OEMs Discuss Today’s Machines & Printers’ Priorities

The Way Forward—Nilpeter

Jakob Landberg, director of sales and marketing at Nilpeter, explains, “For the last 20 years, our focus has been to trim changeover time and material waste. Automation is the way forward! It enables savings in labor too.”

He acknowledges: “Our market is the narrow web market and the strong point is centered around 17-in. web width for self-adhesive labels. However, we see strong interest from flexible packaging printers to go 26-in. for solvent and UV printed inline laminated substrates. Interest from printers for the hybrid combination of inkjet and flexography is visible too, but more so in highly automated and lean modern UV-flexographic presses in 17-in.

“Many converters have seen a growth during the COVID crisis—and that has skyrocketed inquiries for more capacity,” Landberg reports. “However, the speed in ordering has been hindered by financing issues. The market is in a waiting position—holding its breath. Questions abound: ‘Do we replace the old technology? Do we add capacity with well-known equipment?’ We expect that old, automated technology will replace old mechanics—both to get lean and to attract new generations of operators.

“Automation is directly linked to ROI!” decrees Landberg. “That’s why many converters who are very concerned of the level of investment cost look for efficiency after efficiency in their press—anything that speeds makeready, cuts waste and reduces manpower support levels wins their favor.”

According to this sales and marketing executive, “The new standard embraces quick set, auto register, auto impression, tension control, self-diagnostics, viscosity control, anti-bounce technologies, short web paths, clean-hand operation, modular print decks, robotics, analytics and, of course, artificial intelligence.”

Efficient & Sustainable—TRESU

Scott Hibbs, president and CEO of TRESU Americas, notes, “We see continued demand for mid web flexographic presses and still see the inline, HD-quality flexographic press as the most cost-efficient quality solution in today’s printing industry. Furthermore, we are experiencing an increasing interest for a modular design concept that permits easily adapting efficiently to customers’ demand and applications.”

Elaborating on trends, he says, “We believe that flexographic technology is a well-documented solution, able to solve the equation of reducing the cost to print, while securing customers’ green footprint—and we experience a rising interest in sustainability.”

Growing demand for updating existing equipment by adding an extra flexographic printing unit as a cost-efficient way of upgrading an existing press is a common strategy, according to Hibbs.

He explains, “If customers think that now is not the right time to make new capital expenditures, then we have a wide range of upgrades and retrofit solutions that we are installing on offset, flexographic and gravure presses, enabling new efficiencies or new functionality, like coating and finishes—a demanded feature in today’s printing industry with rapidly changing customer expectations, seasonal changes and evolving regulations.”

TRESU has focused on increasing productivity by upgrading existing equipment, Hibbs states. It is committed to making the shift from solvents to sustainable water-based printing and adding new functionality to existing converting lines. “We have several different upgrade opportunities available—either with freestanding frames or integrated units in existing production lines. Engineers retrofit flexographic solutions to apply various coatings, inks and glue to practically any type of surface or substrate.”

On a positive note, he indicates that “there seems to be high project activity despite COVID-19. As we are restrained from traveling, we seek to engage with customers in digital ways, but are looking forward to being able to meet again. High activity is coming from flexible packaging industries, but also from specialty print applications.”

Hibbs remarks, “Running with production speeds up to 2,600 fpm and web widths of 67-in., our HD-quality flexographic technology is able to meet most demands and offer the additional capacity needed at a low cost of printing. We experience more frequent questions on short run implications and job changes and with the sleeve change technology we are able to match and exceed most customers’ expectations.”

“Finishing will continue to increase in importance with branding and personalization driving changes for shorter, more customized manufacturing runs and unboxing experiences in consumer goods and packaging segments,” according to the TRESU executive.

He stresses, “With our flexographic technology, we are able to cut start-up times and control pressure and viscosity through thermodynamics and web tension. We can adjust on almost any parameter required. We recently released our third-generation ink and coating circulators, optimizing ink flow, pressure and viscosity control and now combine these with comprehensive automation features. Additionally, TRESU offers automation that adjusts drying hood temperature(s) to the web temperature—That’s closed loop substrate control!

