Komori-Chambon, together with German company BHS Druck- und Veredelungstechnik, have launched an alternative solution for cigarette packaging production: The GR Mark I, a shaftless rotogravure press with in-line BHS flatbed die-cutter for hinge-lid and outer cartons.
The new press is designed to produce high-quality paper or board cigarette packaging. The press can be equipped with up to twelve printing units and is available in 650 mm and 830 mm printing widths.
Each rotogravure printing unit comes with a fully equipped removable trolley, which allows quick job preparation off-line in order to minimise both change-over and cleaning operations time.
Further change-over capability is achieved through the use of sleeve impression cylinder and/or sleeve engraved cylinder arrangement. Before beginning each job, automatic gravure cylinder zero-setting enables an instant printing in register with minimal material waste.
An exclusive ink applicator design creates an ink flow pressure allowing deep ink spreading in the cells for both solvent and water-based inks.
To fulfil specific production requests, two final printing units can be used for in-line rotary embossing and debossing, thus reducing the capital investment.
This also permits to increase print to emboss register accuracy and drastically reduce waste and make-ready time, for the flat bed die-cutter.
A compact hot air dryer is fixed directly on the top of the unit for high efficiency.
To get the high requested quality the press is fitted with an automatic viscosity control system with solvent mixing, an ink temperature control, a 100% web inspection system and a defaults recognition device with the possibility to identify and mark defective production.
For better printing quality, the unit can be equipped with an electrostatic-printing assistance device.
Regarding safety and environmental concerns, the CE-certified press incorporates a LEL capacity, a solvent laden air exhaust, two way air extraction (solvent or water-based) and a CO2 fire extinguishing system which is monitored unit by unit or for the complete line.
The press potential can be enhanced with various converting capacities such as flatbed die-cutter, rotary die-cutter, hot foil stamping, sheeter, label cutter and rewinder.
The BHS Auto Set Pro flatbed die-cutter manufactured at the German BHS facility utilises modern servo drive technology on all important drives. This not only ensures most accurate positioning of the web in the cutter/creaser section, it also eliminates all kind of change gears or manual set up for the cut-off length, or belt askew section or delivery. The waste stripping section is of modular design and can be made ready offline, while the current job is still running. The unit is servo-driven to ensure exact waste removal even of small waste pieces. All relevant job data can be stored on a hard disk. Recalling these data for a repeat job reduces the set-up time significantly. All servo-controlled set-up positions are automatically adjusted to the exact position as the job was run before.
The cutter/creaser section has been modified with the help of computer-based FEM methods which resulted in an extremely stiff and solid construction of the upper and lower cutting head.
This new solution is the first step of the new range of rotogravure printing/converting presses. A new high speed rotogravure press GR Mark II running up to 400 m/min will be coming soon on the market.