PACKAGING PRINTING MACHINES

OVERVIEW

XFlex X6 Offset  packaging printing machine answers to the needs of standardization requirements of brand owners, who need to rely on the maximum replicability of printed jobs, no matter the volumes or the types of job. Web offset printing involves quite important savings in pre-press and the possibility to find service centers everywhere in the world. The mix of offset and UV flexo printing allows to take advantage of what is good of both, including for the second the ease of ink management and the inner process flexibility. Addressing mainly to large converters printing long runs of flexible packaging or added-value labels, hybrid press XFlex X6 with rotary offset / UVflexo combination is offered in widths up to 530mm / 21’’. The flexo/offset combination can be combined in-line with a whole array of printing, converting and finishing solutions to deliver the most diverse products in one single pass.

SELLING POINTS

OFFSET PRINTING ADVANTAGES

  • Undisputed web offset printing quality
  • Offset standardization
  • Uniformity for the entire run
  • Limited cost of the plates
  • Easy to find a service, staff, print and pre-press in the world
  • Flexibility in the ink management
OMET OFFSET ADVANTAGES
  • Available up to 530mm (21’’) width
  • Easy to handle and lightweight aluminium sleeves or polyurethane / fibreglass sleeves can be used on the same unit
  • Fully automatic sleeve change operation with trolley for sleeves moving
  • Ink train rolls with 21 rolls + deviation ink roll system, which allows an increased flow of ink and a better printing quality at high production speed
  • Print repeat (infinitely variable) from 14” to 25”, the widest on the market. Smaller sizes allow a lower cost of offset and flexo sleeve, a lower cost of the plates, of photopolymers and other equipment
  • Cold foil available on the offset unit
  • Extremely reduced web path, UV installed on chill drums
  • Independent motors on the repeat sleeves on the impression cylinder and on the ink unit
  • Anti-ghosting system added in the inking train
  • Compact and absolutely rigid printing unit, with a single mobile center, the blanket cylinder
  • Absence of axes and parts on sliding guides/rails, which can cause vibrations
  • Touch-screen panel on each printing unit
  • Print adjustments completely outside the unit
  • Remote control of the ink fountain blades, straight from the console
  • Dampening system with independent motor with variable speed
  • Inking roller and ink fountain roller with temperature control
  • Automatic rolls washing with no manual intervention by the operators
  • Automatic pre-register, longitudinal and transversal
  • Vision-1 system for automatic register just pressing a single button for the entire print section
  • Operator ergonomics: access from both sides
  • Use of FEA (Finite Element Analysis) software: analysis when the groups are finished, for final sizing and dimensioning check of the whole project
  • Multiplate mounting unit can be used with both flexo and offset plates

TECHNOLOGIES

  • Flexo

    Flexography has become one of the most versatile printing technologies on the market capable of offering high quality and extreme flexibility on substrates and in mix with other technologies. Flexo is particularly suitable to print full, special, metallic colours, texts and varnishes offering a wide color gamut and precision of details. OMET flexo unit can print using UV, water-based or solvent-based inks. OMET flexo units can be equipped with either light flexo sleeves or traditional printing cylinders.

  • X6 Offset by Sleeve

    The wet Offset by Sleeve unit is added in-line on OMET packaging printing machines to satisfy criteria of print standardization and consistency, which offset technology with the ease access to pre-press and low printing material costs is capable of guaranteeing. The use of light, compact sleeves (aluminum or polyurethane/fiberglass sleeves) allows to reduce the costs of format change and general handling so introducing the real offset variable repeat. The unit features: peculiar geometry of elements minimizing movements and consequently providing exceptional stability and print consistency; accuracy of execution in absence of vibrations; precise pre- and register control performed by the renowned Vision-1 system; ergonomics of use with wide access to both sides of the machine; start-up speed of 10 meters per minute.

