Labelexpo Europe 2023 - finishing and converting

Among the key developments in finishing and converting equipment on display in Brussels were increasingly sophisticated digital embellishment options – primarily inkjet varnish, various forms of digital metallization, and laser die‐cutting – and faster die‐cutting systems that help enable more automated and more efficient flexo printing, helping it push back against digital technology when it comes to production of shorter runs.

Elsewhere on the show floor were the latest developments in inspection rewind units, shrink sleeve converting equipment, specialist units for production of RFID labels, and more.

DIGITAL EMBELLISHMENT

Digital embellishment – the replacement of tool‐based analog decoration and converting processes with fully digital processes – was a key trend among the converting technology on display. It can be achieved through different configurations, from integrated digital embellishment lines that combine inkjet varnishing, digital metallization and laser die‐cutting into fully automated one‐pass label converting systems, to retrofittable inkjet modules that can turn conventional printing or converting machines into hybrid systems capable of applying tactile varnishes or variable white, black and spot colors.

In the latter category, A B Graphic International (ABG) demonstrated the JetFX‐powered DigiJet 330 print bar, Domino launched a digital retrofit module for both flexo presses and finishing equipment, and FujiFilmmarked the Labelexpo debut of its 42K imprinting bar system, successor to the Samba 42000.

Fully integrated digital embellishment systems included ABG demonstrating its DigiLase 4.0 laser die cutter as part of an integrated Digicon line.

Anytron showed its versatile Any‐Jet II which integrates digital printing, lamination, laser die‐cutting, slitting and matrix removal.

Cartes demonstrated its GE363VJL digital finishing technology consisting of a Jet D‐Screen (JDS) inkjet module combined with laser die‐cutting and converting, all based around the company’s Gemini production platform. The Jet D‐Screen digital screen technology, making its European trade show debut following its launch last year at Labelexpo Americas, won Cartes the Innovation Award for companies with up to 300 employees at the Label Industry Global Awards.

GM launched a digital varnish module for its DC350 converting line, featuring digital foil and digital screen varnish, and sold two of the systems during the first two days of the show.

Prati, celebrating its 50th anniversary, showed the DigiFastOne integrated digital finishing line, based on the company’s Futura field‐upgradable open platform technology. The line is fully digital from inkjet module to laser die‐cutting and turret rewind and offers the capability to produce short‐run promotional labels in the food and beverage, wine and spirits, cosmetics, personal care and home care sectors.

Prati also launched the DigiFast 20000, aimed at the mid‐web package printing sector. It can operate as a stand‐alone system or be integrated into the new HP Indigo 20K digital press.

It is configurable to meet individual finishing requirements from varnishing to full or selective printing, embellishing and finishing a job either in roll or in sheet for further processing.

SEI Laser showed its Labelmaster laser die‐cutting and finishing system in‐line with its new high‐resolution KyoJet UV inkjet module, representing a single‐pass system from PDF to shipping.

Digital metallization, meanwhile, continues to make great strides via a range of different technology approaches.

ABG demonstrated the zero‐waste Actega EcoLeaf metallization system, which uses a donor roll of nano‐metallic flakes attracted to a printed trigger image.

Kurz introduced its DM‐Uniliner 2D/3D digital embellishment systems and the Distorun module, a material‐saving cold transfer unit for processing single images and endless décor. It operates by reading a print mark on the web and positioning the images in relation, at the same time monitoring and syncing with the speed of the press. Kurz also premiered an in‐line metallization solution developed specifically for the Xeikon toner press, using a part‐cured ‘tacky’ toner to adhere the metallization effect to the substrate. ‘Embellishment is a key trend: it makes the difference for brand owners,’ says Stéphane Royère, head of the business area packaging and print. ‘We at Kurz have the answer to this need.’

