Grafisk Maskinfabrik DC330 FINISHING SOLUTION Detailed Station Description 1
Grafisk Maskinfabrik A/S constructs advanced digital converting lines for the graphic industry. Our machines have been built for a generation with focus on craftsmanship and in the tradition of Scandinavian quality and design. The backbone of this family-owned company is 40 years of experience in providing solutions for customers in the label industry worldwide. Grafisk Maskinfabrik is firmly based on solid knowledge and insight into the graphic business and we continuously work towards our ultimate goal of Making Converting Easy. We hold a broad experience and expertise in customer-counselling and product development as well as custom designs for very specific products. GM s solutions range from in-line converting of the latest digital presses to coating of plastic photovoltaics, and converting RFID. For both sales and technical support Grafisk Maskinfabrik has offices in Denmark, the US and Chile. Furthermore, Grafisk Maskinfabrik is represented by agents worldwide. Please see www.gm.dk for details. 2
Index...04 Web Guide...05 Web Cleaning...06 Corona Treatment...07 Flexographic Printing Group...08 Screen Printing Group, Rotary...10 Screen Printing Group, Flatbed...11 Die Cut Station...12 Extra Die Stations (for custom tooling)...12 Knife Box Modules...13 Turret Rewinder Module...14 Laser Die Cut Module...15 Sheeting Module (including conveyer for IML/Light board/tags)... 16 Hot Stamping Module, Flatbed...17 Hot Stamping Module, Rotary/Semi-rotary...18 Crossover Module...19 Hot Air/IR Drying Module...20 Inline Modules (buffers)...21 Web Video Inspection Module...22 Configuration Examples...23
DC330 Finishing Solution DC330 in standard configuration As digital label printing continues to grow, label-printing houses are realizing the need for all-inclusive digital printing systems which provide value-adding features for producing fully finished labels. The DC330 from Grafisk Maskinfabrik (GM) offers the ideal solution: a complete converting and finishing unit. The DC330 was created especially for use with digital printing presses. The DC330 can be set up as an in-line extension to a digital label printing system, allowing the web to continue directly into the converter from the digital press. It can also be used as an off-line converting and finishing unit for jobs from other digital presses or conventional presses. It can even function as a printing press for specialized value-adding solutions. The standard configuration of the DC330 finishing line is as seen above: unwind, webguide, flexo group, lamination, die-cutter, slitting box and dual rewind. Unit highlights Modular Customizable to fit your needs, depending on the specific application. Productivity Adjustable repeat lengths from 2-21 ; line speed up to 50 meters per minute Print protection UV flexo varnish station with registration and optional supergloss varnish capabilities Integrated Available as both left-to-right and right-to-left version that runs inline and is integrated with a digital press. Standard for all DC330 configurations: 330mm or 500mm web width. Custom size possible Speed from 0.01m - 72m/min. 55m/min. in semi-rotary Wide substrate thickness range 20um-200um Wide web width range 200-330mm supported Unwind Ø76mm spindle, pneumatic. Maximum diameter 700mm Rewind. Ø76mm spindle, pneumatic. Maximum diameter 450mm (700mm on request) Webguide. BST. With ultrasonic fork. Built-in remote access via internet with self-diagnostics. Weight: less than 800kg per module. 1600kg in standard configuration. Dimensions: Length: 4.0m - Height: 1.6m Depth: 1.1m (standard version) Power: 400V/32A. 8000-Watt average in standard configuration. Air: 5 bar. No running consumption Green (Low power) Running on tri-phase + neutral 400V/32A with an average power consumption of only 8000 Watt. Future Fully upgradeable. Easy retrofitting of options such as laser die cutter, turret rewinder and hot stamp module. 4
Web Guide BST web guide BST 330mm web guide with ultrasonic fork. Built-in splice table with tape dispenser. Optional camera-guide system allowing register-to-line instead of register-to-substrate edge. The BST webguide is engineered for precise control of narrow webs in the label, plastic, and non-woven industries. The highly compact design allows for easy fit onto production machines with minimal space and effort. The controller and actuator have been cleverly integrated into the Compact Guide housing to save space and the entire guide is engineered for fast installation with minimal effort. Featuring solid multi-point support on the displacement frame, precision mounted track rollers, and a high performance actuator that allows for web tension up to 300 N (70 lbs) Standard for all DC330 configurations: Six standard sizes up to 32 width. low Profile versions available for extra tight installations Guiding functions: right web edge, left web edge or center-line Center positioning of rotating frame guide Speed: max. 200 mm/s (0.79 /s) at the exit roller Sensors: Infrared or ultrasonic. Available with CLS line/contrast sensor 5
