Gm dc330 station description

Grafisk Maskinfabrik

DC330 FINISHING SOLUTION

Detailed Station Description

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Grafisk Maskinfabrik A/S constructs advanced digital converting lines for the graphic industry. Our machines have been built for a generation with focus on craftsmanship and in the tradition of Scandinavian quality and design.

The backbone of this family-owned company is 40 years of experience in providing solutions for customers in the label industry worldwide.

Grafisk Maskinfabrik is firmly based on solid knowledge and insight into the graphic business and we continuously work towards our ultimate goal of “Making Converting Easy�. We hold a broad experience and expertise in customer-counselling and product development as well as custom designs for very specific products. GM’s solutions range from in-line converting of the latest digital presses to coating of plastic photovoltaics, and converting RFID. For both sales and technical support Grafisk Maskinfabrik has offices in Denmark, the US and Chile. Furthermore, Grafisk Maskinfabrik is represented by agents worldwide. Please see www.gm.dk for details.

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Index General Description.............................................................................. 04 Web Guide............................................................................................05 Web Cleaning........................................................................................06 Corona Treatment................................................................................. 07 Flexographic Printing Group................................................................. 08 Screen Printing Group, Rotary..............................................................10 Screen Printing Group, Flatbed............................................................ 11 Die Cut Station......................................................................................12 Extra Die Stations (for custom tooling).................................................12 Knife Box Modules................................................................................13 Turret Rewinder Module........................................................................ 14 Laser Die Cut Module........................................................................... 15 Sheeting Module (including conveyer for IML/Light board/Tags)......... 16 Hot Stamping Module, Flatbed............................................................. 17 Hot Stamping Module, Rotary/Semi-rotary...........................................18 Crossover Module................................................................................. 19 Hot Air/IR Drying Module......................................................................20 Inline Modules (buffers)........................................................................21 Web Video Inspection Module.............................................................. 22 Configuration Examples........................................................................ 23

DC330 Finishing Solution

DC330 in standard configuration

General Description As digital label printing continues to grow, label-printing houses are realizing the need for all-inclusive digital printing systems which provide value-adding features for producing fully finished labels. The DC330 from Grafisk Maskinfabrik (GM) offers the ideal solution: a complete converting and finishing unit.

The DC330 was created especially for use with digital printing presses.

The DC330 can be set up as an in-line extension to a digital label printing system, allowing the web to continue directly into the converter from the digital press. It can also be used as an off-line converting and finishing unit for jobs from other digital presses or conventional presses. It can even function as a

Technical specifications Standard for all DC330 configurations: • 330mm or 500mm web width. Custom size possible • Speed from 0.01m - 72m/min. 55m/min. in semi-rotary • Wide substrate thickness range 20um-200um • Wide web width range 200-330mm supported

printing press for specialized value-adding solutions.

• Unwind Ø76mm spindle, pneumatic.

Maximum diameter 700mm

The standard configuration of the DC330 finishing line is as seen above: unwind,

• Rewind. Ø76mm spindle, pneumatic.

Maximum diameter 450mm (700mm on request)

webguide, flexo group, lamination, die-cutter, slitting box and dual rewind.

• Webguide. BST. With ultrasonic fork.

Unit highlights Modular – Customizable to fit your needs, depending on the specific application.

Productivity – Adjustable repeat lengths from 2” - 21”; line speed up to 50 meters per minute Print protection – UV flexo varnish station with registration and optional supergloss varnish capabilities Integrated – Available as both left-to-right and right-to-left version that runs inline and is integrated with a digital press.

Green (Low power) – Running on tri-phase + neutral 400V/32A with an average power consumption of only 8000 Watt.

Future – Fully upgradeable. Easy retrofitting of options such as laser die cutter, turret rewinder and hot stamp module.

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• Built-in remote access via internet with self-diagnostics.

• Weight: less than 800kg per module.

1600kg in standard configuration.

• Dimensions: Length: 4.0m - Height: 1.6m – Depth: 1.1m (standard version) • Power: 400V/32A. 8000-Watt average in standard configuration.

