He said, “Products need to be simple, easy to operate, and non-dependent on skills of the operator. Automation and digitalization equal quality control. Modularity equals upgradability. Converters must position themselves to tackle a wide range of applications.”
Stressing that presses be both “future proof and versatile,” Graber pointed to the Digital Master Series as an example. He identified it as being “both inkjet and flexo, 100 percent modular, offering on-site upgradability and positioning a converter to move from multiprocess to one-pass printing—PDF to ready-to-ship labels.” It was also noted that Accucheck for labels brings smart print control, registration, calibration, maintenance, print quality and embellishment. Integration with the press boosts uptime.”
Collaboration Obligatory
Sara Alexander, marketing communications manager flexible packaging, declared, “Industry transformation is happening and it’s happening right now!” She reported, “All flexo demos now utilize water-based inks to save time, waste, energy and money.”
Further observations she voiced included, “Sustainability is pushing the boundaries of what’s possible and bringing plastics back into the recycling community. It’s not a choice; it’s an obligation. Collaboration creates new solutions. One Barrier mono materials—both paper and film—are a prime example.”
Within the flexible packaging arena, BOBST offers a high-performance range of central impression (CI) flexographic printing presses, including VISION CI, EXPERT CI, MASTER CI and MASTER CI 90SIX.
VISION CI is designed to deliver the most efficient performance for all production lengths on a wide range of substrates. Fast to set up and change over, it features technical innovations and automation that ensure repeatable process consistency, minimize waste and afford easy manufacturing. Of note: A highly modular concept enables very fast installation and startup. Exclusive tapered Key-Way for plate reference, in combination with smartSET, reduces waste of substrate and consumables. Joint action of the two-component doctor blade chamber, the smart inking and easy cleaning systems increase press uptime. A dual technology tunnel, in combination with a heat recovery system, ensures optimum drying performance and energy.
The EXPERT CI maximizes CI flexographic process consistency, delivers stable and controlled printing results and exceptional productivity with both solvent- and water-based inks. Innovations designed to deliver unrivaled performance include: smartGPS or smartSET, exclusive systems for registration and impression setting; smartFLO inking system and triLOCK bearing system with high-torque mechanism replacing manual locking. Connectivity features enable access to production data from remote services.
The MASTER CI combines advanced technologies and smart innovations in CI flexographic printing to enable the highest productivity, process stability and flexibility, independent of the operator’s skill level. Advanced robotics guarantee a fully automated press setup. It features: Modular design for fast installation and commissioning in less than four weeks, and smartDROID system and smartCLEAN II on-board washing for fast cleaning of print units. Combined with the new smartCOL—a color-matching system that measures L*a*b* values before printing—it minimizes ink consumption and facilitates machine handling. Automatic splice at high speed in less than two minutes from loading of reel to splice ready guarantees minimal substrate waste. smartTHREAD for web threading moves from unwinder to rewinder in less than three minutes. Plus, the new-generation smartGPS II allows digital proofing and offline quality check and preparation of print tools, at high production speed of up to 2,625 fpm.
The MASTER CI 90SIX caters to the preprint market for high-end applications and stands as a highly customizable solution, delivering close to offset quality printing on lower grammage paper. It considerably lowers production costs, accommodates print widths up to 110-in. and repeat range 33.5-in. to 81-in. The cantilever sleeve system affords fastest changeovers.
Non-Negotiables
Bodo Junge, product marketing director for folding carton and corrugated, spoke to zero-fault production, functional packaging and protection, plus customized features that promote faster time-to-market, e-commerce and sustainable packaging. He said a single objective applies: “Deliver an out-of-box experience, in and outside printing.” He too stressed automation, connectivity, sustainability and proximity; plus, of course, simple and streamlined machines.
“Here comes tomorrow!” Junge declared. “Tooling matters!” Benefits it brings include improved ergonomics, minimal changeover times and full control. “Zero fault is a non-negotiable requirement.”
In folding carton, ACCUCHECK RECIPE EDITOR for folder/gluers, an inline inspection system, carefully checks carton blanks for defects and guarantees complete quality consistency. Users can create and edit ACCUCHECK recipes remotely within the BOBST Connect platform and send these recipes to several ACCUCHECKs on the production floor. Leveraging the PDF data of the packaging artwork, this solution simplifies and significantly shortens setup. It enables higher shop floor productivity, while also increasing quality and reducing waste by limiting the potential for human errors.
Similarly, SPEEDSET, an enhanced setup time reduction pack available on all flatbed die cutters, reduces changeover times and increases output. It includes improved ergonomics, such as an additional 15-in. screen at the feeder for faster setup of the optical registration system. Increased automation is also part of the pack, like pallet lifting for each new job setup and a motorized micrometric system to perfectly center die and counter plate to ensure perfect matching between cut and creasing positioning. TooLink is included to digitally connect the tool with the machine to exchange job data within seconds.
TooLink brings converting into the digital world. It is the new platform that connects machines and tooling and brings together the entire converting process to transform production flexibility, job turnaround times, and overall productivity. Driven by industry-leading digital technology, TooLink offers a suite of Internet of Things (IoT) applications designed to provide a complete picture of job histories. Data and insights it provides are empowering better decision-making, and delivering increased control, automation and efficiency.
NOVAFOLD 50, 80 and 110 folder/gluer models produce a wide variety of box styles, across a range of substrates and at speeds of up to 984 fpm. The machines boast a blank aligner for folding precision, enhanced quality assurance with ACCUJECT technology, and fast and easy carton collection; plus, they can facilitate rapid changeovers and job recall, as well as the versatile production of straight-line, crash-lock, and 4- and 6- corner boxes.
In the corrugated board sector, the new EXPERTLINE—consisting of the EXPERCUT 1.7 I 2.1 and the EXPERTFLEX—is a large-format converting line, combining flatbed die cutting and postprint flexographic printing. It is ideally suited for producing e-commerce solutions, offers great flexibility, and is available in a standard and mirror version. Short setup times combined with TooLink technology ensure maximum uptime and a productivity of up to 20 million square meters per year. EXPERTFOLD 165 is a new folder/gluer designed specifically to meet the demands of digital retail.
MASTERCUT 1.65 PER is a flatbed die cutter able to process folding carton, corrugated and litho-laminated board, from 0.02-in. to 2,000 g/m2, single or double flute.
MASTERLINE DRO, a new rotary diecutting solution, offers both performance and value because it equips converters in the corrugated industry with a versatile, automated, connected and highly ergonomic solution. MASTERLINE DRO is capable of productivity reaching an output of more than 40 million square meters per year. From pre-feeder to palletizer, it heralds a new era in box making, with high-quality inside-out printing in a single pass, complex diecutting capabilities and quick full-line changeovers.
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