Web Cleaning Teknek NWP series web cleaner Teknek cleaning and anti-static system. Removal of nano particles (tested using 25/45nm silver particles) perfect for use in optical film manufacturing. Silicone free cleaning core no effect on product surface. Surface energy friendly does not affect the dyn level. The rollers can be easily exchanged after use. The unit is used to remove pinholes and loose toner particles before a UV varnish is applied. Cleaning type: Self-adhesive contact surface Particle size: Down to 25nm Web width 330 or 500 Speed up to 100m/min Sides: Front standard, duplex option Antistatic: Optional build in bar Teknek integration before corona unit 6
Corona Treatment Vethaphone corona treater 330mm Corona system from Vethaphone. The system has a treatment power of 1.5kW on a 330mm wide web. The Corona surface treatment is essential in printing. On a plastic substrate the ink tends to become blemished due to its inability to bond to the plastic. This problem occurs because the surface energy of the plastic is insufficient to permit a proper bond. A quality Corona treatment is necessary to ensure the perfect label print quality we all want to see when looking at products at the end of the production line. This module eliminates the problem of silicone or oil left on the web by the digital press. Treating type: Corona effect Power level: Up to 75w/cm (2500W unit) Web width 330,500 or custom up to 1000mm Speed limit depending on the type of substrate Sides: Front standard, duplex option Corona installed before flexo unit 7
Flexographic Printing Group Flexographic station Conventional flexographic station with pickup, anilox and print rollers. All rollers are standard 12 1/8 gear with 100-320mm print width. Print can be done with a SH40 rubber roller (full flood) or with a cliché for specific patterns. Cliché sizes range from 9-19 (depending on the cylinders used). Wet coating thickness from 2um-25um possible (depending on Anilox and speed). Full drawings of all rollers available on request. The unit features a slow run function to keep all rollers wet during stop. Optional re-registration to pre-printed web possible via mark read. Both water- and solvent-based inks can be used (if the needed drying system is fitted) The DC330 platform supports up-to 8 flexographic groups and is fitted with one as standard. Web width: 330 or 500mm. Custom size on request Coating thickness: 3-25um wet (3-25cm 3 /m 2 anilox) Optional registration: Servo drive with spot varnish function Cylinder sizes supported: 80Z to 152Z Print cylinders: Full flood, solid cylinder, optional sleeve system. Number of stations on unit: Maximum 8 Duplex/Back side coating: Optional Fast change flexo unit with modern reverse mounted bridge 8
DC330 with 2x Flexo and 2x lamination/cold foil configuration For spot varnish a good range of cylinders is needed. To meet this demand, GM offers a cylinder pack with 20 cylinders available for the GM line at a highly discounted price. Sleeve system for flood and spot print 9
Screen Printing Group, Rotary Stork RSI compact head The STORK RSI rotary screen station prints with a screen size of 12-18. Different screens can be used to accommodate very high wet thickness (up to 0.5mm). Automatic register allows for re-print on existing webs. Screens for different patterns can be ordered at STORK CHINA. The system has an automatic pumping system included. It is important to have the proper cleaning drums/washing equipment onsite if quick drying inks are used. For more details on the STORK please see the separate documentation on this unit. The Stork unit can be retrofitted to the DC330 and takes up 90 cm of frame space. Repeat range: 12 to 18, 1/8 increments Web width: 330-500mm Mechanical speed: up to 100 m/min Lateral adjustments: up to 5 mm Slow Rotation: Yes Screen suspension ring, automatic positioning and tensioning Squeegee suspension Stork system with XTR, no height adjustments Drying system: Only UV supported. Screen printed tag 10
Screen Printing Group, Flatbed The SC330 screen printing unit The SC330 screen printing unit from Grafisk Maskinfabrik has a printing area of 330mm(width) x 304,8mm(length) and is designed and engineered to perform screen printing of the highest quality possible on flexible materials. After printing, the ink drying is undertaken by UV-curing(GEW). The SC330 is compatible with tooling (screens) from existing equipment. Preparing and setting up the SC330 is very simple and fast, which makes this machine suitable to complete even very short runs. Apart from being a costefficient alternative to rotary printing due to the low costs of mesh and frame, screen-printing also has several other advantages e.g. easy set-up and little waste. The unit is sold as a separate unit or part of the DC330 finishing line. Max. frame/mesh size: 460x500 mm. Print area 304.8x330mm Speed 3-10m/min depending on job Curing system: UV. Servo register control The printing unit can lift up for fast cleaning Printing length adjustable by touch screen Squeegee position adjustable both crosswise and in height by means of handles The squeegee unit can lift up independently from the printing unit Squeegee stroke adjustable by servo motor according to the printing length Adjustable material output speed. Raised varnish done with screen printer 11