• Air: 5 bar. No running consumption

Web Guide

BST web guide

General Description BST 330mm web guide with ultrasonic fork. Built-in splice table with tape dispenser. Optional camera-guide system allowing register-to-line instead of register-to-substrate edge. The BST webguide is engineered for precise control of narrow webs in the label, plastic, and non-woven industries. The highly compact design allows for easy fit onto production machines with minimal

Technical specifications Standard for all DC330 configurations: • Six standard sizes up to 32” width. “low Profile” versions available for extra tight installations • Guiding functions: right web edge, left web edge or center-line

space and effort.

The controller and actuator have been cleverly integrated into the Compact Guide housing to save space and the entire guide is engineered for fast installation with minimal effort. Featuring solid multi-point support on the displacement frame, precision mounted track rollers, and a high performance actuator

• Center positioning of rotating frame guide • Speed: max. 200 mm/s (0.79 ‘’/s) at the exit roller • Sensors: Infrared or ultrasonic. Available with CLS line/contrast sensor

that allows for web tension up to 300 N (70 lbs)

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Web Cleaning

Teknek NWP series web cleaner

General Description Teknek cleaning and anti-static system. Removal of nano particles (tested using 25/45nm silver particles) – perfect for use in optical film manufacturing.

Silicone free cleaning core – no effect on product surface. Surface energy friendly – does not affect the dyn level. The rollers can be easily exchanged after use.

The unit is used to remove “pinholes” and loose toner particles before a UV varnish is applied.

Technical specifications • Cleaning type: Self-adhesive contact surface • Particle size: Down to 25nm • Web width 330 or 500 • Speed up to 100m/min • Sides: Front standard, duplex option • Antistatic: Optional build in bar

Teknek integration before corona unit

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Corona Treatment

Vethaphone corona treater 330mm

General Description Corona system from Vethaphone. The system has a treatment power of 1.5kW on a 330mm wide web. The Corona surface treatment is essential in printing.

Technical specifications • Treating type: Corona effect

On a plastic substrate the ink tends to become blemished due to its inability to

• Power level: Up to 75w/cm (2500W unit)

bond to the plastic. This problem occurs because the surface energy of the

• Web width 330,500 or custom up to 1000mm

plastic is insufficient to permit a proper bond. A quality Corona treatment is necessary to ensure the perfect label print quality we all want to see when looking at products at the end of the production line.

• Speed limit depending on the type of substrate • Sides: Front standard, duplex option

This module eliminates the problem of silicone or oil left on the web by the digital press.

Corona installed before flexo unit

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Flexographic Printing Group

Flexographic station

General Description Conventional flexographic station with pickup, anilox and print rollers. All rollers are standard 12” 1/8 gear with 100-320mm print width. Print can be done with a SH40 rubber roller (full flood) or with a cliché for specific patterns. Cliché sizes range from 9”-19” (depending on the cylinders used). Wet coating thickness from 2um-25um possible (depending on Anilox and speed). Full drawings

Technical specifications • Web width: 330 or 500mm. Custom size on request • Coating thickness: 3-25um wet (3-25cm3/m2 anilox)

of all rollers available on request. The unit features a “slow run” function to

• Optional registration: Servo drive with spot varnish function

keep all rollers wet during stop. Optional re-registration to pre-printed web

• Cylinder sizes supported: 80Z to 152Z

possible via mark read. Both water- and solvent-based inks can be used (if the

• Print cylinders: Full flood, solid cylinder, optional sleeve system.

needed drying system is fitted) The DC330 platform supports up-to 8 flexographic groups and is fitted with one as standard.

Fast change flexo unit with modern “reverse mounted bridge”

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• Number of stations on unit: Maximum 8 • Duplex/Back side coating: Optional

DC330 with 2x Flexo and 2x lamination/cold foil configuration

For spot varnish a good range of cylinders is needed. To meet this demand, GM offers a cylinder pack with 20 cylinders available for the GM line at a highly discounted price.

Sleeve system for flood and spot print

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Screen Printing Group, Rotary

Stork RSI compact head

General Description The STORK RSI rotary screen station prints with a screen size of 12”-18”.

