FLEXOGRAPHIC solutions

Flexo presses deliver a good quality printing on a large number of substrates and at high speeds.The printing forms are cheaper than rotogravure but more expensive than offset plates (especially with HD flexo).

Rotogravure presses allow a greater stability in the printing quality and offset presses achieve better results with lower quality cartonboards. The printing process will therefore be chosen according to multiple parameters.

Using flexo units on an offset line or on a rotogravure line as auxiliary units is a relevant choice for coating applications or reverse printing (for instance couponing). This hybrid configuration grants a great versatility, all the more since the make-ready of the flexo units is made very easily thanks to the sleeve-type cylinders.

Main Applications

Komori-Chambon expertise

  • Hybrid configurations

     

    The Komori-Chambon know-how is obvious in its ability to integrate various printing processes in one production line.

    Take the best profit out of each solution.

  • Flexibility

     

    The flexo units are configured according to the ink types and related drying devices.

    The whole production flow is 100% under control.

  • Agility

     

    Independent servomotor-driven shafts allow precise and safe operations.

  • Safety

     

    The system is protected from wrap-arounds by sensors, web break detector, torque control and reversible clutch parts.

Production flow insights

  • The design to print is split by color and transfered onto flexible printing plates
  • The initial printing costs in flexo are low when conventional plates are used (rubber)
  • HD flexo plates (photopolymers) come at a higher price but deliver a higher printing quality.
  • Automatic circumferential and lateral registration
  • Automatic on/off from main desk of anilox roll and impression cylinder
  • Heater temperature controlled with pre-setting (air temperature).
  • The inking system includes: Chambered Doctor Blade System, Coating circulation and automated cleaning, Automatic internal functions
  • The driving and pressure adjustment of the printing cylinder and of the anilox cylinder are motorized as well as the side register setting
  • Ink circulation is controlled thanks to a viscosity and level regulation.
  • Depending on the ink type, water-based or solvent-based, the flexo unit in configured either for air drying or for UV or EB drying.
  • The web path is either vertical or horizontal.
  • Coating and reverse printing can be performed with the flexo units
  • Offset and rotogravure units can be combined depending on the job constraints
  • Job changes are easy to operate thanks to the ink washing sequence, the lightweight sleeve design and the semi-auto bearing parking sequence

Printing unit versions

Vertical web path

Hot air dryers used for water-based or solvent based inks are mounted on top of the flexo units. The web follows a vertical path all along the drying nozzles then comes down before going through the rotary die-cutter or the rewinder.

Backside printing is managed with the vertical type flexo units, as well as water-based coating.

Horizontal web path

UV drying or EB curing is realized horizontally. The web path is straight, from the unwinder to the delivery stacker or the rewinder in a roll-to-roll configuration.

Coating applications right after offset units are dealt with thanks to the horizontal type units before final dryer.

Gallery

Available configurations

ROLL TO ROLL By-pass

 

The press includes a rewinder right after the printing units
The converting stage will be proceeded offline

For more flexibility, the line can include a rotary die-cutter and a by-pass to transfer the web to the rewinder

ROLL TO ROLL Direct

The press includes a rewinder right after the printing units
The converting stage will be proceeded offline

ROLL TO BLANKS

 

The best configuration to take the maximum profit of your production line.

The inline rotary die-cutter, placed right after the printing stage, can be followed by a high speed delivery solution.

The carton roll is transformed into ready-to-ship blanks within 10 seconds.

ROLL TO SHEETS

The printed web can be converted in sheets thanks to a sheeter.

The sheets can be converted offline with a flat bed die cutter.

Specifications

  • Substrate type
    Paper, paperboard or laminated board
  • Substrate characteristics
    Up to 600 gsm / 34 points
  • Max production speed
    375 m/mn
  • Max Printing - coating width
    Up to 1020 mm
  • Repeat range
    Up to 1100 mm

Usual options

  • Reverse printing
  • Automatic washer
  • Ink temperature controlled with presetting
  • Thermal oil or steam heater battery (KV-V)
  • Closed loop optical inspection