Automation is a key feature of this new generation of digital finishing systems. ABG showcased ABG Connect, a key component for integrating Digicon finishing lines into wider factory communication networks. Developed over 10 years, and involving collaborations with a leading self‐adhesive label converter and MIS specialist Cerm, the ABG Connect is a state‐of‐the‐art, plug‐and‐play system that uses the latest industry‐standard JDF/JMF messaging format to connect converters’ management information systems to their ABG finishing lines.

Grafotronic unveiled its IQ automation system, which places smart cameras on the unwind, varnish, die‐cut and slitting stations of a DCL2 finishing line. The cameras allow for automated set‐up and monitoring of each station, all using simple reference marks printed between the label lanes. An IQ‐equipped DCL2 could be seen in action in the Automation Arena.

RAPID DIE-CUTTING

Two key die‐cutting developments were on show in Brussels. Firstly, the continued development of high‐speed semi‐rotary die‐cutting modules – GM now claims an industry best of 200m/ min. Of course, we have had semi‐rotary die‐cutting for some time on finishing machines optimized for short runs of digitally printed labels. The benefits of not having to change magnetic cylinders between jobs were evident. But the new generation of faster units is now impacting the efficiency of flexo presses. Not having to change cylinders between jobs is matched by the ability to automatically load and eject die plates, reducing set‐up times between jobs.

Taken together with automation on the flexo print stations and ECG color this has the potential to revolutionize the ability of the flexo press to economically produce shorter runs, pushing back against the digital cut‐off point (at the same time as faster digital presses push into the medium run length sector traditionally dominated by flexo).

Quick change rotary die systems were also displayed at Labelexpo Europe 2023, allowing the rapid exchange of dies using side‐address trolleys with automated pre‐registration.

Die systems manufacturers have at the same time been fitting their die stations with the ability to intelligently respond to variations in liner thickness. The Maxcess / RotoMetrics RotoScan intelligent die station is a good example, and this unit is also set up to provide Industry 4.0‐level real‐time data capture and reporting. Kocher + Beck introduced a range of systems that reduce or eliminate manual intervention, including the GapMaster EM and KMS digital pressure gauge. ETI Converting’s Pellicut system can die‐cut down to 12 micron.

Tecnocut presented the E‐Diffsystem, an electronically adjustable anvil. It also showcased the Pit Stop quick‐change cylinder system and a waste matrix removal system. The latest model of the Label Mover unit moves the web by a few millimeters for more efficient waste removal.

Stand‐alone die‐cutting systems are also benefiting from Industry 4.0 integration tools. The Berhalter Swiss Die‐Cutter B4, with a production speed of 500 strokes a minute, incorporates digitally monitored penetration depth control, and the company’s Cutcontrol technology allows operators to access real‐time data streams from the machine, accessories, and punching tools.

SPECIALIST APPLICATIONS

Specialist machines dedicated to the wine sector were shown by Emmendinger Maschinenbau (EMB), which exhibited sparkling wine capsule machines that offer a wide range of decoration and functional possibilities. GM showed, among other converting machines, its DC350Flex+ Wine line for foiling and embossing, incorporating both screen and flexo varnish effects and a 50‐ton pressure hot stamping module. The unit can work standalone or in‐line with a digital press.

Schobertechnologies’ RSM410 IML/MX is specially designed for the high‐speed die‐cutting and stacking of in‐mold labels including the Spider robot‐automated stacking and counting system.

Karlville demonstrated a complete system for laminating then manufacturing stand‐up pouches, operating as part of HP Indigo’s ‘Pouch factory’. The Karlville Swiss compact KS‐SUP‐400 pouch machine offers the capability to manufacture custom‐shaped pouches. This was the first time the company showcased this line at a Labelexpo show.

Accraply showed its new generation Revolve seaming technology, configured to make shrink sleeve seaming simpler and more efficient, while Brotech introduced its SMS shrink sleeve label seaming unit to the European market, alongside a range of differently configured digital label finishing lines.

