flexo f2 - УПГ · the flexo f2 uses 8 printing decks adapted for reverse or surface printing....

FLEXO PRINTING GRAVURE PRINTING LAMINATING SLITTING ENVIRONTMENT & LOGISTICS

CENTRAL DRUM FLEXO PRESS

EFFICIENCY FOR YOUR BENEFIT

FLEXO F2

www.comexigroup.com2 3

COMEXI GROUP, ALWAYS AT YOUR SIDE SINCE 1954

Comexi and its holding company COMEXI GROUP were set up as a business venture guided by a spirit of excellence.

Our nature as a family business moulds our values and marks the Group with the legacy of its founder to pursue long term sustainable activities. Our strategy is to become a global leading provider of machinery and services for the flexible packaging industry by offering highly specialized services in each product line (printing, laminating,

At Comexi, we understand that efficiency is not limited to productivity. Efficiency goes beyond that. For Comexi, efficiency is a philosophy – a philosophy of creating solutions that help our

slitting, rewinding and logistical and environmental solutions) that complement each other and thus give our customers end-to-end solutions with maximum synergies.

Our philosophy is aimed at constantly adapting to the demands of the market and continuously striving for excellence in order to fulfill our customers’ needs.

DEVELOPING MARKETS

The FLEXO F2 press has the capacity to print at greater lineatures, thus opening the door to markets that were previously out of reach until now. This is achieved without increasing costs per square meter as compared to your current conventional printing system. Furthermore, printing quality in short as well as long runs is maintained, and this is exactly where the concept of reproducibility is most critical.

MEDIUM AND LONG RUNS

However, this is not enough. The systematic reduction of run lengths is a reality in most markets, as is the need for presses to maintain printing coherence and improve productivity. Efficiency in

- These days, many industries view printing as a “commodity”; therefore, new markets need to be developed in order to escape from the price wars.

- There is a trend towards reducing the length of runs.

- Customers demand flexographic presses that are easier to operate, and this represents an ongoing process of improvement and a perpetual challenge in our line of business.

clients- and by developing new technologically integrated products, we can deliver competitive advantages to our customers.

MARKET

- We need to create sustainable procedures and use energy saving machines and processes to reduce carbon footprints.

- Customers desire harmonization of flexographic printing processes to make them more predictable.

EFFICIENCY IN FLEXO

COMEXI GROUP, the meeting point

of sustainable innovation

Flexo must mean reduced costs with machinery best suited to the challenges presented by current trends. All this requires ingenious solutions that reduce downtime and maintenance time. These solutions must come with a high degree of automation, while also reducing job change times and increasing profit margins on the final product. The FLEXO F2 helps you confront these challenges and decrease change times with the new doctor blade support design patented by Comexi which boasts, easy accessibility for maintenance and the tool-less concept inherited from the F4 FLEXOEfficiency.

Flexo efficiency is here

Efficiency in Flexo means guaranteeing solutions and providing answers to these real life issues.

Starting in 1989, we developed the first 8-color CNC flexographic press because you needed it. That same press provided a new level of printing quality and created new business opportunities for our flexographic converting customers. Then in 2000, we launched the world’s first 10-color gearless machine, which represented a quantum leap for the industry. Once again we listened to you, learned from you and created what you needed.

In 2004, the FI and FW presses were unveiled at Drupa and K trade fairs and they represented a significant step forward in Comexi press performance. These models have evolved and continue to do so today in order to adapt to our customers’ needs.

In 2006, Comexi Group took the industry by surprise with the debut of EB (electron beam) Flexo printing. Because you needed a differential process with high printing quality and a minimum environmental impact, we created EB Flexo for you.

In 2009, we launched the FPLUS, an innovation that meets the needs of converters working with a wide range of printing developments and requiring high performance at a competitive price.

In 2010, Comexi Group once again shocked the market by launching the FLEXO F4 with its FLEXOEfficiency concept. Because you needed productivity in short runs, and you needed to offer label manufacturers eCOMEXI solutions with EB Flexo technology applied to high performance flexographic printing, we created the FLEXO F4 for you.