Different screens can be used to accommodate very high wet thickness (up to

Technical specifications • Repeat range: 12” to 18”, 1/8” increments

0.5mm). Automatic register allows for re-print on existing webs. Screens for

• Web width: 330-500mm

different patterns can be ordered at STORK CHINA. The system has an auto-

• Mechanical speed: up to 100 m/min

matic pumping system included. It is important to have the proper cleaning

• Lateral adjustments: up to 5 mm

drums/washing equipment onsite if quick drying inks are used. For more

• Slow Rotation: Yes

details on the STORK please see the separate documentation on this unit.

• Screen suspension ring, automatic positioning and tensioning

The Stork unit can be retrofitted to the DC330 and takes up 90 cm of frame space.

• Squeegee suspension Stork system with XTR, no height adjustments • Drying system: Only UV supported.

Screen printed tag

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Screen Printing Group, Flatbed

The SC330 screen printing unit

General Description The SC330 screen printing unit from Grafisk Maskinfabrik has a printing area of 330mm(width) x 304,8mm(length) and is designed and engineered to perform screen printing of the highest quality possible on flexible materials. After printing, the ink drying is undertaken by UV-curing(GEW). The SC330 is compatible with tooling (screens) from existing equipment.

Preparing and setting up the SC330 is very simple and fast, which makes this machine suitable to complete even very short runs. Apart from being a costefficient alternative to rotary printing due to the low costs of mesh and frame, screen-printing also has several other advantages e.g. easy set-up and little waste.

The unit is sold as a separate unit or part of the DC330 finishing line.

Technical specifications • Max. frame/mesh size: 460x500 mm.

Print area 304.8x330mm • Speed 3-10m/min depending on job • Curing system: UV. • Servo register control • The printing unit can lift up for fast cleaning • Printing length adjustable by touch screen • Squeegee position adjustable both crosswise and in height by means of handles • The squeegee unit can lift up independently from the printing unit • Squeegee stroke adjustable by servo motor according to the printing length • Adjustable material output speed.

Raised varnish done with screen printer

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Die Cut Station

Die cut station with K&B GapMaster

General Description The die cut station in the DC330 works after the semi-rotary (format free) principle where any plate between 2” and 22” can be used. The machine automatically compensates for the portion of the die not covered by the cutting

Die cut station used as an embosser

Technical specifications • Speed: 72m/min full rotary, 50m/min semi-rotary

plate. This system is ideal for short and medium runs of digitally printed labels.

• Die size: 25” standard. Drop 0.48.(12” 26” can be fitted in station)

The die cut station features a “fast in register” function where the die locks on

• Plate size: 2 ”-22” (with a 25” cylinder)

register marks in one rotation for a minimum of waste.

• Crimp:Software disprofuction for re-use of conventional plates standard

Extra Die Stations (for custom tooling)

• Drive:Servo drive with automatic register.

The DC330 can be fitted with multiple extra die stations. Stations can be either

• O ptional: Gapmaster from K&B, Automatic lubrication

fully rotary (standard) or semi-rotary (custom machines).

The extra die stations can be used for high speed blank label production or made to fit existing tooling (Mark Andy or similar). GM designs cassettes on request after drawings.

Embossing can be done with polymer plates – Braille writing and wine labels are typical applications for this feature.

DC330 with two die cut stations

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Knife Box Modules

Crush knife box

Removable shaft for fast job make-ready (shear)

Shear cut knife box

Perf and back scorer knife module

Technical specifications • Substrate supported: 20um-300um • Minimum knife distance: 15mm • Control: Pneumatic engage/disengage • Adjustment: +/-10mm cross web direction

Razor knife box (option for crush knife box)

General Description The DC330 converting line can be equipped with a wide range of knife systems. GM offers three main types: Shear, Crush and Razor. Combination boxes or Tideland automatic systems are also available.

Short on the knife types: Shear type: Perfect cut, no dust, long set time Crush: Fast set, a bit of dust Razor: Fast set, small dust amount but quick wear.