“Today’s flexographic technology is well suited for backside printing and single-pass applications due to the advantages of drying technology,” Hibbs observes. “We deliver a range of add-ons combining UV and hot air-drying systems, as well as digital print solutions in our flexographic presses. We integrate multi-functional print solutions into a single production line; i.e., UV, solvent, EB, lamination, backside printing, etc.”

ROI Rules!—Giave

Wally Nard of Novaflex, on behalf of Giave, comments, “Label companies historically go for an inline footprint and narrow web press options. Flexible packaging converters, by and large, prefer mid web and wide web machines. The landscape is changing.

“ROI rules! It is the order of the day for any and every printer looking to derive efficiencies from the press.”

Nard maintains that “high-quality graphic reproduction is essential. Shorter runs and multiple SKUs prevail. Quick setup, auto register, auto impression and auto tension control are being offered by all companies.”

Capacity & Capabilities—Allstein

“Typically, the decision to purchase a new press relates to either replacing aging, less efficient equipment or is supported by the need of additional capacity for new business. Additionally, capacity requirements may also bring the need for higher graphic demands or capabilities,” details Tim Fox, VP sales at Allstein Inc and Kurt Freye, the company’s sales director.

The duo indicates that “It is important to ensure that the operations staff makes full utilization of the features of the equipment. Automated impression and register systems are designed to enhance the equipment’s operation and reduce waste, not replace the operator’s expertise. Management needs to promote their use. Enhanced systems, like robotic sleeve change systems, make changeover significantly faster, enabling operators to focus on other areas of the press changeover process while the robot changes out the sleeves, bridges and/or anilox sleeves.”

Mention was made that, “It is always beneficial to have the manufacturer’s trainer return some time after the start-up of the press, when operators have had a chance to run several production jobs. Typically, that is when they have experienced working with the equipment and have specific questions regarding items that may be unique to specific jobs. A brief period of additional training at this point helps to ensure that procedures are being conducted correctly. It also permits the manufacturer to follow through with a preventive maintenance and training program likely outlined at time of purchase.”

Data Access & Control—Bobst

“Connectivity, digitalization, automation and sustainability are the cornerstones of packaging production!” proclaims Jean-Pascal Bobst, CEO of the company bearing his name.

Bobst comments, “Brand owners, small or large, under pressure from local and global competitors and changing market expectations, face many challenges—shorter time-to-market, smaller lot sizes and the need to build consistency between physical and online sales. The current packaging value chain remains very fragmented, where every phase in the process is isolated into silos. New requirements dictate that all key players have an end-to-end view. Printers and converters want to remove waste and errors from their operations.

“Across the whole production workflow, more fact-based and timely decisions will be made. Entire packaging production lines are being connected. Brand owners, converters, tool makers, packers and retailers are all part of a seamless supply chain, accessing data across the entire workflow,” he laments. “Machines and tooling talk to each other, seamlessly transmitting data through a cloud-based platform, orchestrating the entire production process—from client’s PDF to finished package—with quality control systems.”

Bobst reported, “The digitalization of printing processes is the most visible element of progress in the packaging industry. The coming years will likely see a major acceleration of digital printing and converting. While the solutions are becoming available, the biggest challenge for printers and converters is not the individual printing machines, but rather the entire workflow, encompassing converting.”

“Our vision for the future for packaging production is anchored in data access and control across the entire workflow, helping packaging manufacturers and converters to become more flexible and agile,” he said. “It is vital to provide brand owners, converters and consumers with quality, efficiency, control, proximity and sustainability. It is our responsibility to deliver innovations that fully answer these needs.”

For example, Bobst reports, “The new MASTER CI (central impression) flexographic press impresses with the combination of exclusive smart technologies, including smartGPS GEN II, and advanced automation designed to optimize usability and maximize uptime. Productivity is exceptional—up to 7,000 jobs per year or 22 million stand-up pouches in 24 hours with one operator, helped by the smartDROID robotic system that does the entire press setup without human intervention. It features the job recipe management (JRM) system for a digitalized production workflow from file to finished product with creation of a digital twin of the produced reels. The level of automation and connectivity enables dramatic reductions in waste and makes the output 100 percent consistent in color and quality.”