Die Cut Station Die cut station with K&B GapMaster The die cut station in the DC330 works after the semi-rotary (format free) principle where any plate between 2 and 22 can be used. The machine automatically compensates for the portion of the die not covered by the cutting plate. This system is ideal for short and medium runs of digitally printed labels. The die cut station features a fast in register function where the die locks on register marks in one rotation for a minimum of waste. Extra Die Stations (for custom tooling) The DC330 can be fitted with multiple extra die stations. Stations can be either fully rotary (standard) or semi-rotary (custom machines). Die cut station used as an embosser Speed: 72m/min full rotary, 50m/min semi-rotary Die size: 25 standard. Drop 0.48.(12 26 can be fitted in station) Plate size: 2-22 (with a 25 cylinder) Crimp:Software disprofuction for re-use of conventional plates standard Drive:Servo drive with automatic register. Optional: Gapmaster from K&B, Automatic lubrication The extra die stations can be used for high speed blank label production or made to fit existing tooling (Mark Andy or similar). GM designs cassettes on request after drawings. Embossing can be done with polymer plates Braille writing and wine labels are typical applications for this feature. DC330 with two die cut stations 12
Knife Box Modules Crush knife box Removable shaft for fast job make-ready (shear) Shear cut knife box Perf and back scorer knife module Substrate supported: 20um-300um Minimum knife distance: 15mm Control: Pneumatic engage/disengage Adjustment: +/-10mm cross web direction Razor knife box (option for crush knife box) The DC330 converting line can be equipped with a wide range of knife systems. GM offers three main types: Shear, Crush and Razor. Combination boxes or Tideland automatic systems are also available. Short on the knife types: Shear type: Perfect cut, no dust, long set time Crush: Fast set, a bit of dust Razor: Fast set, small dust amount but quick wear. GM has a quick change cassette for shear knifes where the shaft can be prepared on a stand away from the machine. This allows for faster setup times. 13
Turret Rewinder Module DC3-TUR Turret rewind module direct drive with no buffer. Grafisk Maskinfabrik offers both standard semi-automatic turret rewinds and buffered versions. The GM DC3-TUR unit provides quick change-over times unlike conventional rewinding. This allows shorter runs to be produced more efficiently. The machine is available as an option for a finishing line or as a stand-alone slitter/rewinder. With the addition of a rotary die cutter it is a cost-effective solution to blank/plain label converting with a production speed of 150m/minute. The DC3-TUR is available with either one or two rotary die stations for plain label production. Please see LS360 model for this configuration End of roll function The user is able to program the roll end diameter slowdown and/or stop The system does not use any roll followers or external sensors that can be damaged at roll changes. The diameter is programmed from the touch screen operator interface. 2x Rewind turret with 76mm pneumatic spindles Web width: 330 / 500mm Speed: up to 150m/min Stepless electronic tension Automatic stop on diameter or label count Optional: Non-stop operation with buffer module in front. Turret with buffer for non-stop operation 14
Laser Die Cut Module DC330 line fitted with laser option A laser die cutter is an excellent choice for digital short runs. Offering zero change-over time and no die plate cost, this technology is a perfect partner for a digital press. The GM L330 laser unit offers a fully digital mirror (galvo) system for superior laser cut quality. A digital and automatic 3D focus and power control system eliminates the startuphole burn problem of more simple systems. The system is built using 100% standard industry components from major laser suppliers like Coherent. No tooling required, simply download the file from the Pre-press Department and the GM L330 laser will take off. The laser has an optional bar code reader for quick change over and integration into Esko Graphics pre-press solutions. The GM L330 laser comes as standard plug-in module for the GM converters, but can also be fed into any other rotary web feed machine, Please note that the laser works best in PP. PET and PAPER can be cut as