DCM Usimeca presented a shrink sleeve seaming machine equipped with laser perforation, and a doctoring rewinder for quality control and correction of reels, equipped with a 100 percent inspection system. It also showed a bi‐directional narrow web slitter rewinder for inspection and doctoring.

HCI Converting Equipment promoted the new FP‐X250‐2 shrink sleeve seaming machine with rewind auto splicing, ultrasonic lay‐flat measuring and solvent detection technology, with both seaming and doctoring processes on the same machine. The machine runs at a speed of 500m/min.

For shrink sleeves, Karlville displayed its latest seamer and inspection combo. Its third generation Plus series seamer, K3 Plus, operates at 500m/min and forms the sleeves via an automatic adjustable forming section.

An interesting decoration technology for shrink sleeves was shown by Pantec, which introduced its Cheetah N rotary embellishment system for applying single 3D images to shrink sleeves. Such effects cannot be achieved on shrink sleeves by embossing. The customized 3D images are applied to the shrink sleeve by heat and pressure from a carrier film at up to 20 images a second. ‘It’s a totally new shrink sleeve embellishment,’ says CEO René Abächerli. ‘Many major shrink sleeve players around the world are interested in the machine.’

Specialist converting units for RFID label production was another feature of the show.

Delta ModTech demonstrated an updated Crusader Converter incorporating precision RFID antennae placement. The system integrates multiple processes such as rotary die cutting, winding, conveying and accurate part placement.

Graphimecc spoke about how RFID and QR codes fit into wider Cloud‐based track and trace systems at daily talks in the Automation Arena while promoting its own abilities in that area.

LemuGroup introduced the LI 220 RFID converter for multilayer label production and NFC/RFID chip inserts. The LI 220 offers two operational alternatives in a single module. It enables the production of multilayer labels and also allows NFC/ RFID chip inserts, between the liner and the label, without hindering the visual design of the label.

Melzer showed the SC‐X Smart Label Production Line with integrated punching units and trim removal. This production line for RFID labels and tickets can process both dry and wet inlays at full speed of up to 60 m/min.

Mühlbauer showcased the CL40000, a flexible RFID inlay converting system suitable for mid and high‐volume production. This machine can produce various output products such as smart labels, smart tickets and wet inlays, and features a high throughput rate, label/ ticket lamination, die‐cutting and 100 percent output testing. It achieves a throughput of up to 40m/min.

Voyantic demonstrated the Tagsurance 3 in‐line quality testing system for RFID

tag and label production lines. The system offers full visibility into the RF performance of labels and measures the performance of UHF and HF RFID inlays, tags and labels at different production stages. It is scalable to various production volume needs from one to eight lanes with one to five stations per lane, handling lane speeds up to 200m/min.

AROUND THE STANDS

ABG, among 17 machines on its stand, launched a new turret unit and introduced the Converter, a compact, fully modular high‐speed converting line incorporating an automated flexo coating station. Among other products on display were a Digicon with screen and Ecoleaf unit for sustainable metallization, DigiLase 4.0, DigiJet 330, DigiLite, SRI3 430 with monochrome inkjet, shrink sleeve seaming (SR), doctoring solutions (DR), an entry‐level SRI, in addition to a booklet module.

Ashe Converting launched the Diamond duplex slitter series for wider web applications and the Opal TST range of high‐speed blank label converters with auto two‐spindle turret rewind.

Also operating on the stand was a fully automated ‘glueless/coreless’ four‐spindle turret slitter, an Opal ISR with 100 percent camera inspection and a mid‐web sized (800mm wide) Solitaire duplex slitter for flexible packaging products. The latter was bought on the show floor by a US‐based label converter. Ashe was sharing a stand with its partner Parkland International, a manufacturer of core cutters.

