexpo. Here's just a sampling of the new technologies we uncovered during the three-day converting event.

Via an alliance with Barco Graphics (Vandalia, Ohio), pressmaker Mark Andy (St. Louis) demonstrated "the.factory" web-fed, UV ink-jet digital press. First seen at Drupa, the 360-dpi, drop-on-demand ink-jet system runs at 70 fpm, employs a corona treater for running more difficult-to-print film substrates, and uses a chill drum and UV lamps to handle thinner, extensible films. By next summer, Mark Andy says it plans to introduce a combination of conventional printing and "the.factory" system on a standard 2200 press body. A mix of flexo, screen and ink-jet is expected.

Mark Andy's Model 7000 press with Fine.DotT and Accu-DriveT technologies from Multi Print Systems (The Netherlands) also made its debut. This new model contains harder, thinner plates and proprietary rubber impression rolls. The Accu-Drive web transport system provides automatic pre-registration of all print or rotary screen and die cylinders. The 7000 delivers flexibility with the capability of switching between UV-flexo and rotary screen on any print station.

Using its InstaPrep 10-min.-changeover press as a base, Chromas Technologies (Ft. Lauderdale, Fla.) debuted the Argio 75 SC UV ink-jet digital system developed through the Digital Label Alliance. The 7.5-in.-wide, 600-dpi unit uses mixable, pigmented UV inks to print coated paper, film, foil and board at speeds to 100 fpm. Reportedly suitable for HBA, pharmaceutical, industrial and electronic packaging, the Argio 75 SC was teamed with a WFT SoftDie laser diecutter, which is capable of kiss-cutting materials at up to 250 fpm. The Argio, intended for spot-color printing and retrofittable on any conventional press, is priced at about $230,000 per unit. Currently, the UV ink goes for about $150 a liter.

Making its North American debut, the new Xeikon (North Billerica, Mass.) DCP 320 S digital color press is a 13-in.-wide web-fed unit which prints on multiple substrates (label stocks, paper and film) at speeds to 48 fpm. A choice of two digital front ends allows variable-data applications such as versioning, personalization, sequential numbering and bar-code printing. Nilpeter (Ft. Lauderdale, Fla.) demonstrated the DCP 320 S integrated with varnishing, diecutting, slitting and rewinding.

The Omnius Webstream 200, also making its North American bow, is the latest higher-speed, digital web offset press from Indigo (Woburn, Mass.). Capable of printing up to six colors on multiple substrates, including two opaque whites, the Webstream handles webs 12 in. wide, with variable repeats up to 17.2 in., at speeds to 100 fpm. The press was shown with Partoria's Digicon QC 330 finishing system from Burton Engineering (Hull, U.K.) The Digicon, linked with the Webstream, offers 330-mm-wide rotary die, flatbed platen or optional laser diecutting and is priced at about $225,000. A Digicon capable of running 500-mm-wide webs is due soon. The newest customer for the Webstream is Beau Label Corp., New York.

Digital developments aside, Labelexpo USA also had news for the offset, gravure and UV-flexo fields.

The new Supra 1600 is an advanced multisubstrate version of Chesnut Engineering's (Fairfield, N.J.) successful Model 150 narrow-web gravure machine. Offered in 16-in. web width, the press' forte is said to be short runs of p-s labels, shrink labels, unsupported films, paper and foils, down to 0.5 mil. It can use interchangeable flexo and screen units, as well. Chesnut says it plans to introduce the Supra 1900 (23-in.-wide) press later this year.

Closely tied to the Supra is the new Primis direct-print gravure, polymeric image carrier. Reportedly 50% lower in cost than conventional gravure and even high-quality flexo plates, Primis can be engraved by conventional electromechanical means or laser. Imagery is produced directly from a digital engraving machine and requires no chemical or water washout or plating.

The Interflex 13.75-in.UV-flexo press from Intercoat Canada, Ltd., (Mystic, Conn.) is sold completely equipped, including quick-change slide-out print stations, four die stations, ceramic anilox rolls, drop-in doctor blades, laminator, 360-deg motorized registration and a Tandler gearbox drive. Low overhead provides significant price advantages.

Sanki USA, Inc., (Apple Valley, Minn.) introduced a four-color, UV-waterless offset press, the SKO-250C, with variable repeat. The press has one flexo printing/coating station, five UV-curing lamps at 3000W and one rotary diecutting station. A 40-in. dia. unwinder and a 30-in. dia. rewinder are also included.

RDP Marathon, Inc., (Laval, Quebec, Canada) introduces its LF-Series combination web press. Available in 20 and 26 in. widths, the LF-Series will print and convert paper, film, paperboard, pressure-sensitive materials or foil. This series features interchangeable printing inserts and is available in hybrid configurations of litho, flexo, screen, waterless and gravure technologies.