  • Rotary silkscreen

    The rotary silk-screen printing unit is designed to be easily integrate in any printing position for best screen print results, quick set-ups and easy print adjustments. A high technological level and the simplicity of use make of the Rotary Silkscreen unit  the ideal investment for high coverage printing and the printing of thick ink layers, typical of the cosmetic and pharmaceutical market sectors. The screen cassettes are compatible with any OMET printing line in replacement of other technologies. This interchangeability, easily and rapidly realized, is synonymous with flexibility of the machine configuration, quick job changeover, and offers the possibility to secure the print sequence most suitable to the application. The unit features a patented and fully automatic screen tensioning and screen positioning system for no operator adjustments in case of repeat size changes.The unit is independently supplied and servo-driven; the register is immediate and precise, the ink supply and calibration are constantly controlled and the meshes have a long-life guarantee.

  • Rotogravure

    Rotogravure is synonymous with excellence in metallic inks printing (silver and gold) and high coverage of opaque backgrounds (at the highest speeds); in general, it is the most suitable printing technology for labels and packaging with metallic effects. Thanks to its typical versatility and ease of use, the Rotogravure unit by OMET can be used with a wide range of substrates, from cardboard to labels; it can be inserted in-line in any position or sequence and the connection performed by one single operator. The unit is a valid support for the transfer of glues for Lamination or Cold Seal in one pass. Faultless results are ensured by the possibility to include the electrostatic interlocking device (ESA) into the unit to aid ink transfer on non-flat surfaces like cardboard. The Rotogravure unit by OMET is explosion-proof and Is compliant with the international standards in use. A wide choice of drying systems is available to dry any ink thickness.

  • Digital inkjet

    Specially recommended for very high-quality labels and packaging used to present and give value to prestigious products in small and medium runs with just-in-time deliveries, JetPlus by OMET can print on a wide range of different substrates. The heads, with a resolution of 600x600 dpi, can be easily changed to maintain a high level of printing quality and rapidity in job turnover. A special washing system prevent the printing heads from drying when the press is in stand-by. The user interface is easy to handle, start-up procedure is very easy and fast. JetPlus ensures high throughput due to high linear speed (up to 50/60 meters per minute) and large format print up to 650 mm. The group has Domino technology inside.

FINISHING & CONVERTING

  • Cold foil

    The Cold foil by OMET delivers precious cost-effective metallic printing effects. The unit slides on rail and can be positioned anywhere along the press. The system grants accurate web tension controls. Cold foil is available also on XFlex X6 with offset groups.

  • Hot Foil on rail

    The Hot Foil unit by OMET delivers excellent metallic effects on outstanding labels and packaging, with reduced costs and a special attention to the machine configuration. The Hot Foil, in fact, is an independent unit, movable on an overhead sliding rail and positioned anywhere in the printing line as an additional group. The unit is equipped with servo-motors, pre-register function and web tension control. By using a specific kit, the unit can be used for cold foil finishing.

  • Flat-bed hot foil / embossing

    Flat-bed hot foil/embossing at OMET stands for Rhino by Pantec. The Rhino unit compliments OMET press design flexibility thanks to its turning foil head and delivers cost-efficient production of complex designs in one pass, with the superior quality of flat-bed technology. The Rhino can be used with low-cost flat-bed foil and flat embossing tools also on rotary presses, thus involving savings in material cost. In addition, a special foil saving system reduces the overall material supply. The robust mechanics of Rhino enables operation speeds of up to 120 meters per minute.

  • Monotwin Cut

    Monotwin Cut, special die-cutting unit by OMET, works with one single magnetic cylinder for any label shape or dimension. Main advantages are: dies stock reduction, minimization of dies handling and elimination of the risk of receiving non-compliant dies. Further plus is the time saving during set-up and format change (the only thing that changes is the flexible die). 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. Monotwin Cut is paired to JetPlus digital inkjet unit to reach the best performance in terms of speed.

