Heidelberg and Gallus synergise for an unrivalled label printing machine

Seven years after the market launch of the Gallus ECS 340, currently the best-selling and thus most successful conventional label printing system in its class, Gallus is set to write another chapter in its success story. In a world première, Gallus showcased a pre-series model of its latest generation of machines at the Gallus Innovation Days (September 20-22, 2016, St Gallen, Switzerland). This machine has been developed in association with offset press manufacturer Heidelberg. The Gallus Labelmaster is a label printing press platform designed for the label and packaging market. It features a special platform design and can be configured by customers to meet their own specific requirements.

The partnership…

World premiere – Klaus Bachstein, CEO of the Gallus Group, Ferdinand Rüesch, anchor investor of Heidelberger Druckmaschinen AG and vice president of the board of directors of the Gallus Group and Stephan Plenz, management board member of Heidelberger Druckmaschinen AG and head of the Heidelberg Equipment Division start up the new label printing system Gallus Labelmaster.With its open interfaces and Heidelberg platform development know-how for offset presses of Heidelberger Druckmaschinen AG (Heidelberg), this machine series represents a highly secure investment and enables users to respond flexibly to future changes in the market. The new Gallus Labelmaster for label printing thus builds on the successful, tried-and-tested design principle of Speedmaster offset printing presses from Heidelberg.

“Gallus and Heidelberg have harnessed a great many synergies in developing the new platform technology for the label market. A modular design and a reduction in complexity benefit both sets of customers, sheetfed and label market, and make them more competitive,” says Stephan Plenz, member of the Heidelberg Management Board responsible for Equipment.

The Gallus Labelmaster augments the existing digital label printing portfolio – also developed in collaboration with Heidelberg and based on the Gallus Labelfire 340 – with a solution for high-quality packaging and label applications. Gallus is set to launch the first series machines with a web width of 440 mm. Other, wider web widths will follow as development of the machine system continues. A Gallus customer is currently putting the first machine through its paces in an intensive field test programme and the first series deliveries are scheduled for the second quarter of next year.

What’s new?

In the new platform system, the Gallus Labelmaster is made up of modules that each comprises two printing units. These modules are available in three different variants – The basic version already covers all the required standards of the label printing. The “Plus” version allows greater flexibility and the “Advanced” version leaves almost nothing to be desired and is configurable for all needs in the level of automation. By opting for a modular system, Gallus is ensuring that label printers can satisfy prevailing market requirements and stay fit for the future at all times.

This modularity is made possible by, among other things, a new locking system that makes it easy to change printing units accurately. The system positions the printing units on the base unit with absolute precision and locks them in place, thus ensuring 100 percent register accuracy from the moment the press is started up, regardless of what substrate is chosen. What’s more, the machine system supports a wide range of substrates, from paper and PE to PP and foil.

The developers at Gallus have also introduced a very special feature to make the Gallus Labelmaster exceptionally user friendly. Summarised under the term “best-spot interaction”, the Gallus engineers have ensured that the press is simple and above all fast to operate across all sectors. The press can be controlled centrally via an HMI touch panel, although manual intervention is also supported, with operators able to make changes with ease and, more importantly, very quickly, thereby achieving extremely short setup times. The lightweight aluminium printing cylinders that have been specially developed for this machine type can be changed in just a few quick steps, thus ensuring that job changes can be completed with unparalleled speed.

However, it is not just setup processes that have been speeded up – the high printing speeds of up to 200 m/min on the press ensure outstanding operational cost-efficiency with absolute register accuracy. A short web path of just 1.1 m from printing unit to printing unit significantly reduces waste and an optimised ink duct for the chambered doctor blade needs just 250 g of ink and therefore keeps the associated costs low, in addition, the ink duct has been improved in ink spitting and foaming. The newly designed flexographic printing unit - developed with the experience from the structural principles of the Heidelberg sheetfed offset printing - is driven directly by two servomotors and delivers premium Gallus quality from the start. Besides being fitted out with flexographic printing units, the press can also be equipped with a newly developed screen printing unit that enables users to make the most of high-end finishing options.
The new Gallus Labelmaster

The register accuracy of the Gallus Labelmaster is particularly striking – whether the press is running at a low setup speed or being accelerated to a high maximum speed, the printed image is always in register, without the slightest correction necessary. This performance highlights the precision of the Gallus Labelmaster.

Unrivalled flexibility promise…

By developing this machine platform for label printing, Gallus has succeeded in giving the market a press for conventional label and package printing that offers virtually unrivalled flexibility. Thanks to the three module variants, this platform can be used to configure the right press for any business model – and all for an outstanding price-performance ratio coupled with the famous Gallus quality. Put simply, it is Gallus-like.

Vinsak@LabelExpo India 2016

VINSAK, a leading manufacturer of label printing and security solutions is going to participate for the record 20th time in Label Expo 2016 and every year VINSAK brings something new for visitors.

VINSAK will display their most watched USAR machine equipped with slitter, rewinder and 100% inspection system for label finishing. Being a modular machine, it can be equipped with die-cutting, variable data printing and, adjustable splicing table with pneumatic clamps for removal of the waste product.