Gi Due USA (St. Louis), a partnership between Allied Gear & Machine Co. (St. Louis) and Gi Due S.r.l.(Milan, Italy), produced the new Combatr flexo press. Web widths from 11-17 in. can be handled, and up to 10 printing heads with repeats from 8-24 in. are available. The Combat stands out for its ability to change over four stations in less than 10 mins.

While last spring's Drupa show may have been noted for "gearless" wide-web flexo presses, Labelexpo USA took up the mantle when it came to servo-driven, narrow-web presses.

First up is the 520 CID from Japan's Ko-Pack Intl. (Williston, Vt.), reportedly the first automated, servo-controlled CI letterpress in a 20.5-in. width. AC servos replace all mechanical components. An added plus is the press' heavy-duty rotary die stations, cutting 15- to 30-in. repeats for materials from synthetics to paperboard.

The new Gallus RCS 330 (St. Gallen, Switzerland) carries the "gearless" torch on the European side. Using digital and servo technology, the press lets labelmakers cut setup and changeover times, while boosting print quality on a range of substrates. Launched with flexo and rotary screen heads, the RCS 330 will soon be available with letterpress, foil hot-stamping and laminating, as well as a wider web. Gallus' first European customer for the RCS 330 was to take delivery following the show. Other units for production are said to be planned.

Heidelberg Druckmaschinen's (Kennesaw, Ga.) partnership with Gallus, via its 30% purchase of Gallus Holding AG last year, was evident at the booth. Labelmaking systems combining Heidelberg equipment and software (Duosetter imagesetter and Prinergy Powerpack PDF workflow) were displayed alongside the RCS 330 and Arsoma EM 280 flexo presses.

Not to be outdone is the 1800SIL inline servo-drive press from Propheteer Intl. (Palatine, Ill.). Following on the heels of the company's servo-drive stack press introduced last winter, the 1800SIL went online at its first customer's plant this summer. Among the unit's features are a programmable touchscreen and independent servos at infeed, on each impression roll, each print cylinder and at outfeed. Exact positions are verified 4,000 times/sec. Demonstrating the variety of materials run, Propheteer also displayed its Ultra 1800 UV-flexo carton press, which has a shortened web path and uses quick-change ink cassettes which reportedly can be changed in 1 min. without tools.

The Model 8500 servoflex press by Roto Press Intl. (Cincinnati) is a fully driven, AC-brushless servomotor machine. Digital AC-servomotors use resolver feedback and high-speed real-time, fiber-optic communication. With press speeds of 750 fpm, this model also contains a laminating station, print pacing station and diecutter. A WTI 50-in. heavy-duty rewind is provided with a soft tensioning system for film applications.

Label and narrow-web substrate printing certainly has come a long way from just a few Labelexpos ago, when all the rage was only UV flexo. Now, "gearless" and digital are the watchwords for this market as it heads boldly into the new century.

In a material world

Several new inks, substrates, coatings and a whole host of holograms stood out at Labelexpo USA. A quick scan of the available data reveals the following developments.

CFC Holographics Security Group's (Countryside, Ill.) Holowashe is a proprietary process that affixes holographic material to coated polyester cloth for the apparel industry. The hologram contains an extremely difficult-to-counterfeit security image that holds up to initial washing prior to retail sale for authenticity.

Metamow Color from Tomen America, Inc. (New York) is a new type of ink that changes color to reflect temperature fluctuations. Converters can choose almost any color-orange, red, pink, purple, blue, green, brown, black, and so on. Printable materials include wrappings, synthetic paper, nonwoven fabric, textiles, ceramics and glassware.

Secutagr from Micot Corp. (St. Paul, Minn.) identifies and protects products using microscopic particles that are unique, like a fingerprint. The particles can be applied to the product's surface or incorporated into it and cannot be copied. Possible uses include labeling/pasting, coating, embossing/stamping and spraying a product with Secutag.

National Starch and Chemical's (Bridgewater, N.J.) MULTI-LOKr removable pressure-sensitive adhesive lets labels be easily repositioned or replaced. At the same time, it provides high tack, low peel-build and high humidity resistance. It is said to adhere well to a broad range of papers from uncoated to highly coated.

3D Ltd. (Switzerland) offers hot-stamping foil embossed with holographic images and diffractive patterns. The company will meet exact requirements by providing foils in various sizes, colors and thickness.