Bar Graphic Machinery (BGM) launched its BGM Elite Digiflex 330 flexo die‐cutting and converting system with semi‐rotary print station, quick‐change

ink system and screen‐printing unit, and the new BGM Elite Dieflex E. Achieving speeds up to 160m/min, the Digiflex 330 is designed with servo infeed and outfeed, a semi‐rotary re‐register flexo print station with LED drying, and cold foiling and laminating units. The new BGM Elite Dieflex E is a high‐speed plain‐label converting and finishing line that can also be equipped with an adjustable anvil.

Brotech launched the SDF Plus digital converting system, which supports multiple processes including hot foil stamping, flexo printing, cold foil /adhesive lamination, screen printing, varnishing, die‐cutting, slitting, snowball waste removal and dual rewinds.

Also displayed was the modular SDF‐E series which can be expanded with options such as additional flexo coating stations, printing, cold foil/lamination, hot air (I/R) dryer for water‐based primer or printing, auto‐slitting unit, sheeting or IML stations.

Cartes presented six machine configurations. The GE363VJL digital finishing technology is a Jet DScreen (JDS) on the Gemini platform, combined with laser die‐cutting. The GT360 series with Jet D‐Screen (JDS) is integrated with flexo, silkscreen printing, hot stamping and semi‐rotary die‐cutting. The GE362WL+turret rewinder laser die‐cutting machine will be shown with automatic job change. The ILC laser cutter allows cutting of colored substrate without leaving white edges or can remove white borders from dark labels. GE361L is an entry‐level laser die‐cutting and converting machine. GE364VHWR is equipped with hot stamping on the Gemini platform, along with two flexo stations and a semi‐rotary die‐cutting unit.

Daco Solutions launched its SRV350 inspection slitter rewinder. The servo‐driven machine features an inspection system from Nikka, closed‐loop unwind tension control, and a fully automatic slitting unit with servo‐driven positioning of the knives. It runs at speeds of up to 300m/min with a 350mm web width and 800mm unwind diameter. An optional accumulator can be added, so any labels replaced on the web will pass back underneath the camera to ensure 100 percent inspection. Daco also exhibited the PLD350 with a rotary die station for blank label production.

Darui China showcased a new generation of laser label die‐cutting machines. This technology offers both roll‐to‐roll and roll‐to‐sheet finishing options. The fully digital laser process system performs well in handling small and medium‐sized orders.

DPR showed Aries and Taurus label finishing systems, which are equipped with rotary module or laser technology and can handle up to 350mm media width. The machines offer UV flexo varnish, lamination, die‐cutting, slitting and dual shaft rewind functionality in a single pass. DPR also introduces the Virgo and Scorpio X2 series, powered by cutting knife technology and featuring two in‐line plotters with two separate and independent cutting heads.

DYM Machinery showed its nonstop roll‐changing technology for narrow and mid‐web applications. Its portfolio includes automatic butt splicer unwinder, nonstop cold stamping film systems, nonstop waste matrix collector and automatic turret rewinder.

Eclipse Label Equipment showcased its latest ‘print and finish’ systems designed for in‐line label production from blank labelstock. It also presented a new in‐line laser label finishing machine, the Eclipse LF220‐LAS. This is designed to operate either with a pre‐printed roll of media or in line with any digital label press or finishing system.

Ecosystem Costruzioni showcased its new single pass roll‐to‐roll finishing line. It handles reels up to a diameter of 1,000mm with speeds up to 90m/min. The base system can be expanded to a double bar version for simultaneous metal transfer and high‐build varnish application.

Errepi showed an updated Leonardo automatic rewinder and featured products from its portfolio including the Volta and Archimede winders, Galileo flexo printing machine, Giotto inspection machines, and die‐cutting machines such as the Dante and the Vittoria and Vittorino core cutters.

ETI Converting promoted its Cohesio converting, printing and coating machine for in‐line pressure‐sensitive label manufacturing, launching a new nitrogen curing chamber for UV silicone and a new modular coating station. ‘There is a clear trend towards in‐house coating, and we make it easy,’ says president Maxime Bayzelon. ‘After the Covid material shortages, companies want to remove uncertainty from the supply chain. Sustainability is another driver.’