Apart from VINSAK, Lombardi and ABG International machines will also prove their mettle in the show.

Lombardi will be demonstrating its new Synchroline 430 UV Flexo press, known for its versatility and printing on the wide gamma of materials. SYNCHROLINE is equipped with printing groups governed singularly by brushless motors and the setting and maintenance of the printing register of the whole press are governed by the electric board with a system of register control.

While, ABG International, one of the leading manufacturers of label finishing solutions, will showcase their turret rewinder-VECTRA ECTR 430 which is fully upgradable with a wide range of options, which include servo technology upgrades, allowing the ETCR to produce a range of finished rolls from a wide spectrum of substrates. The ECTR is also fully compatible with automatic core loading options and finished roll label application options. The ECTR, with its wide range of optional extras including automatic core loading, is fully compatible with A B Graphic International Ltd’s own 100% camera inspection system.

Besides watching live demonstrations of machines, buyers will have an opportunity to explore products of Lead Lasers, Iwasaki International, Schober, and Petrel. Each of the strategic associates will provide sample, brochures and related information about its products and most of all; managers from each company will be present to guide them about nitty-gritty of their machines.

Lead Lasers will focus on promoting its unique hybrid direct laser engraving machines - Printmaster hybrid - used to produce high-quality laser engraving on plates and sleeves ranging from 1 mm to 7000 mm.

When it comes to offset flexo press, it’s IWASAKI International which has created a big reputation in the international market with Intermittent Press TR2 UV offset flexo printing machine with 5 offset print station and 3 flexo printing stations. TR2 is available in web width of 100 to 330 mm and speed of 30-250 rpm.

Visitors will also have the luxury of knowing about brand protection solutions from Petrel known for world class security inks, fibres, and thread. Petrel Security inks are printable by offset, silk-screen, flexography, gravure, and are used for protecting documents against falsifications and counterfeiting.

Last but not the least, Schober USA Inc.will offer its world class equipments for punching and cutting of labels and other extensive materials. Schober develops, manufactures and supplies a wide range of tools, modules or complete processing lines for the manufacturing of longitudinal, cross, contour and half cuts as well as perforations by proven technologies.

BOBST to present comprehensive range of technologies for the label industry

BOBST will showcase its latest range of technologies to produce technically demanding, defect free output for label industry applications at Labelexpo India.

Quality of production is one of the fundamental necessities that make a winning solution out of a production line: although it must also win the challenges of operational efficiency, safety, sustainability and profitability. The scope of BOBST solutions for the different segments of the label industry is very comprehensive, from narrow- to very-wide web, and offering a host of printing and converting options. Depending on their market segment, visitors to BOBST’s exhibition stall will find information on the latest technology innovations and dedicated solutions appropriate to them.

BOBST presses in the narrow- and mid-web flexo and multi-process inline range of solutions for labels deliver profitable production and superior quality across a wide spectrum of applications, including linerless labels, PS labels, wet-glue labels, in-mold labels, wrap-around labels, sleeves and coupons. The M4 line is a very efficient press for printing a variety of applications. The press delivers new standards of precision in servo control, providing stability and perfect register quality and consistency at all speeds.

The advantages of the BOBST Digital Flexo process will be explained by the BOBST specialists on the stand. When fitted on BOBST narrow- and mid-web inline flexo presses, the system enables users to digitize all their press operations, delivering on the one hand the assurance of packaging color consistency through the use of the REVO extended color gamut, and on the other a highly efficient, hence profitable, production flow with automatic job changeovers and up to 95% press run time.

Other BOBST solutions that Labelexpo India visitors will be able to discuss with BOBST experts include the brand new MW CI flexo and the CL 750 - SL 750 compact laminating solutions, which are especially effective for mid- to wide web short run production, as well as the range of wide web gravure printing presses, coating lines and vacuum metallizers suitable for a great variety of applications in the label manufacturing industry.

Rukson uses Esko technology to bring prepress in-house

Navi Mumbai-based Rukson Packaging has undergone a major transformation from offset printer to becoming a complete packaging solutions provider. Recently, the company equipped its prepress unit with Esko’s Kongsberg XE10 sample maker and Esko’s prepress workflow. Rukson specializes in met-pet folding box cartons and its product mix includes a large share of cartons for the pharmaceutical segment.

“Over a period, our client base has expanded in the pharma and FMCG segments. The adoption of Esko hardware and software solutions is an attempt to enhance our efficiency in prepress in order to drive our growth in line with the evolving demands of the consumer product companies,” says Kishin Punjabi, director at Rukson Packaging.

Going forward in the expansion, Rukson plans to extend its customer base in other segments, including FMCG. “To reach out to a wider client base, we develop and supply samples to brand owners, in order to acquire larger volumes of printing and converting. Esko is undoubtedly the leader in its space and Kongsberg is the best means to meet the design and prototyping requirements from design to approval which helps brand owner teams to address marketplace demands,” says Punjabi.