And we continued to listen when we created the new FLEXO F2 press. This new development meets the needs of medium and long runs for retailers, on the one hand, and the needs of packaging converters for wholesalers, on the other.

To top it all off, our customers are well-supported through our extensive sales network, that includes branch offices in five countries, a manufacturing facility in Brazil and sales representatives in more than 65 countries.

For more than 50 years we have been at your side helping your business grow thanks to your commitment to innovation.

WHAT DO OUR CLIENTS HAVE TO SAY ABOUT THE PRINTING INDUSTRY?


CI FLEXO PRESS

EASY MAINTENANCE

QUALITY PRINTING

PRODUCTIVITY

REPRODUCIBILITY

ENERGY EFFICIENCY

FLEXO F2


The printing body, manufactured at the Comexi Group facilities, is the heart of the machine. It consists of two cast frames each 80mm/3.1’’ thick and stabilized to eliminate internal stress. The central printing decks are arranged horizontally on the frame and the lower and upper printing decks are inclined at a 20 degree angle, occupying minimal space to create a truly compact machine.

The FLEXO F2 uses 8 printing decks adapted for reverse or surface printing. They are horizontally mounted in a radial pattern around the central drum. This compact arrangement makes the printing decks easily accessible and is specially adapted for presses with widths greater than 1.2 meters.

Its design meets today’s demands for accessibility in order to perform maintenance and daily operations with ease. Thanks to

The technological innovation and development of Comexi offer you the most cutting-edge technologies in flexographic press design, such as our MONOBLOCK frame concept – a technology that integrates the printing decks into the resilient frame for a complete integration of components, minimizing vibration and consequently improving print quality.

the FLEXOEfficiency concept, everyday regular operations can be completed rapidly and easily. The grids can be effortlessly moved aside, remaining inside the machine. In addition, a new doctor blade support has been designed which can be removed without having to disconnect the inking system lines. Both concepts are patented by Comexi.

PRINTING BODY: PRINTING DECKS

The contact/separation printing movement of each printing deck is controlled via servomotors in a new preloaded ball screw system, specially designed to withstand the most adverse industrial conditions. We integrate the highest precision technology into the unit by using encoders on each motor. Additionally, the strength of the structure has been enhanced with preloaded linear guides..

These design enhancements improve the pressure control on the plate and result in the highest quality print possible.

PRINTING BODY: PRINTING DECKS

Side detail of printing decks

New doctor blade support

Front detail of printing decks

Monoblock frame


CENTRAL DRUM: THE STRATEGIC PART

No other flexographic press manufacturer so strictly controls the manufacturing process of this highly important component. As part of our policy to internally manufacture the key components of our flexographic presses, Comexi dedicates part of its industrial process to the production and quality control of the central drum.

During this industrial process, the drum is stabilized, balanced and adjusted to meet the tightest tolerances in the market. These adjustments are conducted at working temperature maintained via an internal temperature stabilization circuit. Stabilization is conducted at 30ºC/86ºF via an automatic system integrated into the press. Additionally, an anti-corrosive Hastalloy coating is applied to the central drum to protect it against oxidation.

The engine control is also another key area in which Comexi relies on the most sophisticated technology. In a joint effort with Siemens, we have integrated the Gearless DDDrive, CNC and servomotors into the only technology platform in the market based on the SIMOTION control system. This “direct-drive” system is the most advanced in the market, reaching the highest levels of precision and eliminating all types of mechanical transmission (e.g., belts or gears).

DDDrive controls the motor via a high-resolution hollow shaft encoder, directly coupled to the drum axle. The encoder is designed for easy access, which makes maintenance easy.

DD

Dri

ve

Access to central drum encoder

Not all “gearless” systems are created equal. VIRTUALMaster technology – used by Comexi throughout our entire product range – unites all motors electronically and controls them via a common virtual signal that ensures registration even during the acceleration and braking stages of the machine.