GM has a “quick change” cassette for shear knifes where the shaft can be prepared on a stand away from the machine. This allows for faster setup times.

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Turret Rewinder Module

DC3-TUR Turret rewind module direct drive with no buffer.

General Description Grafisk Maskinfabrik offers both standard semi-automatic turret rewinds and

Technical specifications

buffered versions.

• 2x Rewind turret with 76mm pneumatic spindles

The GM DC3-TUR unit provides quick change-over times unlike conventional

• Web width: 330 / 500mm

rewinding. This allows shorter runs to be produced more efficiently.

• Speed: up to 150m/min

The machine is available as an option for a finishing line or as a stand-alone

• Stepless electronic tension

slitter/rewinder. With the addition of a rotary die cutter it is a cost-effective solu-

• Automatic stop on diameter or label count

tion to blank/plain label converting with a production speed of 150m/minute.

The DC3-TUR is available with either one or two rotary die stations for plain label production. Please see LS360 model for this configuration

Optional:

End of roll function – The user is able to program the roll end diameter – slow-

Non-stop operation with buffer module in front.

down and/or stop – The system does not use any roll followers or external sensors that can be damaged at roll changes. The diameter is programmed from the touch screen operator interface.

Turret with buffer for non-stop operation

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Laser Die Cut Module

DC330 line fitted with laser option

General Description A laser die cutter is an excellent choice for digital short runs. Offering zero change-over time and no die plate cost, this technology is a perfect partner for

Technical specifications • Cutting area: 330x350mm

a digital press. The GM L330 laser unit offers a fully digital mirror (galvo) sys-

• Power: 125,250 & 400 Watt models

tem for superior laser cut quality. A digital and automatic 3D focus and power

• File format: AI, DWG, DXF, and SVG.

control system eliminates the “startuphole burn problem” of more simple sys-

• Integration: Reads files from ESKO hot folder

tems. The system is built using 100% standard industry components from major laser suppliers like Coherent. No tooling required, simply download the file from the Pre-press Department and the GM L330 laser will take off. The laser has an optional bar code reader for quick change over and integration into Esko Graphics’ pre-press solutions. The GM L330 laser comes as standard plug-in module for the GM converters, but can also be fed into any other rotary web feed machine, Please note that the laser works best in PP. PET and PAPER can be cut as well. PE and PVC are not supported. Thick substrate, e.g. for wine labels will cut slowly.

Production advantages of the GM L330 Laser Die Cutting System • No more ordering conventional tooling and waiting days for delivery.

• No more long make-readies and less waste material.

• Speed: 5-72m/min depending on cutting pattern & material • Laser type: CO2 sealed (no running gas). Water cooled.

• Laser tube life: 14000 hours / replace cost EUR 6000-10.000.

• Exhaust: Ø200mm to the outside.

Optional carbon smell free filter • Optional barcode scanner for job change scan.

• Power: 32A/400V. Typical 10kW running consumption.

Speed in PP: 2 Labels Ø100 - 50m/min

• No more capital tied up in conventional tooling.

3 Labels Ø100 - 30m/min

• No more lifting heavy rotary tools.

4 Labels Ø60 - 20m/min 10 Square boxes 20x20mm - 10m/min

• No more storage of conventional tooling.

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Sheeting Module (including conveyer for IML/Light board/Tags)

Heavy IML processing on DC330

General Description For roll-to-sheet production the DC330 can be equipped with a conveyer. The conveyer fits on quick-release handles that allows changing from roll-to-sheet

Technical specifications • Fits models: DC330 & XP500

production in 30 minutes. The die cylinder operates in full rotary mode when

• Web width: 330mm/ 500mm

this option is used. Please note that a GAP master (cutting depth control) is

• Length: 1.5 meters

most likely needed for this process.

• Speed: Up to 30 m/min

The materials can be paper, board (light 250 gsm) or IML materials. Delivery is

• Substrates: Paper, IML, Board (job specific)

done on a fast and then secondly slow running conveyer. The end result is “sling” stacking.

