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FLEXO Magazine : August 2010
Technologies & Techniques dry the ink on that substrate? The anilox rolls have to have the right volume, and be able to release the ink without sending it everywhere. Not to mention, mandrels and carriers have to be suitable to run that fast; TIR tolerances have to be much tighter. Only when all these are in place, can a printer run at 2,400fpm or higher. The Long and ShorT of IT There are three parameters that have the greatest affect on production: changeover time, waste generated from startup, and speed of the press. One of these alone does not give a competitive edge. Today, many printers are looking for ma- chines that reduce waste and facilitate faster startup. Truth be told, many of them are forsaking speed. The reason is, in today ’s flexible packaging industry, the portion of long runs to short runs is increasing in favor of the latter. Customers will not accept stock inventory, and packag- ing is being constantly redesigned, even for legacy brands. As such, many printers are running at lengths of 10,000 to 20,000 feet. With a 10,000 foot job, there is too much waste generated by running at a high speed, not to mention roller handling is another concern. You are better off having a faster changeover. Today, most people with geared presses are changing over eight colors in three hours! With gearless technology and the introduction of sleeve presses, it’s happening in as little as 20 minutes. Most eight color servo presses can be changed over in 20 to 30 minutes. With automatic impression setting, this time can be reduced even further. Most wide web press manufac- turers have some version of this technology. This also reduces waste—bringing it down to as little as 150 feet per job. Not to mention, there’s also automatic wash-up systems. Wide web anilox rolls are heavy, even if they are sleeved. To not have to remove each one and clean it by hand after every job saves a tremendous amount of time. Lastly, there’s also a human factor that can be controlled and finetuned for even faster changeovers, by establishing a pit crew mentality and adopting elements of a Lean or SMED (single minute ex- change of dies) workflow. High speed matters the most when it comes to long run lengths. When you are producing orders of 1 million units, or the work load duration spans over two working shifts, then speed will have a massive impact on profitability. But when daily changeovers occur six to eight times a day, the speed that matters most is in changeover. n ABOUT THE AUTHOR: Mario Mucciacciaro is executive vice president of Uteco North America. Are run speeds really the key to maximizing uptime in your operation? www.flexography.org August 2010 FLeXO 53 Uteco Flexo Presses Uteco offers a complete product line of printing and laminating equipment featuring high end printing presses and the flexibility to integrate multiple down stream processes. ALL presses can be equipped with UV curing systems! UTECO ITALY UTECO NORTH AMERICA, INC. Viale del Lavoro, 25 Z.I. - 37030 Colognola ai Colli - Verona 3400 Town Point Drive, Suite 160, Kennesaw, GA 30144 T:+39-045-6174555 F:+39-045-6151004 www.uteco.com T: 770-427-4100 F: 770-427-4872 www.utecona.com DIAMOND The Diamond HP is the ideal solution for converters requiring increased flexibility and consolidation of equipment to streamline operations. The Diamond is Uteco’s premiere press available in 8 and 10 colors with standard or long repeat print ranges. • High speed press reaches a maximum printing speed of 600 m/min (2000 fpm) • Equipped with Uteco’s patented True Direct Drive System (UDD) • High productivity press available in widths up to 80” • Features reduced job changeover times • P2P: Dynamic adjustment system to control the printing pressures • SprintWash: features the latest generation of Uteco’s automatic washing system • FlexoSmartPackHP: Uteco engineering platform for improved performance and profitability in high speed flexographic printing • ShopWareHP: Production Management, Control & Monitoring easy machine-operator interface to manage high-productivity • LogiPack: Automatic handling of reels and cores ONYX The state-of-the-art solution for moderate budgets. Onyx CI presses are profitable printing solutions offering an extremely high level of value versus cost of investment. Available in 8 and 10 colors with standard or long repeat print ranges. • Maximum press print speed of 365 m/min (1200 fpm) • Equipped with Uteco’s patented True Direct Drive System (UDD) • Simple: Due to its easy sleeve change system • User-friendly: Both the anilox and plate sleeves can be changed, even when the print deck is in the print-off position. • Modern: Compact accessible design for quick job changes using Uteco synchro-deck gearless drive technology. • P2P, Sprintwash, FlexoSmartPackHP and ShopWareHP modules are also available on the Onyx. CUSTOMIZABLE FLEXIBILITY Our engineering is extremely flexible and very experienced with the integration of downstream processes to precisely match your printing and conversion requirements. Any of our equipment can be supplied with in-line lamination, down-stream printing and/or coating units. August2010_mech.indd 53 8/13/10 2:14 PM
Sustainable Summer 2010