In a typical system, adjusting the motor position requires a reference signal obtained from an encoder located on a reference shaft (Real Master). This type of system has two main disadvantages. First, any reading error from the reference signal is transmitted to the rest of the shafts that are synchronized to it. Second, the true signals include a set of delays in the readings and retransmission of the

VIRTUALMASTER: THE ORCHESTRA CONDUCTOR

- Perfectly aligns the surface speeds of the material, the plate cylinder and the anilox, improving print quality.

- Performs direct, automatic and rapid positioning of longitudinal registration between printing decks, decreasing the waste generated in adjustment.

signals, which results in deviations between the master shaft and the synchronized shafts. The consequence of these two disadvantages is a variation in machine speed.

These two disadvantages are resolved with the patented VIRTUALMaster system. This system generates a virtual signal, created digitally by the Motion Control Processor (MCP). The virtual signal is transmitted to all the shafts simultaneously, thereby eliminating the concept of a “master” shaft. In this way, the signal is generated without errors and, consequently, without affecting the rest of the synchronized shafts.

- Regulates and memorizes the positions of longitudinal registration for future projects, thus saving adjustment time prior to printing jobs.

- Can slightly vary the plate cylinder and anilox speeds in relation to the material in order to specifically and precisely adapt the printing development tolerances.

ADVANTAGESVIRTUALMaster ALSO PROVIDES THE FOLLOWING ADVANTAGES:

Machine acceleration Precision


SLEEVE CHANGES: NEVER BEEN THIS EASY IN A WIDE BAND MACHINE

Changing anilox and plate cylinder sleeves is just a matter of minutes. The clamps, manufactured in a single cast iron block, are opened manually, simply and quickly.

The system as a whole demonstrates an extraordinary durability. The plate cylinder shafts and anilox are held in place by conical and needle bearings specially sized to allow overhanging suspension, and they incorporate pneumatic supply which forms an air barrier. These two elements are essential for performing quick sleeve changes.

This bearing positioning ensures a high degree of stiffness and permits transverse movement of the plate cylinder roller for transverse registration between colors.

Comexi also utilizes DDDrive technology for driving shafts. Absolute encoders directly coupled to the shafts control the alternating current motors, which use no mechanical transfer. These technological advancements improve registration and, in turn, the quality of printing.

Clamp opening sequenceShutter coupled to the clamp

Plate cylinder sleeves changeover

Anilox sleeve changeover

A BODY OF STRENGTH


DOCTOR BLADE: COMEXI’S NEW DOCTOR BLADE SUPPORT SYSTEM

The doctor blade is assembled in a closed swinging chamber mounted on linear guides. In turn, the doctor blade automatically moves horizontally thanks to the low friction pneumatic cylinders. The entire system is perfectly designed to maintain the inking position with a minimum blade pressure against the anilox and to offer a high response capacity.

The system can be easily disassembled without having to disconnect the inking lines, greatly simplifying all cleaning and changing tasks.

Additionally, the doctor blade is anodized for improved cleaning. It weighs less than 12.5 kg (1250mm in width) which facilitates changes and minimizes risks of injury for the operator.

Changing the blade is fast and safe thanks to the MAGNETBlade technology patented by Comexi consisting of a tool-less magnetic changing system. Changing the seals is also conducted without tools so that changes can be completed quickly on or outside the machine.

Extracting the doctor blade

Blade extraction

PLATFORM: EXTREME USER-FRIENDLINESS AND ERGONOMY

The FLEXO F2 represents excellence in ergonomics and usability. The press is equipped with an overhead platform that allows access to all elements requiring maintenance in order to simplify the replacement of parts, maintenance and cleaning in areas such

Overhead platformAccess to central drum for cleaning

Video threading

as the central drum and refrigeration and drying systems, among many others.

In standard configuration, the press incorporates an automatic threading system which includes chill rolls, dancer rolls, a viewing system and a corona treater (if included in configuration). The viewing system consists of an illuminated double screen that allows the operator to inspect front and back side printing at a comfortable height. A ladder has been completely integrated into the machine to allow access to this area.

In addition, the press can be configured with an automatic drum cleaning system as an option.

