Packaging
CHANGE ON THE FLY – MORE FLEXIBILITY WITHOUT MACHINE STOPS
Thursday 01. October 2009 - Omet presented its newly developed technique at Converflex 2009 on a VaryFlex line and will make it available on the X-Flex. It has many advantages.
Todays market continues to demand innovation with inspiration, and this combination is nowhere better found than in the opportunistic and groundbreaking resources of Omet’s Research & Development department. This translates into maximum production flexibility combined with the simplicity of getting into register quickly and reducing expensive downtime in the production hall.
It is from these essential market requirements that Omet has created its new change on the fly” system, which was shown working on a VaryFlex line at the Converflex international showcase, and will be made available on the X-Flex series.
From pre-register to insertion of new text or graphics
The aim of this new technique is simple: it allows the insertion and register of new text or graphics while the machine continues to run at full speed. Applications for this new technique are many and various.
In its simplest form it offers pre-register, which removes the age old technique of using operator know how to get the job into register. But, its real advantage and most frequent use will be the ability to change on the fly to insert or replace label text (the language, a bar code etc) without stopping the machine (eg – the same label, but written in a different language). Another use is to insert one or more colours for special printing needs during the run (eg – end roll marks for coupons in rolls), or to change the printed subject completely during a run. Finally, when it comes to reprints, change on the fly is useful for quickly bringing the job into register.
But let’s examine these different applications more in detail.
The applications
Pre-register – As far as the pre-register function is concerned, the new change on the fly technique allows the operator, after starting the machine at low speed (10 m/min), to insert the master print, and then go down the line of the machine to the local console of each printing unit and insert the subsequent print, which will be automatically set in register, adjusting pressures if necessary. Each colour will be inserted one after another. Then, on arrival at the end of the machine, the final fine registration adjustments will be made using either the Vision System or manually from the operator’s panel. At this point it will be possible to ramp up the machine to the required production speed so that the job can begin.
Insertion on the fly of one or more changes to the print – In this case, done at full production speed, the operator will already have carried out the print pressure adjustment upstream, inserted the inking carriage, and be in register with the master print (the one printing the mark).
At the right moment, from the main operator’s panel or from the local console on each printing unit, the operator presses a special button to insert the new print or graphic on the fly. The final adjustment is made through the Vision System or through the register control. It is also possible to disconnect unused print units, but for obvious reasons it will not be possible to disconnect master print unit.
Getting into register on reprints – For getting into register on reprints, the method is the same as with pre-register. The only difference is at the first point: from the moment when the mark has been printed, the job to be reprinted will be simply inserted on the fly.