“Before smartGPS, it was practically impossible to reliably reproduce settings for repeat print jobs, so there is no questioning the fact that smartGPS has been instrumental in the evolution of CI flexo printing technology toward becoming a fully digitalized and automated process, where waste and the variables that can adversely affect print quality, repeatability and productivity are eliminated,” comments Marco Carrara, technology sales director, CI flexo.
Next-Level Production
After resolving to take automated label production to the next level, BOBST first introduced DigiFlexo technology in 2015, with the objective of automating processes and reducing makeready time and waste in label or flexible packaging production.
Fast forward seven years, and DigiFlexo technology has come a very long way. From a few automated elements, we now have All-in-One, All-Inline technology, fully digitalized and automated production lines, from printing to embellishment and cutting.
BOBST recently launched its latest All-in-One, All-Inline technology with the new DIGITAL MASTER series, leveraging proven flexographic experience and recent innovative inkjet developments. Modular design enables tailoring and further optimization. The DIGITAL MASTER series consists of the DIGITAL MASTER 340 and DIGITAL MASTER 510, two presses intended to completely change the way label production is set up.
Running at up to 328 fpm in four or six colors, plus optional digital white, the DIGITAL MASTER series bridges the gap between traditional digital and flexographic machines. The lineup stands for flexibility, fast turnaround, and inline end-to-end label production, with exceptional quality and productivity in increasing run lengths. It’s the latest step in a journey toward total digitalization and automation.
Skills Assist
Back in 2015, the arrival of DigiFlexo was the first step in a journey where the destination was to digitalize and automate every analog process involved in label or flexible packaging production: printing, finishing, die cutting, matrix stripping and more. This makes flexographic production really similar to digital, in terms of easiness of the operations, plus time needed to set up a job and move from one job to another.
All photos courtesy of BOBST
The digitalization of flexography brings another huge benefit to converters: a DigiFlexo press can be managed by any kind of operator, regardless of skills. This is particularly valuable at a time when many converters are facing a shortage of human resources.
DigiFlexo technology automates the two main parameters in printing: register (lateral and longitudinal) and pressure. It’s all done through a camera which is located on each printing unit. This allows users to reduce makeready time and waste to a matter of a few seconds and a few feet.
Now, with the new DIGITAL MASTER series, the modular architecture allows customers to configure the exact machine they need—from a digital-only version to highly customized converting line—integrating all modules available in inline flexography. It also provides the possibility to be upgraded on-site at a later stage.
“The DIGITAL MASTER series is an extremely future-proof solution because customers can adapt the machine over time to changing application needs and new market trends,” says Strategic Marketing Manager Patrick Graber. “And when new technologies for these platforms are released, they can be retrofitted on site, adding even more value and protecting the investment.”
Flexographic modules can be included for priming demanding substrates, high-ink coverage jobs for long printruns to save on digital ink, applications with high white coverage, or for printing Pantone colors. Available embellishment features include varnishing, tactile and holographic effects, cold foil, UV lamination and security printing. For end-to-end label production, fully automated semi-rotary die cutting or rotary die cutting are ready for integration.
Each print, embellishment and finishing module is digitally automated for exceptionally high uptime, low waste and outstanding repeatability regardless of the operator’s skills. Quality control is guaranteed by the inclusion of ACCUCHECK for 100 percent inline inspection at full speed. This proven technology checks registration, quality and color consistency of digital and flexographic print and all embellishments to ensure fault-free production.
About the Author
One of the world’s leading suppliers of substrate processing, printing and converting equipment and services for the label, flexible packaging, folding carton and corrugated board industries, BOBST was founded in 1890 by Joseph Bobst in Lausanne, Switzerland. It now has a presence in more than 50 countries, runs 19 production facilities in 11 countries and employs more than 5,600 people around the world.BOBST recently shared all the features and benefits of the new DIGITAL MASTER series during a webinar. Watch it at bobst.com/DIGITAL-MASTER-WEBINAR.