Packaging
Ultimate Efficiency in Folding Carton Converting The new Gallus ICS 670
Thursday 15. May 2008 - Gallus describes its exciting new Gallus ICS 670, due to be launched at Drupa 2008, as the the ultimate in efficiency and flexibility for folding carton conversion.
To find out more about this claim we talked to Uli Kretzschmar, Business Development Manager, who explained the
philosophy behind the machines development, which is the first
collaboration between the Gallus and BHS team under the new flag
Gallus Stanz- und Druckmaschinen GmbH, and identified the key
elements that will make the new Gallus ICS 670 attractive to carton
converters worldwide, all of whom are seeking new ways to protect their profit margins while remaining competitive for their customers.
The concept of narrow and mid web carton production is not new. The
attraction of single pass production that converts a blank web of board to a finished folding carton in the space of a 30 metre footprint at speeds up to 350 m/min (1,140 fpm) with minimum handling and without the need to stack down pallets of sheets is appealing.
But, the concept has never really found favour in the more traditionally minded European market, where sheet fed offset printing and offline converting are dominant. All that is about to change, according to a buoyant Kretzschmar, who says the new Gallus carton team: “Just cant wait for Drupa to open!”
Setting the background for the new machine, he said: “We have
deliberately targeted the new Gallus ICS 670 at mid size cartons in
medium to long run lengths with a high degree of added value.
Independent sources are predicting this sector of the market will grow substantially over the next five years, which makes our positioning of the Gallus ICS 670 so exciting.”
The new press sits alongside the Gallus CCS 510 (formerly Gallus KM 510 S) at the top end of the quality market, complementing the Gallus Intro L/XL models that serve the low cost and high volume sector.
“Carton converters should know that the Gallus ICS 670 brings new
technology and years of valuable expertise to the market. Its modular design offers the very latest in production flexibility, including hot foil embossing, which was previously only available offline,” he added.
Typical target markets for the new press are the highly prized and highly priced beauty care and cosmetics, personal and healthcare,
confectionary, tobacco, and other non-food areas such as blister cards and clear plastic boxes. The common thread running through all of them is small format size coupled with high added value content.
“There are four key features that give the Gallus a clear lead in this market sector: its platform design; its dedicated inline flat-bed die- cutter; its hot foil embossing facility; and its capacity to change jobs on the fly, explained Kretzschmar.
Configurations for the Gallus ICS 670 can include HiDef flexoTM, gravure, and screen printing, cold foiling, hot foil stamping and embossing, as well as laminating. The bonus with the Gallus FCL 670 flat-bed diecutting unit is that can be used inline or offline with equal ease and accuracy, and as well as offering the prospect of cheaper tooling than its rotary counterpart, it is familiar technology to converters.
Hot foil embossing brings the third dimension into graphic design, which because of its zero tolerance register, adds an additional and unique element to package printing and significantly to high value product differentiation, so beloved of Brand Managers around the world.
Rotary hot foil embossing on the Gallus ICS 670 is contained within one unit, and can feed up to six foils across the web. It is also fitted with a foil saving device for maximum foil utilisation.
With increasing demand for graphics or text variations within the
production run, Gallus flying imprint facility on the new Gallus ICS 670 is a boon. “It allows us to accommodate these language or graphics variations on the job at full press speed, which is perfect for regional or test marketing,” explained Kretzschmar. The additional print unit is set up while disengaged and then accelerated to running speed when required. By allowing the machine to continue at a constant speed there is no drop in quality and no start up waste. “Perfect for todays market,” exclaimed Kretzschmar.
Setting the new Gallus apart is the servo drive and high degree of
automation that offers the optimum level of machine control, pre setting functions and job recall. Good ergonomics make it a comfortable machine for the operator to use, which combined with short make ready times and low waste levels, mean the Gallus is cutting edge in the ecology stakes.
“We set out to offer maximum efficiency – before, during and after the print run,” explained Kretzschmar, alluding to the Gallus ICS 670s open architecture, which not only facilitates maximum interchange of process units, but also permits remote diagnostics to optimise machine performance. “Everything from the performance of the hot air dryers to the automatic register is designed to improve production efficiency and maximise profit opportunity.”
Looking down the press line for the first time the overall impression is of a well designed and beautifully finished machine. This is clearly a machine designed with years of expertise and crafted with the precision of a Swiss watch.
Too often web presses betray their origin with bare side frames and a series of pre-drilled but unused holes. Not here – this is engineering as an art form.
The infeed section is servo driven to ensure constant web tension and can be supplemented by automatic roll handling and splice units as well as a corona treater for pre-laminated board of plastic substrates. The printing section, platform in nature, offers a slide-in – slide-out facility for HiDef flexoTM, gravure and screen heads, as well as laminating, cold foiling, hot foil stamping and hologram insetting. All can be changed without breaking the web. Hot foil embossing is, of necessity, a fixed unit, while reverse side printing and a variety of drying or curing systems may be specified according to customer requirement and brand preference. Thanks to its complete modular design, the machine configuration can easily be extended to adapt to changing market demands and job requirements.
The Gallus FCL 670 (Flat-bed Cut Line) is a sophisticated, heavy duty unit that is both easy to set up and operate inline or offline. It sheets the printed web before creasing, embossing and die-cutting. After stripping, the die-cut carton blanks are separated (de-nested) and then delivered on a shingle conveyor or optional stacking unit. The advantage of the concept is the total flexibility to finish the job simultaneous to printing inline with the Gallus ICS 670, or convert the pre printed web offline at a
later more convenient time. Capable of 350 strokes/min, the Gallus FCL will allow the inline machine system to run at 220 m/min (720 fpm).
Maximum printing and processing web width, as its name implies, is 670 mm (26″) on a 690 mm web (27″). Standard rolls can be up to 1800 mm (70″) diameter with an option of 2100 mm (82″). Minimum and
maximum repeats are 330 and 820 mm respectively (13″ and 32″), while
the repeat length is infinitely variable thanks to the servo drive.
Board capability is from 180 to 600 gsm (37 to 123 pounds per msf) with a maximum thickness of 750 micron (30 points). Plastic substrates for clear box applications like PET and OPP as well as paper down to 60 gsm (12 pounds per msf) can also be processed.
But, the new Gallus ICS 670 is more than these statistics and engineering it is a genuine and exciting alternative to traditional carton thinking – thinking that has seen profit margins shrink around the world in successive years. “We have combined the know how of two market leaders to create this machine, not to be seen as just another competitor in the inline market, but to offer the hard pressed carton converter an opportunity to develop his business into new and profitable areas previously outside his capability – and do it in the knowledge that Gallus and BHS experience is supporting him,” added Kretzschmar.
The proof of what Gallus says will be available for all who visit Drupa 2008 to witness in Hall 3 Stand F17, where it will be demonstrating two different jobs, a value added sun cream carton, using HiDef UV-flexoTM printing and varnishing, screen printing, laminating, hot foil embossing with micro embossing, creasing and die-cutting, and a generic soccer kit carton, using HiDef UV-flexoTM printing and varnishing, window punching, creasing and die-cutting.
The need for lateral thinking has never been more important than in
todays ultra competitive carton market, and Gallus believes it has timed the launch of its new machine system to perfection. If the buzz generated by the Gallus ICS 670 inside the company can be translated to the converters, it may be that the time for inline carton production has finally reached maturity.