well. PE and PVC are not supported. Thick substrate, e.g. for wine labels will cut slowly. Production advantages of the GM L330 Laser Die Cutting System No more ordering conventional tooling and waiting days for delivery. No more long make-readies and less waste material. No more capital tied up in conventional tooling. No more lifting heavy rotary tools. No more storage of conventional tooling. Cutting area: 330x350mm Power: 125,250 & 400 Watt models File format: AI, DWG, DXF, and SVG. Integration: Reads files from ESKO hot folder Speed: 5-72m/min depending on cutting pattern & material Laser type: CO2 sealed (no running gas). Water cooled. Laser tube life: 14000 hours / replace cost EUR 6000-10.000. Exhaust: Ø200mm to the outside. Optional carbon smell free filter Optional barcode scanner for job change scan. Power: 32A/400V. Typical 10kW running consumption. Speed in PP: 2 Labels Ø100-50m/min 3 Labels Ø100-30m/min 4 Labels Ø60-20m/min 10 Square boxes 20x20mm - 10m/min 15
Sheeting Module (including conveyer for IML/Light board/tags) Heavy IML processing on DC330 For roll-to-sheet production the DC330 can be equipped with a conveyer. The conveyer fits on quick-release handles that allows changing from roll-to-sheet production in 30 minutes. The die cylinder operates in full rotary mode when this option is used. Please note that a GAP master (cutting depth control) is most likely needed for this process. The materials can be paper, board (light 250 gsm) or IML materials. Delivery is done on a fast and then secondly slow running conveyer. The end result is sling stacking. Fits models: DC330 & XP500 Web width: 330mm/ 500mm Length: 1.5 meters Speed: Up to 30 m/min Substrates: Paper, IML, Board (job specific) Automatic speed control (follows die) Power: 240V / 3 Amps. (From main unit) Options: External sling conveyer (slow speed) External stacker (RietStack) Slow running stacking conveyer 16
Hot Stamping Module, Flatbed FB330 Hot stamp The FB330 hot stamping unit offers high-quality foil stamping and embossing. Stamping and embossing is possible in one step or as separate steps. Advanced features such as foil saver, servo-register and electronic temperature control comes as standard. Consumers are most easily impressed with the right combination of quality and beauty, and this is where the FB330 flatbed hot stamp unit from Grafisk Maskinfabrik becomes interesting. On the matter of the quality of hot stamping, flatbed is the best choice, and on the matter of beauty, the FB330 can add intricate details of gold, silver or even holograms to your labels. Furthermore, the FB330 is not a one-trick-pony, it will do both hot foil and cold embossing to serve all your needs. The system uses magnesium, brass or polymer plates and booth single-side and male/female tools are supported. The unit offers a high-precision servo drive for perfect register. Four electrical rods connected to a digital heat regulator provides the heating for the unit. Plates can be changed in the hot state using a slide system. Speed: 20m/min (at 12 ). Speed depends on art-work and substrate Web width: 330mm or smaller (down to 50 mm) Max impressions: 5000/H Register: Servo system Foil saver: Built-in as standard Plate size: Maximum 304.8 x 330 mm Plate type: 7mm-12mm magnesium or copper (compatible with older machines) Unwind and rewind: 3 pneumatic. Ø300mm Foil unwind and rewind: 1 or 3 (flange type select at order) Max foil diameter Ø200mm Options: 2x foil unwinds Cross web foil tower (foil direction cross and along web possible) Examples of labels hot stamped on FB330 17
Hot Stamping Module, Rotary/Semi-rotary Rotary hot stamp module The rotary hot stamp module can be supplied in 330mm or 500mm web width. It features an oil heated magnetic or clamp based cylinder. The magnetic system offers fast plate-change times, however the plates are expensive compared to our clamp system. Here standard 1mm magnesium plates can be used. Repeat size is from 2-12. Cylinder size is standard 15 but other sizes are possible on request. Fixed cylinders (engraved) can be used as well. Rotary hot stamp systems are good for high volume production where job changes are not frequent. For short run digital production, our flatbed system is more flexible and offers a more economical tooling. Operation mode: Full-rotary or semirotary (option) Speed: 32m/min full-rotary, 5-20m/min semi-rotary Register: +/-0.15 mm + heat variations in plate. Control system: Servo drive with register Foil drive: Built-in foil saver. Foil tension set via stepless control. SH 60 rubber drive nip. 18