Davis Liquid Crystals, Inc. (San Leandro, Calif.) introduced Vinyl FlexT, a thermochromic "mood film" that changes to reveal a rainbow of colors with the touch of a warm hand. Unlike conventional mood film on a polyester substrate, the product is pliable and curves around corners and circular packaging. It can be printed with visible images, designs or logos.

Glow-in-the-dark foils from API Foils (Lawrence, Kan.) are available in a transparent version for printing over inks and a silver metallic finish for a unique foil-stamped look. Applications range from coated and uncoated paper and board stocks using platen or rotary equipment. Average glow time of 20 min is achievable with 5 min of light exposure.

A new p-s film stock from Emtech (Medina, Ohio) is labeled as "tough duty" for automotive underhood, outdoor and harsh environmental uses. Its construction includes 2-mil white polyester facestock, P 1650 permanent tackified acrylic adhesive and a choice of release liners.

Hanita Coatings (Kibbutz Hanita, Israel) describes its polyester films for color ink-jet and laser printers as matte ultra white and matte translucent. Converted with an ink-receptive coating to allow printing of full-color graphics, the films feature waterfastness with pigmented inks and superior drying time.

Metallized RayofoilT label facestock from UCB Films (Smyrna, Ga.) is available in clear or white and is supplied as a complete film structure. It eliminates the extra step of sending the film out to be metallized. Rayofoil is a biaxially-oriented polypropylene (BOPP) with a print-receptive coating on one side and a metal layer on the reverse.

Uvividr 800 series UV-flexo ink from Sericol, Inc. (Kansas City, Kan.) features an ultra-low viscosity range of 700-900 cP. Good flow and leveling properties allow for a high gloss level. The 800 series 311 white may be overprinted with thermal transfer, ink jet, ion deposition, dot-matrix or laser imaging. Special colors can be supplied against prints, wet ink, Pantoner numbers or other Sericol standard colors. Uvivid can be applied to coated paper and board, p-s vinyls, and top coated and corona-treated p-s polyesters, polyethylenes and BOPP films.

FoilBond-C, UVX00162 made by Akzo Nobel Inks (Langhorne, Pa.) is a cationic UV-curable, cold-foil adhesive designed for flexo presses. With running speeds up to 300 fpm, FoilBond-C is designed to adhere foil in a printed pattern to the substrate by way of foil transfer. It reportedly prints evenly on most surfaces and is suitable for use with a wide range of substrates.

DuPont's (Wilmington, Del.) photopolymer holograms feature a deep, 3D appearance with ultra-high resolution. These holograms are mostly used to provide high security for a wide variety of applications or to promote a product's authenticity. Various two-color images and individualized images are available.

MACtac Roll Label (Stow, Ohio) offers RadianceT, a hazy, clear, conformable polyolefin engineered for fully squeezable to rigid substrates. A clear acrylic adhesive, PC5000, is used to provide extended open time for clean removability and repositioning of misapplied labels without adhesive residue.

Microsphere adhesive from Green Bay Packaging, Coated Products Operations (Green Bay, Wis.) is said to solve tough labeling problems that require removability on demand. The custom acrylic adhesive features enhanced tack to hold onto a variety of surfaces. Individual spheres of acrylic act as microscopic points of adhesion in the coating.

Accessorize your operation

No labelmaking process is accomplished with only a press and some substrate. Often, it's the components and subsystems that surround these main players that make or break a saleable product. And Labelexpo USA was no slouch in the new accessories department.

Pillar Technologies (Hartland, Wis.) unveiled its newly designed, unitized narrow web corona treater and P6000 power supply combination. The compact unit has a removable electrode magazine with hands-free, high-voltage connection for simple cleaning and maintenance. Designed for most any label or narrow web application from 7.5 to 26 in., the system is equipped with front access, single-point gap adjustment and power-supply control panel. It can be integrated with power ranges from 0.5 to 3.5kW per side.

Building on the system's launch at Drupa, BST Pro Mark (Elmhurst, Ill.) expanded its range of Genius 100 percent defect-detection equipment with the Genius LeXT and Genius 10² CT units. Engineered for narrow and intermediate web applications, the LeX processes and analyzes 10 images/sec, providing a higher sampling ratio than other systems. The 10² C, intended for process management and post-processing, uses up to 12 digital cameras to inspect at speeds to 1,700 fpm.

Cleveland Motion Controls' (Cleveland) WebPro advanced digital web-tension controller provides closed-loop control with a tension transducer (load cell) feedback for a variety of applications. A 32-bit microprocessor measures values in digital and analog simultaneously. Its 240x64-pixel graphics display can be read over a wide viewing area. The WebPro can be configured for unwind brakes, unwind motors, intermediate tension needs, surface winders, clutch winders, and center winders with taper tension. It's offered as new machinery or for retrofitting uses.