The Kongsberg XE10 sample maker is used as a digital tool for precisely cutting blankets that are used for spot varnishing as well. The Kongsberg XE10 is a small-format digital cutting and creasing sample making table that provides fast, high-quality samples for short-run production of folding cartons.

The company also invested in Esko’s DeskPack, prepress editor software. This prepress software helps Rukson to prepare error-free files & move different jobs for printing quickly. DeskPack has functions like interactive trapping, remapping of Ink channels, quality control & white under print which comes handy during met-pet printing.

Umesh Kagade, channel manager for Esko India says “With Esko’s ArtiosCAD, Rukson Packaging is able to enter in new segments that demand innovative structural designs in cartons. They can now cater to customer demands of 4-5 design options with a physical mock-up within couple of hours of receiving an enquiry.”

Konica Minolta to unpack bizhub PRESS C71cf at Labelexpo India 2016

Marking a landmark foray into label printing market with this production press
Footprints of Konica Minolta have now been expanded into the label and packaging domain with the introduction of bizhub PRESS C71cf, a digital production label press, which is introducing at Labelexpo India 2016. In an exclusive chat with Jyaneswar Laishram from Print & Publishing, Yuji Nakata, MD, Konica Minolta Business Solutions India Pvt Ltd, narrates about their new label press and strategic moves they are taking up to expand their digital production press portfolio. In response to the current need for suitable label printing system in the Indian market, Konica Minolta is introducing its resourceful digital press, bizhub PRESS C71cf, at Labelexpo India 2016. Launching of this production press has marked an optimum printing solution for label converters, printers and brand owners. “We have brought bizhub PRESS C71cf to India after thoroughly observing the market requirement. This mid-level system is positioned between the entry-level and the high-end, suitably designed for short-run jobs,” says Yuji Nakata, adding that the press brings a smooth transition of label printing from analogue to digital.

Yuji Nakata (centre), Yoshinori Koide and Manish Gupta.“This newly introduced bizhub PRESS C71cf stands apart with its ease-of-use features; the system is perfectly engineered for the short-run production of labels, complementing to traditional offset process,” mentions Yoshinori Koide, EGM–business strategy & project management - business planning division, Konica Minolta Business Solutions India Pvt Ltd. He adds that they are utterly excited to introduce the economical and productive press in the Indian label printing market.

Technical details

With its flexibility and efficiency, bizhub PRESS C71cf delivers a new value that no other conventional short-run machines in the label and packaging industry could ever meet. About the machine’s technical features, Manish Gupta, national manager-PP & IP Marketing, Konica Minolta Business Solutions India Pvt Ltd, points out the revolutionary dry-toner electrophotography printing mechanism that offers full colour (CMYK) support. “This compact press can deliver print in resolution of 1,200 dpi and is based on already proven Konica Minolta dry toner technology,” he informs.

“Capable to support a paper width of 330 mm, bizhub PRESS C71cf is ideal for medium-sized label and packaging printing businesses whose activities involve production of diverse applications for clients from different market clusters,” explains Yoshinori Koide. He mentions some unique features of the press, such as low-temperature fusing technology and Simitri HDE toner, which configure the machine to print on a wide range of materials, including polypropylene and synthetic paper.

Versatile media handling

When enquired about the substrates bizhub PRESS C71cf is compatible with, Yoshinori mentions a range that consists of pressure-sensitive gloss papers, white BOPP, PET, polypropylene, semi-gloss, wine stocks, among others. And the press is attuned to file formats like PDF, PS (APPE compatible), 8 bit TIFF, among others. According to Yoshinori, bizhub PRESS C71cf is capable to perform seamlessly at the speed of upto 18.9 m/min, depending on the type of substrate it takes.

On the other hand, bizhub PRESS C71cf is characterised with cutting-edge digital technology to offer easy prototyping, customisation as well as the convenience of personalised text and graphics on labels. Worth notable among all efficacies of the press is its highly proficient mechanism that keeps power consumption barely at a minimum level. Impeccably engineered with an unwinder and rewinder diameter of 500 mm, bizhub PRESS C71cf is an end-to-end digital printing solution for variable data printing (VDP) too, supporting PPML and PDF-VT file formats.

Exclusive focus

Yuji proudly remarks that the launch of bizhub PRESS C71cf in India is Konica Minolta’s dedicated attempt to leverage the country’s label and packaging industry. “This press opens up new business opportunities that digital press can deliver for both traditional and start-up firms,” he mentions, adding, “Those firms using offset technologies can pick up bizhub PRESS C71cf for extended on-demand jobs.”

Around 3,000 KM units have so far been installed in the production setups of a host of leading printing firms around the country. Of them, according to Yuji, we already have few placements with the customers engaged in label and packaging jobs. “As label and packaging printing is one of the aggressively growing sectors in India, driven by several factors like customisation and regionalisation of consumer products, we are accelerating the growth with the introduction of bizhub PRESS C71cf,” says Yuji. In this context, as a piece of advice to everyone, he conclusively conveys that the digital label press is a new marvel from Konica Minolta to every new and old player alike in the label industry.

Group Publications