ROTOGRAVURE Solutions

The rotogravure printing process has always been characterized by a constant printing quality and high speed.
Such printing quality is quickly achieved and can be repeated from one run to another for millions of copies, regardless of the skill level of the operators.

Printing in rotogravure allows to achieve either color swathes (solid colors) or a great range of tones.
Special inks, metallic or dedicated to printed electronics are easily implemented as well thanks to the capacity to lay down a thicker ink film on the substrate. For specific applications like coating or foils, gravure units can be used in combination with offset units.

Thanks to recent improvements, the engraved cylinders are prepared more quickly and at a lower cost. Moreover, the greater engraving accuracy – electromechanical or laser process – enable printers to handle thinner fonts and precise texts.

In the packaging industry, the rotogravure presses reach their full potential, on the longest runs and now on shorter runs as well.

Main Applications

Komori-Chambon expertise

  • Stability at high speeds

     

    Outstanding mechanical sturdiness.

    Best printing stability at highest speed.

    Max speed 500 m/mn (roll to roll).

  • Maximum OEE

     

    Automated job parameters and low maintenance increase the operating time and the ease of use.

  • Ease of use 

     

    The printing units can host OEM gravure cylinders.

    They include pre-washing, anti-splash and solvent odour control devices.

  • Profitability

     

    Energy saving, waste reduction and high speed boost productivity and profitability

Production flow insights

  • The plate cylinder is engraved via an electromechanical process, or in laser.
  • The depth of cells is adapted to the target color density and the related quantity of ink needed.
  • The engraving precision varies from 500 dpi (conventional) to 5080 dpi (laser).
  • For extended runs, the plate cylinder is chrome-plated.

 

  • The make-ready operations are very simple and quickly realized.
  • Being a direct printing process, the construction of a printing unit comprises only two key elements: a gravure cylinder and an impression cylinder.
  • The inking cassette is smoothly introduced in the unit thanks to a trolley or a simple pallet truck.
  • Automatic pre-settings.

 

  • The ink flow is controlled via a pneumatically assisted ink roller.
  • An optional pre-inking roller helps fine-tune the flow depending on the ink type or the production speed.
  • The printing quality is ensured by the easily adjustable doctor blade (offline) which will remove any excessive ink on the gravure cylinder.
  • The number of printing units is adapted to the required special colors and to the added value steps (coating, holograms, metallic inks…).

 

  • Air temperature control and optimized air/solvent ratio.
  • Choice between thermal oil, steam or electrical heater.
  • New generation nozzles for boosted efficiency up to 500 m/mn.
  • UV curing available for added value steps

 

  • Many added value operations can be proceeded, such as foils and holograms in one pass.
  • Flexo or offset units can be added either for varnishes or variable design details.
  • The reverse printing is possible in gravure as an option.

 

  • Easy and quick change of gravure cylinder.
  • Sleeve impression cylinder for a fast changeover (ESA).
  • Quick offline job change (10 minutes).
  • Doctor blade replacement without pulling the cassette out.
  • One-touch gravure cylinder pre-washing system.

 

Printing versions

Solvent based

Printing with solvent based solutions means high quality and a wide choice of inks.
Komori-Chambon provides printing units with pre-washing systems and protection devices to reduce the maintenance time and the odours.
Efficient air exhaust, ATEX configuration, fire extinguishing systems are available.

 

Water based

Complying with growing environmental expectations from customers and brands, water based inks can be used instead of solvent based solutions.
Komori-Chambon presses help you reach your quality targets with water based inks.

 

Gallery

Available configurations

ROLL TO ROLL

 

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 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 slitter.

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

 

Specifications

  • Substrate type
    Paper, Paperboard or laminated paperboard
  • Substrate characteristics
    Up to 600 gsm / 34 points
  • Max production speed
    500 m/mn
  • Max printing width
    Up to 850 mm
  • Repeat range
    Up to 1100 mm

Usual options

  • Reverse printing
  • ESA Electro Static Assistance
  • Fire extinguishing (CO2)
  • Viscosimeter
  • Pre-inking rollers
  • Flexo or offset units
  • Others upon request