Rotamesh screens by Stork Screens America, Inc., (Charlotte. N.C.) are a 100 percent nickel non-woven mesh and are manufactured through electroforming. A unique hexagonal hole structure creates cylindrical stability. These screens are not affected by web splices or high production speeds and can be re-engraved if necessary.

Solatell's (Cornwall, U.K.) Sola-Check is for shop-floor situations where a straightforward check on UV levels ensures efficient operation of equipment, such as print machines. The product is programmable to measure the exact curing window waveband.

The ML humidification system by Husson Inc. (Sturtevant, Wis.) uses a built-in distribution fan to benefit the production process and also create a perfect indoor climate with more constant temperature levels. A comfortable humidity level of about 50 percent will minimize problems with dust, allergies and static electricity.

The Crusaderr rotary converting system from Delta Industrial Services (Minneapolis) has six spindles and six rotary die stations driven by 12 servomotors. It provides a flexible platform to handle a variety of materials. A touchscreen allows convenient operator interfacing for programming and fast changeovers.

Complete Inspection Systems, Inc. (Melbourne, Fla.) introduced the AutoProof Pro to automatically inspect, verify and manage documents and labels retrieved from several inputs. Comparing stored master files to incoming documents can be sourced from a camera or at scanning speeds of 1.3-in./sec. and at resolutions up to 800 dpi.

A Uni-Dyne sheet treater from Corotec Corp. (Farmington, Conn.) is designed for narrow webs from 12- to 20-in. wide, and incorporates an "all-in-one" design allowing for fast and easy installation on web presses or other converting equipment.

Specially-designed rotary screen printheads are the result of an agreement between Comco Intl. (Milford, Ohio) and Stork Screens America. The agreement makes Comco the sole source for the Stork ProGlide Rotary Screen Print Head, which features operation over 400 fpm as well as two-sided printing capabilities. The head can slide in and out of any print deck position within a ProGlide MSP press.

Precision Airconvey Corp., Newark, Del., helped Comco solve different real-world printing problems by pneumatically removing and densifying a different edge trim from the MSP press each day of the show: from clear-shrink PVC film to p-s materials and 16-pt carton matrix. Using a Model 811 in-line cutter at speeds up to 500 fpm, the chopped material was conveyed to PAC in a separate booth to simulate a truer plant environment.

A laser diecutting system from Precision Coatings, Inc., (Walled Lake, Mich.) is said to be ideal for label operations requiring short runs and fast turnaround. Laser diecutting can also produce shapes that are not possible with hard tooling. It can microperforate, kiss-cut, through-cut, score, mark and slit with two 2,500 W modules. Roll-to-roll processing of webs up to 36 in. wide is possible, and a vision system for online inspection is also available.

Narrow-web corona treater from Softal 3DT (Germantown, Wis.) is engineered for label printers. The CEE 56 treats both conductive and nonconductive web materials without the need for setup changes. Capacity is from 10-18 in. wide. A compact design and mounting plate allow easy installation and integration into any printing line.

Two crucial processes are combined in the Web Guide Clean Machine (WGCM) for narrow-web printing from Teknek Electronics, Ltd., (Scotland). The unit can be installed directly onto the top frame of an existing web guide, and provides simultaneous guiding and cleaning.

The S-3110cT digital tension controller from Montalvo (Portland, Maine) for closed-loop unwind or rewind is compact and panel-mounted. It features a uniform response regardless of roll diameter, and stores up to 15 different sets of control data.

Offline is really online

Enhancements to the online customer web center of GE Silicones (Waterford, N.Y.) make GESilicones.com more useful to customers and prospects. The product selector includes more detailed descriptions, keyword searches, data sheets and MSDS. The MySilicones(tm) Order Center allows customers to transact business, check inventory availability, access shipping and pricing data, and order samples. Customers can also receive online order confirmation via return e-mail, with complete product and ship details.

Mail-Well Label's Specialty Films Div., Cincinnati, will be the recipient of a new Model 638 slitter/rewinder from Stanford Products LLC (Salem, Ill.) displayed at Labelexpo USA. Well-suited for film applications, the system will be used to finish film labeling for beverage, dairy, aerosol and industrial containers. A second 638 is to be delivered in February 2001.

The K-Series flexo printer from Retroflex, Inc., (Wrightstown, Wis.) offers economical application of inks and coatings inline with existing extruders or bagmaking machinery. The one-color system can be easily expanded to two colors; a total of eight can be arranged in a stack-type layout. With the addition of an unwind and rewind, the K-Series also works offline.

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