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FLEXO Magazine : August 2012
WASTE MANAGEMENT It's common knowledge that job changeover in flexo gener- ates unwanted waste cost. This cost is not fixed, it's variable by length of the job and it carries great variation from job to job. As can be seen in Graph 1 (page 42), waste's cost impact is not negligible. In fact, it's a main concern for any print manager. Additionally, this cost is becoming more and more impor- tant, due to the reduced length of the jobs and the quantity of job changeovers that can be made in daily production (mean about three-to-four job changeovers per shift). Since profit margins on jobs are being slashed, it´s more and more important to be able to precisely determine, in ad- vance, the cost that a job will involve, so accurate quotations can be made. This is why all OEM´s are focusing their strategies on de- veloping systems to help customers to reduce the waste, but also to make it less variable, as well as less dependent on the skill of the operator. There are various options on the market to tackle this problem. Some of them offered and developed directly by the OEMs, and thus only available in new machines; some of them offered and developed by video suppliers, and thus more adequate for retrofitting of old machines; and some others, developed jointly by the OEMs and video suppliers, and thus available either for new machines or for retrofits in old ones. The key point in selecting a system to help reduce waste, is the reliability of the adjustment, i.e. how close the automatic adjustment is to the manual adjustment carried out by a skilled operator. Obviously, it's critical that it be correct. For example, if we specify that overpressure not exceed 30-to-40 microns, it has to hold each and every time the job is run. DIGITAL INTERCHANGE When focusing on reliability, we have to consider how many parameters have impact in the adjustments: • Pressure Plate, Tape, Substrate, Surface Treatment, Ink, Anilox... • Register Plate, Mounting Precision... • Color Plate, Tape, Substrate, Surface Ttreatment, Ink, Anilox... Printing the job is the only way to evaluate the real impact of all the above mentioned parameters, because only when the substrate is printed, can all the factors make their respec- tive impact. Considering the above facts, Comexi Group has focused research and development on the new CINGULAR real solu- tion for pressure and register. The solution is able to make the pressure and register adjustment by considering the entire printing (100 percent vision). When carrying out the register adjustment, the image is processed and compared to a PDF file using real-time image processing algorithm (Graph 2, page 40, Workflow of the adjustment process) The system opens the world of digital interchange to ana- log printing. Here are just a few points about the benefits: • Objective match with a well-known broadly used file format www.flexography.org AUGUST 2012 FLEXO 41