  • Die-cutting / Embossing cassette

    OMET has designed independent and interchangeable die-cutting cassettes that allow the preparation of a new job offline, while the machine is engaged in the production of the previous work. After the traditional die-cutting changeover operations, the cassettes are inserted on the die-cutting unit (two positions available on each group); afterwards the machine is ready to print. Thanks to the movable die-cutting stations the machine set-up is accelerated and the possible inclusion of embossing is facilitated with less waste. On the independent cassettes, in addition, it is possible to insert male/female cutting tools for the die-cutting of cardboard.

ADDITIONAL UNITS

  • Double unwinder

    The double unwinder is a semi-automatic unwinding system for ultra-fast change of the printing substrate. The operator only needs to switch from one material roll to another, previously uploaded on the second shaft of the double unwinder, cut, splice and start printing. The two shafts can be used alternatively so the preparation of the new roll on the free shaft can be done while the machine is still in operation. The double unwinder helps saving several minutes in the changeover process; as a consequence the productivity and profitability of the machine increase with any type of run.

  • Multiplate plate-mounting unit

    Existing in 3 versions (standard, advanced, flexo / offset compatible), Multiplate is a robust Plate-mounting unit with 2 video cameras and high resolution monitor for cross or microdot register centering. Multiplate by OMET is practical because it requires only mechanical and no electronic transition moves during plate (or sleeve) assembly. Plates are positioned flat to allow, with the help of the integrated video cameras, the alignment of the register marks. Sharper thanks to the black and white video, the monitor is divided into two parts (split screen) in order to control both marks at the same time.

  • UV LED curing system

    The system is a turnkey solution for Flexo narrow and medium web printing presses. A water-based chilling system ensures long life for the LED lamps and a cool, quiet, and safe operation around the press, with a unique system that protects against condensation damage. The LED units can co-exist with traditional UV lamps if needed.

  • MultiVision Register Control System

    Automatic printing registration adjustment and control system based on a running printed image. Both machine and cross side axis are controlled simultaneously and concurrently, simply by pressing a single button from the back end of the press with refresh mode capability. Predictable, consistent and repeatable performance, regardless the operator skills, with remarkable time and material savings during start-up. MultiVision is available in Single-head configuration and Multi-head configuration with one camera on each printing group, which allows reducing set-up waste to few printing repeats. Offset Mode: Possibility to offset the register of all colors, both longitudinally and transversally, to balance incorrect plate positioning or filmic substrates issues.

MARKETS & APPLICATIONS

  • Self-adhesive labels

    The market of self-adhesive labels is growing at a rapid pace especially in emerging countries. Innovation in design, material and end-use characterize it while it expands in different market sectors. Special effects are often originated by the use of cold foil, varnish or creative die-cutting to increase the labels appeal potential. The use of laminated effects or of transparent substrates have also become a typical feature. Pressure-sensitive is also the preferred technology for variable information print labels (track-and-trace/bar coding and in-store price-weigh applications, using thermal or uncoated paper stocks). Main markets of reference are: food and beverage, wine & spirits, health & beauty, pharmaceutical, industry, household & cleaning and commerce.

  • Unsupported filmic labels

    In-mold labels relate to a container that is made and labeled at the same time through high-speed injection or blow-molding. IML are especially used for thin-walled margarine, ice-cream, yogurt containers printed in high volumes. It is a rather new ‘niche’ market in strong expansion.
    Wraparound labels regard mineral water, soft drinks, beer and have excellent resistance to wet. They are often printed on clear materials and embellished with metallised effects.

  • Flexible packaging

    Packaging, especially food packaging, is an intrinsic part of modern urban life. It is also vital for export as it protects the contents and ensures that quality products reach the consumer. The production of film flexible packaging is growing consistently worldwide as consumers’ habits change, especially in emerging countries. Among the different use of flexible packaging, a special concern regards food packaging and its safety issues. Flexible packaging is mostly used in the food & beverage sector where it takes the form of flexible wrapping packaging, laminated food packaging or pouches.

