Save & Recall
“Applying the science of flexography to an automated platform allows converters to be more productive with less and allows press manufacturers to help them close the skills gap with advanced technology. These innovations bring a new level of productivity and quality to the operation,” comments Paul Teachout, vice president, Nilpeter.
He claims, “The largest challenge a converter now has is the need for skilled labor. Innovations close the skills gap and allow a newer generation of operations personnel to engage with a new level of automation.”
Paul maintains, “When determining the correct platform for future needs, it is imperative the offering have a clear path for future requirements and upgradability. Open architecture design allows for future expansion of any level of automation controls and value by adding units for specific applications.
“This concept allows for converters to invest in the level of technology that meets their needs today, with a clear path forward to add and upgrade, as new opportunities and applications arise in the future, without the need to reinvest in additional equipment,” he continues.
Priority considerations in Paul’s mind list out like this:
- Workforce retention and skills gap—Nilpeter’s FA is more automated and has clean hand technology operation that appeals to this workforce, as it features total job save and recall capabilities with wireless tablet controls
- Meeting tomorrow’s needs—the FA line provides multiple widths, as well as multiple automation levels. It is designed to be the most flexible platform available to meet ever-growing needs
- New CLEANINKING design—the new generation of Nilpeter’s CLEANINKING system features new, operator-friendly options. The system offers consistent density performance at all speeds, with a consistent filling of the anilox roller over a large range of ink chemistries, representing simple, one-piece design for the quickest exchange of inking systems available
- Optimized motion control—each print station on the FA is equipped with seven motors; three on the rotational axis and four controlling print functions. There are no more handles or knobs
- Gearless plates, sleeves and anilox rollers—gearless plate sleeves are lightweight and cost effective, allowing for infinite variable repeat and optimized servo automation. There is no sense in investing in servo automation to drive a gear. The anilox roller is a gearless cylinder, quick-change design to maximize life cycle and performance
- Integrated driven chill rollers—manage the transportation and temperature of the web, resulting in precise tension control and superior registration and print performance. There is no compromise in using the chill roller as an impression roll. It allows you to optimize the location of the UV on the apex of the chill cylinder, rather than the exit side of an impression roller
- Real estate and environment—the new FA has been designed to reduce required space and offer more environmental sustainability. Electrical cabinets are an integral part of the machine, offering more production space and easier access to press surroundings
- Global customer care and support—with three global manufacturing sites and 64 markets covered, Nilpeter offers an extensive 24/7 hotline support system, where every time zone is represented, any time of the day, anywhere in the world
- Continued commitment—innovative technologies like the FA and the Panorama Hybrid, creative solutions and excellent customer support reveal that innovation is in Nilpeter’s DNA, and its people and partnerships build mutual success
- Security in a printing partner—when selecting a partner for the future, it is always good to look into the past. Nilpeter is very proud to say it is family owned and run for nearly 100 years
“High performance, consistent color control, easy handling and easy cleaning are must-haves,” according to Paul. “A completely automated and tablet controlled press, with all motor settings, can recall jobs for all future runs. This allows for the fastest makereadies with the absolute minimal amount of waste. The first label off will look just like the last.”
Options & Opportunities
“Boost your competitive advantage.” “Maximize operating efficiencies.” “Realize consequent business growth.” Omet has identified these three concepts as the pillars in what it deems “The Transparent Factory,” according to Gianni Gerosa, electronic R&D manager. Together, he says, they represent the real key to “Industry 4.0,” thanks to new devices for connectivity, evolution toward the Internet of Things and Big Data.
Gianni explains: “More and more operations are now easily managed by remote control; the diagnostic is even more precise and allows quick and focused assistance,” he continues. “Production data is always traceable and available, and the supply chain is oriented toward complete digitalization… This huge change is based on connectivity, automation and the integration between human labor and ‘intelligent’ machines.”
Massimo Bellingardi, marketing coordinator at Omet S.r.L, elaborates on Gianni’s point and lists out his firm’s 10 essentials as follows:
- Manufacturing quality—the base for a successful purchase. Insist on original design and engineering. Accept no imitations
- Register stability—manufacturing quality leads to quality results; quality results lead to orders, acquisitions and money
- Multiprocess capability—inline printing, finishing and converting, all-in-one process, equals production time optimization
The Omet iFLEX, the most recent label press with laser pre-register iLight and iVision systems - Ease of use—no need for high-skilled operators, thanks to back-to-basics concept
- Maintenance necessity—less downtime and less wearing components means less cost for maintenance after warranty
- Customization—tailor-made solutions offer exclusive options and add value to the final product
- Technology and electronics—automation is the future of manufacturing. It reduces the cost of manpower
- Waste production and setup time enhancements—reduce cost per job and speed up production
- Support service—just-in-time (JIT) maintenance limits downtime
- Configuration flexibility—add new options and change the configuration after order
Gianni concludes, “The pursuit of excellence depends more and more on quality and timing of information.” Today, sophisticated systems integrate into packaging production lines because customers need immediate and intuitive information to improve productivity and profitability. Everyone realizes, “Innovation is the only possible strategy to constant growth.”