Crossover Module Crossover label (Example from Dan Labels) GM offers a module for crossover labels, also known as peel and reveal labels. The module consist of 4 stages a) A de-lam/re-lam section where the glue on the backside of the front page is eliminated. This is done with a spot flexo-graphic UV varnish printed directly on the glue side of the label b) A top flexo-graphic spot varnish is then applied to form the hinge of the label (if needed) Web width: 330 or 500mm Lanes: 2x standard. 3x optional Speed: 72m/min + Cross register adjustment: +/- 5mm Separation knife: Crush cut. Material: Restrictions. Not all materials are good for crossover. c) The web is divided and the crossover operation is performed. d) In the final stage the newly formed sandwich label is die cut into the finished product and rewound Crossover unit 19
Hot Air/IR Drying Module 2 meter hot air ovens at 200C IR Drying system Grafisk Maskinfabrik has made hot air drying systems for decades. We offer a wide range of Hot AIR / IR and combination systems for priming, screen printing and custom applications. The hot air box can fit on the DC330 as a compact inline solution for water based inks or as a larger external unit for high-speed priming. Web width: 330mm and 500mm Power: 2000Watt up to 17500Watt Exhaust: 800 m 3 /hour (adjustable) Options: Post heat cooling Stone coated rollers Single pass hot air oven for priming 80C 20
Inline Modules (buffers) DC330 Mini inline with HP WS6600 The DC330 finishing lines can as standard operate inline with a digital press. A 3-meter buffer is built in as standard in the lines. For high speed integration (operation over 20m/min) GM offers a wide range of buffers with a capacity from 10 to 48 meters. The buffer can store the web while the operator changes a roll on the finishing line. Thus, the press is never stopped doing production. GM has more than 10 years of experience in inline operation with Xeikon, HP, Epson & Domino presses. Technical Specifications Capacity: From 10 to 48 meters Web width: 330 and 500mm Speed: up to 50m/min inline operation Tension control: Pneumatic with feedback (constant tension) Options: Web guide (strongly recommended) DC330 inline with Xeikon 3500 press 21
Web Video Inspection Module Nikka web inspection module The DC330 finishing line comes with an interface for Nikka web inspection as standard. The system can stop the finishing in case of a fault/missing label/ misprint. Camera inspection is a valuable tool for quality control in the roll-to-roll production of labels and flexible packaging. When installed in a finishing line, the inspection system prevents defective material from reaching the end customer. The cameras on the printing press contribute to waste reduction and higher production speeds. Inspection systems also collect objective process information and supply data to production monitoring and system scheduling. Web width: 330 and 500mm Speed: up to 100m/min inline operation Standard store master and compare Options: Label count, PDF verify, Matrix fault stop, Barcode verification. 22
Configuration Examples Configuration example: Unwind, flexo, cold foil, lamination, rotary hot stamp, full-rotary embossing, semi-rotary die cut, dual rewind. Configuration example: Unwind, flexo, cold foil, lamination, 2x semi-rotary die cutters, slit and rewind. 23
Configuration Examples Configuration example: Unwind, flexo, cold foil, lamination, rotary hot stamp, full-rotary embossing, semi-rotary die cut, dual rewind DC330 with extra custom Mark Andy compatible full-rotary die station DC330 with integrated hotfoil stamping 24
Configuration Examples DC330 direct inline with digital press The DC330 with laser die cutter 25
Configuration Examples DC330 Mini finishing line with inline option for HP Indigo digital press. This configuration offers compact and economic processing of labels. Features are flexo varnish, lamination, spot varnish and die cutting. DC330 compact finishing line for high quality flatbed foil stamping. Integrated foiling unit with dual foil unwind, foil saver and servo register. Embossing and foiling can be done using the same tool. Flexo varnish, lamination, spot varnish and die cutting. DC330 compact finishing line with combined high quality flatbed foil stamping and flatbed screen printing. Servo register and foil saver. Embossing and foiling can be done using the same tool. Laser die cutting unit, flexo varnish, lamination, spot varnish and traditional die cutting. 26
DC330 finishing line with built-in inline/offline option. Flexo varnish with spot, lamination, cold foiling, semi-rotary die cutting, slitting and dual rewind. DC330 finishing line with built-in inline/offline option. Hybrid laser and traditional die cutting. Flexo varnish with spot, lamination, cold foiling, semi-rotary die cutting, slitting and dual rewind. DC330 finishing line with built-in inline/offline option. Stork rotary screen unit for raised varnish/special colors/silk screen finish. Flexo varnish with spot, lamination, cold foiling, semi-rotary die cutting, slitting and dual rewind. 27
Grafisk Maskinfabrik Grafisk Maskinfabrik A/S Bregnerødvej 92 3460 Birkerød Denmark Phone: +45 45 81 23 00 Fax: +45 45 81 99 56 Email: gm@gm.dk Web: www.gm.dk Converting made easy Concept: JS Media Tools A/S www.jsdanmark.dk 28