• Automatic speed control (follows die) • Power: 240V / 3 Amps. (From main unit)

Options: External sling conveyer (slow speed) External stacker (RietStack)

Slow running stacking conveyer

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Hot Stamping Module, Flatbed

FB330 Hot stamp

General Description The FB330 hot stamping unit offers high-quality foil stamping and embossing.

Stamping and embossing is possible in one step or as separate steps.

Advanced features such as foil saver, servo-register and electronic tempera-

Technical specifications • Speed: 20m/min (at 12”). Speed depends on art-work and substrate

ture control comes as standard.

• Web width: 330mm or smaller (down to 50 mm)

Consumers are most easily impressed with the right combination of quality

• Max impressions: 5000/H

and beauty, and this is where the FB330 flatbed hot stamp unit from Grafisk

• Register: Servo system

Maskinfabrik becomes interesting. On the matter of the quality of hot stamp-

• Foil saver: Built-in as standard

ing, flatbed is the best choice, and on the matter of beauty, the FB330 can add

• Plate size: Maximum 304.8 x 330 mm

intricate details of gold, silver or even holograms to your labels. Furthermore, the FB330 is not a one-trick-pony, it will do both hot foil and cold embossing to serve all your needs.

The system uses magnesium, brass or polymer plates and booth single-side and male/female tools are supported. The unit offers a high-precision servo

• Plate type: 7mm-12mm magnesium or copper (compatible with older machines) • Unwind and rewind: 3” pneumatic. Ø300mm

drive for perfect register. Four electrical rods connected to a digital heat regu-

• Foil unwind and rewind: 1” or 3” (flange type – select at order)

lator provides the heating for the unit. Plates can be changed in the hot state

• Max foil diameter Ø200mm

using a slide system.

Options: 2x foil unwinds Cross web foil tower (foil direction cross and along web possible)

Examples of labels hot stamped on FB330

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Hot Stamping Module, Rotary/Semi-rotary

Rotary hot stamp module

General Description The rotary hot stamp module can be supplied in 330mm or 500mm web width.

It features an oil heated magnetic or clamp based cylinder.

The magnetic system offers fast plate-change times, however the plates are expensive compared to our clamp system. Here standard 1mm magnesium

Technical specifications • Operation mode: Full-rotary or semirotary (option) • Speed: 32m/min full-rotary, 5-20m/min semi-rotary • Register: +/-0.15 mm + heat variations in plate.

plates can be used.

Repeat size is from 2”-12”. Cylinder size is standard 15” but other sizes are possible on request. Fixed cylinders (engraved) can be used as well.

Rotary hot stamp systems are good for high volume production where job changes are not frequent. For short run digital production, our flatbed system is more flexible and offers a more economical tooling.

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• Control system: Servo drive with register • Foil drive: Built-in foil saver. Foil tension set via stepless control. SH 60 rubber drive nip.

Crossover Module

Crossover label (Example from Dan Labels)

General Description GM offers a module for crossover labels, also known as ”peel and reveal” labels.

Technical specifications • Web width: 330 or 500mm • Lanes: 2x standard. 3x optional

The module consist of 4 stages

• Speed: 72m/min +

a) A de-lam/re-lam section where the glue on the backside of the front page is eliminated. This is done with a spot flexo-graphic UV varnish printed directly on the glue side of the label b) A top flexo-graphic spot varnish is then applied to form the “hinge” of the label (if needed) c) The web is divided and the crossover operation is performed. d) In the final stage the newly formed “sandwich” label is die cut into the finished product and rewound

Crossover unit

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• Cross register adjustment: +/- 5mm • Separation knife: Crush cut.

•M aterial: Restrictions. Not all materials are good for crossover.

Hot Air/IR Drying Module

2 meter hot air ovens at 200C

General Description Grafisk Maskinfabrik has made hot air drying systems for decades.

We offer a wide range of Hot AIR / IR and combination systems for priming, screen printing and custom applications.

IR Drying system

Technical specifications • Web width: 330mm and 500mm • Power: 2000Watt up to 17500Watt • Exhaust: 800 m3/hour (adjustable)

The hot air box can fit on the DC330 as a compact inline solution for water based inks or as a larger external unit for high-speed priming.