DOCTOR BLADE


The drying system is composed of two circuits that evaporate the solvent or water content of the ink by blowing hot air at high speeds.

DRYING: POWER AND ACCESSIBILITY

The second circuit consists of the 5 m-long drying tunnel, equipped with carefully positioned line pipes to reduce heat loss and made up of sixteen drying screens each with a blower lip, the screens can be easily disassembled for cleaning. In addition, a specific opening in the tunnel has been designed to allow rapid threading of the machine.

The first circuit is used for drying between printing groups. The screen lip can be freely withdrawn from the machine by disconnecting the tubes from the inside, and the casing incorporates an inspection port, thus making maintenance comfortable and simple. Both concepts are patented by Comexi.

Access to the cleaning port of the drying screen between printer groups

Drying tunnel

DRYING

UNWINDERS AND REWINDERS: CHANGEOVERS WITHOUT DEAD TIMES DOWNTIMES

SIMOTION AND THE CONTROL CONSOLE: THE BRAIN OF THE MACHINE

The configuration of the FLEXO F2 is designed for high productivity. To achieve this, the unwinders and rewinders best suited to your productive system are composed of a turret system that automatically changes and splices the reel at production speeds.

Duplex rewinder Duplex unwinder

Control console

Printing deck control

The FLEXO F2 press is designed so that the majority of functions can be controlled from the control console. Similarly, our COMPACTronic concept, based on the SIMOTION platform, creates a high degree of electronic integration, eliminating electronic equipment containers and simplifying maintenance tasks.

The control system is totally integrated in a graphical environment that simplifies operation and understanding.

Many operations can be conducted through the EASYTouch display, such as advancing/reversing the printing decks, placing all accessories in operation, tension selection, machine speed and temperatures, inserting change orders at a pre-established footage, operations and more.

Additionally, production data can be obtained for later analysis, such as the quantity of quality footage, the quantity of waste, work time, stoppage time, printing time and average real speed, among others.

There is also the option of incorporating an in-line slit unit in the unwinder.

Register deck control

Additionally, job tickets can be created for the purpose of increasing the efficiency of job changes, enabling the operator to later recover these job tickets

As the operator is able to assign reasons for stoppages, statistics can be gathered on the distinct causes of downtimes and the duration of each one. All the data can be stored in the computer memory and/or on discs as necessary.

The entire drying system is located on a platform which creates comfortable access for maintenance tasks, especially when accessing the set of rolls at the end of the tunnel


Autowash and inking system Ink tanks

The structure is completely integrated into the machine’s cowling and the ink tanks are located on the exterior. These tanks use NATURALMixing technology to eliminate air consumption in the pneumatic agitators (pneumatic agitation is an option).

The selfcleaning process is fast and easy, with a complete wash cycle taking as little as 4 minutes (*).

(*) In the 8-color PREMIUM version with options.

Excitink technology is essential for controlling the inks (viscosity, temperature and, optionally, pH) so that the selfcleaning system remains efficient during changeovers. This technology maintains a balance between supply ink and return ink and can thus print with an optimal pressure in the inking chamber.

The inking system comes in 3 versions: LITE, PREMIUM, and EXCEL which meet different viscosity and temperature control needs. Each version comes with various levels of automation.

EXCITINK: SELFCLEANING AND INKING SYSTEM

CINGULAR MODULES

NATURALMixing

At Comexi, we focus on innovation that is socially and environmentally responsible. That’s why we have developed the ENERGYSavvy concept. It is applied to a set of electrical and electronic control

ENERGY EFFICIENCY

Pressure: dot spreading Registration: Initial dot spreading Final DOT

It’s common knowledge that job changes in flexo presses generate waste and ink that significantly impact the end results. On top of that, if we add the current trend towards reducing runs, this means more changes and an increase in total waste generated during adjustments. Consequently, the press loses in efficiency.

There are various options on the market on how to tackle this problem. However, no one pays attention to the singularity of their customers. Each customer is a whole new world with different investment capabilities, different markets to tend to and an endless list of peculiarities that makes each one unique.