  • Shrinkable films

    Shrink Sleeves (similar to stretch and ROSO/reel-fed shrink) are labels that are applied to a container and shrunk to fit its outline through the addition of heat. Sleeve labels are meant to wear bottles and containers of various shape, even those with complex geometries, with impressive 360° graphics and uniqueness of layout. Their shelf stand-out, coupled with their tamper-evident properties and ability to act as a barrier to any container damage or breakages, are driving their popularity with both brand owners and consumers. They are mainly used in the beverage sectors (soft drinks, beers, aperitifs) but are also popular in the dairy, health & beauty and household & cleaning sectors. Delicate clear polycarbonate boxes are mainly used in luxury packaging and are often enriched by 3D effects through screen or gravure printing.

  • Aluminum

    Aluminum packaging, being it a blister or a lid, plays an important role in packaging since it creates a safe barrier between the product and the outside world. But printed aluminum has also decoration purposes and is used especially in yogurt lids, pharmaceutical blisters, jars & glasses, coffee creamers, paper cups and in general in high speed packaging applications. The aluminum thickness varies from 30 to 40 microns to be used with jars, glasses and cups. Used in multilayer structures, aluminum is an integral part of printed lamitube used for toothpaste tubes, gels and creams.

  • Booklet and coupon labels

    A Booklet Label is comprised of a booklet or pamphlet that folds out that is coupled to a pressure sensitive label. A coupon label is a multi-layered construction with a peel-off top for immediate consumer redemption or gratification.

  • Tube laminates

    Laminated tubes are made from at least five different layers including the barrier layer. They are tipically used in the cosmetics and health & hygiene industries to produce, for example, toothpaste tubes.

  • Special applications

    The flexibility of packaging printing machines and the practical availability of a large number of in-line finishing and converting possibilities allow the printing of a large number of special products including: promotional labels, booklets, coupons, RFID labels, smart labels, parking and transit ticket with magnetic band, hologram or variable information printing applications for anti-counterfeiting or security use, lottery tickets. Multi-process combination printing is what is needed to reach the best results in the case of lottery tickets and security label printing in general.

  • Paper

    Wet glue labels made of paper still hold an important market share in the food & beverage sector, including wine labels, though pressure-sensitive labels are eroding market shares. Paper is also used for ice cream cones. A special sector is represented by high-end flexo printed envelopes.

SCROLL RIGHT 430 530
Max speed up to 200 m/min (690 fpm)( up to 200 m/min (690 fpm)(
Unwinding roll diameter 1000 mm (40'') 1000 mm (40'')
Web width 430 mm (16 7/8'') 530 mm (20 7/8'')
Print width 420 mm (16,5'') 520 mm (20 4/8'')
Infeed/Outfeed servo-driven servo-driven
Printing axes indipendent direct driven motor, gearless technology indipendent direct driven motor, gearless technology
Cross registration servo, +/- 5mm servo, +/- 5mm
Longitudinal regulation of print 360° 360°
Cross registration Vision-1 Vision-1
Printing plates technology Plates mounted on sleeves Plates mounted on sleeves
Register control integrated integrated
AVAILABLE PRINTING TECHNOLOGIES
Offset (Sleeve) 14''-25'' 14''-25''
Flexo UV 12'' - 25'' 12'' - 25''
Flexo Water Base 12'' - 25'' 12'' - 25''
Rotary silk-screen 12'' - 18'' 12'' - 18''
Rotogravure 12'' - 25'' 12'' - 25''
CONVERTING
Die-cutting section Max 25'' Max 25''
Matrix Rewinder with servo tension control (with contact rider roll) 760 mm (30”) 760 mm (30”)
OTHER TECHNICAL INFORMATION
Rewinders diameter 2 x 760 mm o/or 1 x 1000 mm 2 x 760 mm o/or 1 x 1000 mm

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