Imagine a system between the mounter and press that assures not only tight registration, but also very quick makereadies. A modern press can also handle a variety of inks—solvent-based and water-based—as well as UV or UV LED. It means the press can print on a wide variety of substrates. UV LED, cured by a UV light source, opens up a wide world of flexible (including food) packaging, and labels; particularly beverages.
Automation & Connectivity
There are significant Industry 4.0 components that add a lot of synergistic power. The Internet of Things (IoT) is exemplified by connected devices—workstations as well as equipment—throughout the manufacturing chain. To make devices even smarter, sensors and cameras offer real-time information about the system’s performance.
This is all about communication between devices. There are—or should be—no more islands of production. The more information you can automatically send and receive between devices and software systems, the more efficient and error-free you can become. Data is collected from a wide range of sources, from factory equipment and IoT devices, to ERP and MIS systems. Connectivity with these systems gives companies an exceptional level of visibility and control, improving decision-making and automation in every area of the manufacturing chain. Smart, autonomous systems use computer-based algorithms to monitor and control physical things, like machinery.
Even communication between devices, like a mounter or slitter and a press, can be critical to efficient work. Automatic mounting has become the norm now. In 2020, SOMA launched its own automatic mounting devices, which can communicate both registration and plate impression settings to the press, using an RFID chip embedded in the print sleeve.
Press manufacturers can offer a communications platform to provide data between the press and service sources, connecting service, supervision and other facets to streamline the entire print process.
Assuring that all connected equipment can accurately define the process, there becomes only one set of parameters—or intelligent recipe settings—for each job. With a pre-defined recipe, operator errors are eliminated because we always know the specific parameters for each job.
What does an intelligent recipe do?
- It makes the plate mounter setup process easier and faster because the operator doesn’t have to enter any data—It’s already there
- The press can be operated automatically, using data to offer effective changeover guidance to less-skilled operators
- Intelligent recipes provide additional functions, such as calculating ink consumption
Recipe parameters can be entered on a press control panel, from any cloud-connected device.
Extending this idea to changeover yields taking the unique, defined recipe for any particular job—the specific job information required to set up an automated mounter and get a press prepared, from ink colors to anilox to substrate—and guides the press operator during the process of changing jobs, reducing the number of tasks required, and automating as many steps as possible, minimizing operator error.
Process Controls
We are finding that many printers are either implementing their own process controls or asking flexographic press manufacturers to include on-press print inspection. While much of the original attention was on camera systems, the more advanced systems can also automatically control the press and maintain the press results that handle colors and registration.
While the SOMA Optima2 press utilizes a 100 percent inspection camera system to view jobs, we are also currently working with process control developers to add more advanced functions.
One applies to color management. With the ability to look at a job through a camera and to measure L*a*b values with a spectrophotometer, there are many direct things a flexographic press can do to help improve color during the pressrun.
There are even some macro things that a press can do, such as offering bounce control to provide speed to the press with consistent quality and being able to maintain an impression setting to help keep uniform density.
SOMA is working with vendors like Baldwin to offer online spectrophotometers. We are also working to offer how to set color into the specs, so that the press can monitor color online and even reduce Delta E color variance.
Multiprocess Print
Printers need variability to be able to offer different options to print different things—or even just differentiate themselves from others. So, it is not any surprise that they are finding one or two print units tied to a flexographic press are beneficial for tasks that are not necessarily in flexography’s wheelhouse.
For example:
- Digital print offers the ability to add variable data—even if just serial numbers—on packaging
- Gravure can offer backside cold printing for adhesives
- Even another flexographic outboard for an extra color or varnishes is welcome
One SOMA customer, Bomarko, uses a gravure unit to provide backside coatings for products that we use every day.
Remote Diagnostics
Many press manufacturers have taken advantage of online connectivity to make their presses as efficient as possible, as well as offering a quick connection to the service department—“space age technology” to some.
In terms of efficiencies, significant press parameters are targeted:
- Energy consumption can be monitored online
- Any internet-connected device may review and manage what is—or has been—happening with the press
- Management in any press facility can make sure the press is operating as cost-effectively as possible
Press manufacturers understand that an idle press does not generate revenue. But how do we help during a pandemic, or from miles away? COVID accelerated—and illustrated—the need for virtual service/support and training, to the point that there is a lot that can be done online. While virtual reality may be a rare convenience, we have also learned that video works very well.
The press-to-service-solution provides a quick problem-solving communications channel for a printer. In case of an emergency, communication is conducted remotely and allows the transfer of files, pictures and videos attached from any cloud-connected device. Content available from the press manufacturer’s side includes all relevant information, such as press supervision, instructional videos, spare parts list, and retrofits or service programs.
Even training can be enhanced with the right technology. We know of one printer who insists that he can take almost anyone off the street and make the person an efficient press operator in one day.
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