Comexi Group has launched a symphony of singular solutions onto the market to adapt to the different challenges our customers face.

The CINGULAR modules offer automatic and semi-automatic solutions with or without marks that are best suited to the singularities of our industry.

CINGULARDot2: CINGULAR DOT2 makes adjustments based on the true print of one 1.5mm dot in less than 90 meters/270 ft.

iREG:Among different options, we offer a system developed exclusively for Comexi by AVT, iREG, which enables semi-manual registration adjustment in less than 30 meters.

CINGULARPress2: This system adjusts printing pressure at the start of a job. It does not use marks and is based on the pressure control during the adjustment process, or in other words, to achieve the kiss point

To make adjustments, the system uses a special algorithm that determines the correct adjustment from the differences in pressures which are internal in the machine. This system does not rely on a printing operator’s experience or skill.

The evolution of reducing emissions with the Comexi ENERGYSavvy concept

technology and it allows us to save enormous amounts of energy and, consequently, drastically reduce CO2 emissions.

0,0000

0,0010

0,0020

0,0030

0,0080

0,0040

0,0050

0,0060

0,0070

2K

g C

O / m

Electricity consumption

-58%

2K

g C

O / m

0,0000

0,0010

0,0020

0,0030

0,0080

0,0040

0,0050

0,0060

0,0070

Gas consumption

-72%

2K

g C

O / m

0,0000

0,0010

0,0020

0,0030

0,0080

0,0040

0,0050

0,0060

0,0070

-80%

Air consumption

15700

5650


Lay out FLEXO F2

TECHNICAL SPECIFICATIONS

Technical features are subject to change depending on the configurations selected. The picture on the front page corresponds to the FLEXO F2 8 color press, with additional options. The final image might differ from the machine offered.

Type GEARLESS

Colors 8

Printing width (mm) 1270 - 1470

Minimum format dimensions (mm) 350

Maximum format dimensions (mm) 850

Maximum speed (m/min) 500

Dimensions (m) 15.70 x 5.51 x 5.65 m (standard machine with a width of 870mm

and shaftless unwinder and rewinder)

FLEXO F2

COMEXI LATINOAMERICANACalle de Allende, 283Int. 5 Col Clavería02080 Azcapotzalco, MEXICO Tel: +52 (55) 55368407 Fax: +52 (55) 55368407 [email protected]

COMEXI DO BRASIL, LTDA.Estrada Buarque de Macedo, 4499Bairro Faxinal Montenegro / RSCEP 95780-000-BRASILTel: +55 51 3649-8500Fax: +55 51 3649-8515 [email protected]

COMEXI NORTHAMERICA, INC. 142 Doty Circle MA. 01089 West Springfield UNITED STATES OF AMERICA Ph: +1 4137893800 Fax: +1 4138219988 [email protected]

COMEXI ITALIAVicolo Cieco Agnello 1,37121 Verona, ITALYTel./Fax: +39 0458015743Mob: +39 [email protected]

© 2011 Comexi Group Industries SAU. Polígon Industrial de Girona· Avinguda Mas Pins, 135· 17457 Riudellots de la Selva GIRONA (SPAIN)· Tel: +34 972 477 744· Fax: +34 972 477 384· [email protected] · www.comexigroup.com

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- FI, FW, FPLUS, F2 FLEXOEfficiency, F4 FLEXOEfficiency - FLEXO PRINTING

- OPTIMA, POWER, DUAL, EVO, ONE - LAMINATING

- EIKON, E-TURRET, S-TURRET, DUO2/HD, UNO, COMPACK2, BLADE, GUIDE - SLITTING

- SELFCLEANING, AUTOMATIC SLEEVE STORAGE, ECODISTIL, AUTOMATIC ROLL UNLOADER, LASER WASHING UNIT - ENVIRONMENT & LOGISTICS

- RG EXCEL, RG PLATINUM - GRAVURE PRINTING

For more information

The information in this brochure may be subject to modifications.comexigroup.com

flexo f2 - УПГ · the flexo f2 uses 8 printing decks adapted for reverse or surface printing....

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