Coating
In front of more than 80 international customers in its Mex, Switzerland, facility, Bobst unveiled what the company describes as the highest productivity metallizer in the world.

The Bobst K5 Expert, successor to its K5000 metallizer, can run at speeds up to 1,200 metres per minutes and is available in widths from 2,450 to 3,650 mm and can house increased roll diameters of up to 1,270 mm to meet new industry trends. The vacuum metallization system, aimed at the packaging industry, houses what Bobst describes as the largest coating drum in the industry at 700 mm, which improves collection efficiency by 16 percent. This means less aluminium consumption and increased boat life.

The K5 EXPERT features a totally redesigned evaporation source providing the widest coating window in the market, which Bobst states to be up to 50 percent wider than some competitor. This larger window translates in better coating uniformity and collection efficiency, minimizing aluminium wire waste.   

A more intuitive HMI screen and software interface make the machine easy to operate. Its new design allows the operator to run everything from the front of the machine and to be positioned much closer to view the evaporation source and metallization process through the strobe window.

Another new feature, which the company describes as unique in the industry, is the Automatic Sequential Control (ASC) system, which speeds up start-up of the machine with minimum operator involvement required, making the K5 EXPERT easy to operate.

In addition to the Bobst Winding Mechanism, based on true tension control, the new model incorporates low friction Ferrofluidic seals for better tension control on the rewind – producing a virtually wrinkle-free roll-to-roll vacuum metallization process.

The K5 Expert also has a variety of energy saving and waste reduction features including ECO mode which reduces energy consumption by up to 50 percent during stand-by and Film Save mode which has a synchronized faster shutter action (opening in just five seconds) and aluminium wire ramp up to minimize the amount of un-metallized film (waste) to less than 400 metres per roll, explains Bobst.

As an option, the High Deposition (HD) source has an improved design for higher speed of operation for those metallization jobs that require a high deposition rate of up to 4.0 OD.
Drytac has introduced the newest model in its line of second generation JetMounter roller laminators. The JM63 Pro XD is a freestanding roller laminator with a 63-inch (1,600 mm) laminating width. It can be used with thermal overlaminates, as well as pressure sensitive overlaminates and adhesives.

The system has a top roller with adjustable temperature to 248° F (120° C); large diameter non-stick silicone rollers; adjustable speed control up to 20 feet (6 metres) per minute; a maximum nip opening of 2 inches (50.8 mm); and five auto-grip supply and take-up shafts with brake tension control on the operator side.
TRESU Digital Solutions of Kolding, Denmark, launched a range of proprietary water-based and UV-curable overprinted varnishes (OPVs), called iVarnish, for what the company terms as digitally printed folding-carton applications.

The TRESU iVarnish range is specifically formulated for use with TRESU's iCoat and TRESU Pinta flexo coating systems, which offer inline spot and flood varnish applications, following the printing stage.

TRESU describes iVarnish properties as providing strong slip angle for easy feeding of the substrate, rub resistance for brand integrity, and viscosity characteristics for optimized curing and drying at speeds of up to 5,000 sheets per hour on board substrates ranging from 180 to 500 gsm.

The iVarnish OPV range includes UV-curable and water-based high-gloss, gloss and matte varnishes.


Drytac is introducing its next generation of JetMounter roller laminators. The new JetMounter Fuzion XD is a heavy-duty wide format roller laminator with a metal construction.

Available in a 63-inch laminating width, the JetMounter Fuzion XD features interchangeable, large diameter non-stick silicone rollers; a heat-assist top roller with digital display for Celsius/Fahrenheit; a heavy-duty lift mechanism for precise, calibrated pressure control; adjustable speed control up to 20 feet per minute; and four auto-grip supply or take-up shafts with adjustable brake tension on the operator side for roll-to-roll lamination.

Additional features on the JetMounter Fuzion XD include a centre release, fold down feed table with a lay-flat paper in-feed guide; latching storage compartment on each side of the stand; maximum nip opening of one inch; and heavy-duty lockable casters for greater stability and maneuverability. The model can also accommodate 10-inch diameter rolled material and is cTUVus and CE-certified.


TRESU Group of Denmark reached an agreement with HP to supply an inline coating system for the new HP Indigo 30000 press, which is aimed at the folding-carton market. The TRESU iCoat 30000 coater is to use standard UV and water-based varnish, which can be applied in a single pass.

“The deal between TRESU Group and HP reinforces the digital print process as a competitive solution for short-run folding carton packaging with higher shelf-appeal in smaller volumes,” stated Søren Maarssø, COO of TRESU Group.

The solution was demonstrated inline with the HP Indigo 30000 for the first time during an HP Indigo customer event in Israel on June 18. The TRESU iCoat 30000 coater is equipped with quick changeover mechanisms for sleeves and plates designed to reduce setup time.

"Understanding how critical coating is in the folding carton market, we needed to work with a company that has vast experience in the specific needs of the industry," said Alon Bar-Shany, Vice President and General Manager, Indigo Division, HP.

The technology will be publicly demonstrated in HP’s booth at Labelexpo Europe in September 2013. The first units of both the HP Indigo 30000 Digital Press and TRESU iCoat 30000 are expected to be installed at select launch customer sites by the end of 2013.


MGI Digital Graphic Technology introduced a new “twin option” for its JETvarnish 3D inkjet spot UV coater at a Paris, France, exhibition called Graphitec running from June 11 to 14.

The new twin-option system, described by MGI as the market’s fastest inkjet spot UV system for raised coating, is to be made available in Fall 2013. Existing JETvarnish 3D systems can be upgraded in the field.