Options: Post heat cooling Stone coated rollers

Single pass hot air oven for priming 80C

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Inline Modules (buffers)

DC330 Mini inline with HP WS6600

General Description The DC330 finishing lines can as standard operate inline with a digital press.

A 3-meter buffer is built in as standard in the lines.

For high speed integration (operation over 20m/min) GM offers a wide range of buffers with a capacity from 10 to 48 meters. The buffer can store the web while the operator changes a roll on the finishing line. Thus, the press is never stopped doing production.

Technical specifications • Technical Specifications • Capacity: From 10 to 48 meters • Web width: 330 and 500mm • Speed: up to 50m/min inline operation • Tension control: Pneumatic with feedback (constant tension)

GM has more than 10 years of experience in inline operation with Xeikon, HP, Epson & Domino presses.

Options: Web guide (strongly recommended)

DC330 inline with Xeikon 3500 press

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Web Video Inspection Module

Nikka web inspection module

General Description The DC330 finishing line comes with an interface for Nikka web inspection as standard. The system can stop the finishing in case of a fault/missing label/ misprint.

Camera inspection is a valuable tool for quality control in the roll-to-roll production of labels and flexible packaging. When installed in a finishing line, the inspection system prevents defective material from reaching the end customer.

The cameras on the printing press contribute to waste reduction and higher production speeds. Inspection systems also collect objective process information and supply data to production monitoring and system scheduling.

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Technical specifications • Web width: 330 and 500mm • Speed: up to 100m/min inline operation • Standard “store master” and compare

Options: Label count, PDF verify, Matrix fault stop, Barcode verification.

Configuration Examples

Configuration example: Unwind, flexo, cold foil, lamination, rotary hot stamp, full-rotary embossing, semi-rotary die cut, dual rewind.

Configuration example: Unwind, flexo, cold foil, lamination, 2x semi-rotary die cutters, slit and rewind.

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Configuration Examples

Configuration example: Unwind, flexo, cold foil, lamination, rotary hot stamp, full-rotary embossing, semi-rotary die cut, dual rewind

DC330 with extra custom Mark Andy compatible full-rotary die station

DC330 with integrated hotfoil stamping

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Configuration Examples

DC330 direct inline with digital press

The DC330 with laser die cutter

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Configuration Examples

DC330 Mini finishing line with inline option for HP Indigo digital press. This configuration offers compact and economic processing of labels. Features are flexo varnish, lamination, spot varnish and die cutting.

DC330 compact finishing line for high quality flatbed foil stamping. Integrated foiling unit with dual foil unwind, foil saver and servo register. Embossing and foiling can be done using the same tool. Flexo varnish, lamination, spot varnish and die cutting.

DC330 compact finishing line with combined high quality flatbed foil stamping and flatbed screen printing. Servo register and foil saver. Embossing and foiling can be done using the same tool. Laser die cutting unit, flexo varnish, lamination, spot varnish and traditional die cutting.

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DC330 finishing line with built-in inline/offline option. Flexo varnish with spot, lamination, cold foiling, semi-rotary die cutting, slitting and dual rewind.

DC330 finishing line with built-in inline/offline option. Hybrid laser and traditional die cutting. Flexo varnish with spot, lamination, cold foiling, semi-rotary die cutting, slitting and dual rewind.

DC330 finishing line with built-in inline/offline option. Stork rotary screen unit for raised varnish/special colors/silk screen finish.

Flexo varnish with spot, lamination, cold foiling, semi-rotary die cutting, slitting and dual rewind.

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Grafisk Maskinfabrik Grafisk Maskinfabrik A/S Bregnerødvej 92 3460 Birkerød Denmark Phone: +45 45 81 23 00 Fax:

+45 45 81 99 56

Email: gm@gm.dk Web: www.gm.dk

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• Concept: JS Media Tools A/S • www.jsdanmark.dk

• Concept: JS Media Tools A/S • www.jsdanmark.dk

Converting made easy