The New Millennium
The year 2001 marked another great global innovation in the narrow web sector and new record for Omet: the launch of the Varyflex, the first mid web press with servo technology, fully gearless and equipped with sleeves. Since the use of sleeves is common in tissue converting, Omet was able to perfectly manage the technology—later all press manufacturers would adopt this solution. The machine, designed for printing flexible packaging, is equipped with chill drums and is configurable for printing both plastic films and cardboard. Innovative rotogravure units or screen printing groups were available in addition to UV, water- or solvent-based flexo in any desired position on the machine or on the upper sliding rail.
Omet didn’t stop research on the Varyflex and in a few years presented several innovations:
- The inline hologram unit, which won a 2005 FlexoTech International Print & Innovation Award
- The solvent and water lamination
- The adhesive lamination
- A proprietary register control system suitable for reprinting with perfect register on previously printed rolls
Varyflex is also the first machine that reduces waste at startup thanks to the use of pre-register. Varyflex is a true modular platform that can suit the most unusual request, for example the printing of scratch-and-win tickets or food packaging laminates in one-pass printing.
The launch of XFlex in 2007 came with two major novelties: the short web path with an impression cylinder to work as a chill drum for UV, and the direct-drive motor on the plate, to secure precise registration. The press won the 2008 FTA Technical Innovation Award for its achievements. XFlex was also the first machine equipped with an Omet-patented Vision-1 register control system, with registration accuracy of less than 5-cm. of tolerance.
To date, there are approximately 300 XFlex presses in operation around the world, all emphasizing multiprocess printing—the ability to combine multiple technologies inline and print complex products in one pass.
In 2009, Omet launched the Monotwin Cut special diecutting unit that works with a single magnetic cylinder for any label shape or dimension and brings advantages like die stock reduction, minimization of die handling and elimination of the risk of receiving non-compliant dies. It also saves time during setup and format change (the only thing that changes is the flexible die) and can cope with high speed printing rates. The process is simple and effective: Monotwin Cut rotates at constant speed during the cutting phase; thanks to its servo drive it accelerates and decelerates in perfect synchrony with the machine speed while this gets ready for the next cut.
In 2011, the XFlex family grew with the addition of the XFlex X4, an entry-level press that incorporates the winning concepts of XFlex (became XFlex X6) as well as a short web path, integrated impression cylinder and chill drum, UV on the chill drum, automatic register control (provided by the Vision-1) and upper rail. Alongside the launch of XFlex X4, a new matrix waste stripping system, Rock’n’Roll, was presented. The system allowed waste removal very close to the stripping and waste rewinding shaft, so there is no need to reduce the machine speed before die cutting.
In the last few years, Omet has continued innovating in the printing sector:
- Its first hybrid inkjet digital flexo press in 2012—the XFlex X6 JetPlus
- Its first hybrid offset with sleeve plus flexo with sleeve press in 2013—the XFlex X6 Offset
- Its first laser application in narrow web printing in 2015—the iFLEX
- Its first 33.5-in. (850-mm.) width web offset with sleeve press, with ebeam drying system in 2016
Omet received an important award in 2010: the Global Award for Continuous Innovation, awarded from Tarsus, organizers of Labelexpo.
Looking Forward
Today, Omet can offer a complete range of machines: from label printing (iFLEX) to complex label and film printing (XFlex) to flexible packaging (Varyflex); a complete range of printing technologies—flexo UV, flexo UV LED, water-based flexo, solvent flexo, offset, rotogravure, silk screen, digital inkjet, cold foil, hot foil, holograms—and a complete range of printable substrates which includes paper, self-adhesive paper, plastic film, aluminum and carton.
The demand now is not only for flexible and highly automated machines but the combination of mechanics and electronics, embodying the concept of mechatronics. Machines are more complicated, but this sophistication should not lead to pure complexity. There is a famous quote: “Simplicity is the ultimate sophistication”—hence the need to rely on the support of research institutes and calculation software to create a product easy to operate and highly productive.
About the Author: Claudio is the sales director for Omet Americas, Inc. Omet Americas Inc. is the U.S. branch of the Omet Group, Italy. The target of Omet Americas Inc. is to provide customer service, technical support and sales across all North and Central American countries. With more than 50 years of excellence in service, technology and innovation, Omet is a world market leader in the development, production and marketing of narrow and mid web printing presses for the inline production of labels, folding cartons and cardboard products.
Beside its portfolio of printing presses, the Group also provides narrow and wide web tissue converters for embossing, folding and printing for the towel and napkin industries. The Omet Group has employees in North and Central Americas, Italy and China.