The JETvarnish 3D twin option can apply 3D raised effects at speeds of up to 2,234 12x18-inch sheets per hour. It also doubles the amount of coating that can be applied in one pass to a maximum of 200 microns, which MGI explains can help open up new markets like Braille.

With the twin option, speeds for 3D spot UV coating with raised effects are doubled compared to the standard JETvarnish 3D configuration. MGI’s inkjet technology features a fixed head configuration for obtaining these speeds in one pass.

At Graphitec, MGI is also previewing its Nova UV system designed to work inline with the company’s Meteor presses. The Nova UV system is also available as a standalone unit.


At the Print UV 2013 Conference going on this week in Las Vegas, Wisconsin-based Air Motion Systems (AMS) unveiled a new high speed UV LED coating and varnishing system which employs UV light emitting diodes.

Called C-LED, the company claims the system’s shorter UV wavelengths allows its users to employ low-energy curing at previously unattainable production speeds. Compared to traditional mercury vapour lamps and IR driers, C-LED uses roughly one third the energy. The C-LED process is also compatible with existing UV coating formulations already in the market.

"Because of their narrower wavelengths, prior generation Hw-UV and LED curing systems have had difficulty drying coatings and varnishes at production speeds without compromising on the coating price, optical quality or surface cure" said Steve Metcalf, President and CEO of AMS. "And traditional UV and IR/Hot Air coating systems generate damaging heat and consume excessive amounts of energy. With C-LED, the process moves to UV LED, and the results are simply amazing."

C-LED technology can be used on high speed offset, narrow and wide web flex as well as inkjet UV applications. AMS says C-LED can replicate water-based aqueous varnishes from a litho print unit without the need of a dedicated coating tower.

"Any reason to ignore LED UV for high speed commercial production is officially over" said Hans Ulland, VP of Sales at AMS. "With C-LED, we can now expand the benefits of UV LED printing - such as increased speed, quality, color vibrancy, flexibility and safety, and greatly reduced operating costs - to a much wider group of printers and converters where heavy finishing effect requirements are the norm."

At the upcoming Dscoop8 conference, an annual gathering of HP technology users, taking place February 21 to 23 in Nashville, Duplo plans to unveil its new Ultra 300Ai UV coater fully integrated inline with an HP Indigo 7600 digital press.

The Ultra 300Ai is designed to protect print from scratches and scuffs when running at high press speeds, reaching up to 148 feet (45 metres) per minute. The new Duplo coater can apply a gloss or satin finish on substrates up to 350 gsm, and paper sizes up to 13x19 inches.

The Ultra 300Ai is connectable inline with any HP Indigo 7x00 series press. The electronic interface provides bi-directional communication that will alert the press to stop in the event a paper jam occurs in the UV coater. The Ultra 300Ai can also be used near-line or off-line using an optional high-capacity, air-suction feeder. The Ultra 300Ai features what Duplo refers to as an intelligent control system for producing coated sheets with a smear-free finish.

While at Dscoop8, Duplo also plans to exhibit its DC-745 slitter/cutter/creaser and the DFS-3500 full-bleed bookletmaking system. The DC-745 is describes as Duplo’s most powerful all-in-one finishing system, performing up to 10 slits, 25 cuts and 20 creases in a single pass.

Combining the creasing and slitting functions of the DC-445 creaser with the stitching, folding and trimming capabilities of the mid-range DBM-350 bookletmaker, the DFS-3500 bookletmaking system is described by Duplo as an all-in-one solution for lower volume jobs. 


 
Hi-Tech Coatings International, a wholly owned subsidiary of Heidelberg, has cut the ribbon on a new coatings plant in Taylor, Michigan, a suburb of Detroit.

From this new 32,000-square-foot installation, the company will produce Heidelberg Saphira Aqueous Coatings for the North American market. This new plant follows Heidelberg's acquisitions of two European plants in the UK and Netherlands in 2008.

According to Thomas Topp, SVP Consumables and CtP, Heidelberg North America,  “The new coatings plant strengthens Heidelberg's commitment to help its customers achieve consistently high quality and high productivity while lowering waste and reducing cost. Centrally located for fast, convenient shipping, the new installation puts the quality and reliability of Saphira Aqueous Coatings within easy reach of companies across the U.S., Canada, and Mexico.” 

The plant had been in production for several months before the ribbon cutting ceremony on August 30th. Hi-Tech Coatings was founded in 1983 and its main markets before the acquisition were Britain and Eastern Europe.


At PRINT 09, MGI Digital Graphic Technology plans to introduce its new JETvarnish system, which is an inkjet-based, UV coater that works in a 20 x 29-inch format. Its drop-on-demand architecture is designed for handling variable-data runs, while working with coated paper and plastic substrates up to 600 gsm or 220 lb cover.
Meteor DP60
Also at PRINT 09, MGI is highlighting its recently released press Meteor DP60 Pro, which the company describes as providing Super Format printing in its unique 13 x 47-inch format. This toner-based press can also operate with sheets in a 4 x 6-inch format. An optional feeder-table kit is needed to work with sheets up to 13 x 40.15 inches, while the largest format (13 x 47 inches) work must be fed manually. The press is rated to produce up to 3,900 A4-size pages per hour at up to 200-lpi resolution – with full variable data.

In addition to tP09 Previewhe DP60 Pro, MGI is also highlighting the Meteor DP20. Described as a 4-in-1 photo press, the DP20 can duplex print, laminate, cut and crease in one pass, making it suitable for applications like photo-books, calendars, photo prints, greeting cards and flyers.



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