Gietz showed its ROFO 450 web‐fed flatbed hot foil stamping system for narrow web embellishment processes. The ROFO 450 Eco processes PS materials, paper, cardboard, film and composite substrates. The machine achieves speeds of up to 120m/min with a dynamic foil web transport with a 90‐degree rotating foiling unit. Gietz also introduced a wider version, ROFO 570 Eco, with a larger stamping surface.

Golden Laser launched a new sheet‐fed laser die‐cutting system. It also showed a laser die‐cutting machine designed for the roll‐to‐roll or roll‐to‐sheet finishing of package printing. Golden Laser’s laser die‐cutters work with all pre‐press and post‐press systems including rotary die‐cutting, flatbed die‐cutting, screen printing, flexo printing, digital die‐cutting, varnish, laminating, hot stamping and cold foil.

Grafisk Maskinfabrik (GM) demonstrated nine machines, including the DC350Flex+ wine line for foiling and embossing, screen colors, and flexo varnish effects. With 130m/min rotary die‐cutting (80m/min semi‐rotary) and a 50‐ton pressure hot stamping module, the DC350Flex+ series is fully customizable and can work either standalone or in line with a digital press. The new HF350 hot foil machine adds embossing and foiling effects in a compact footprint.

The company also showed the DC350Mini compact label finisher – the most compact in‐line finishing system available on the market, according to GM – and the DC350Nano.

The SR350 slitter inspection rewinder and the LR250+ inspection rewinder were also on display. The machine can be configured for pharma labels and even turned into a mini‐inkjet digital press.

Also shown were the CC160S semi‐automatic core cutter, and the CS350 high‐speed sheeter.

CEO Uffe Nielsen reported particular interest from visitors in GM’s compact finishing lines. ‘Space is at a premium in factories,’ he explains. ‘We have also seen many more private label visitors than usual.’

Grafotronic showed 10 machines, eight of which featured new technology. The company showed Revolver, a hot stamping machine with rotating head; new modules for full in‐register lamination, crossover and printing on the glue side; and the DCL2 in five different configurations. Grafotronic demonstrated five machines equipped with the AI‐based computer vision system Grafotronic IQ – described by business development director Morten Toksværd as a ‘virtual operator – which allows autonomous job changes, handling all job settings automatically.

In the Automation Arena, Grafotronic was the exclusive finishing partner. Together with Xeikon, Esko and Cerm, Grafotronic showed how the converting processes can be automated, showing an IQ‐equipped DCL integrated into a fully automated end‐to‐end workflow.

Also on display was the new Haptic series, with two new screen modules, a new hot stamping machine and the latest digital embellishment system powered by Kurz.

Grafotronic also showed its SCI‐FI laser for the digital converting of printed labels and stickers. The company also presented its Boon‐Tech auxiliary machines including slitter/rewinder, fan‐folding equipment, core cutter and label cutter.

‘It has been a fantastic show,’ says Toksværd. ‘We have sold numerous machines and seen lots of new companies as well as existing customers. It was important to be part of the Automation Arena – it helped us to demonstrate our automation capabilities.’

HCI Converting Equipment launched its latest FSL‐TR1300 turret rewinder designed for slitting labelstock, wraparound labels, shrink sleeve label films and flexible packaging films. It features automatic splicing and roll changing, stand‐by paper cores with auto‐positioning, finished roll eject and an unloading device.

Hontec promoted the MPX series finishing system based on the company’s Digifini platform. It combines a variety of process modules, such as flatbed hot stamping, intermittent flexo printing, flatbed silkscreen printing, rotary die‐cutting, flatbed die‐cutting, laser die‐cutting, buffer and turret rewinding, and sheet cutting.

Inglese exhibited with its partners Toray Industries, DuPont Cyrel, Esko, Refine Finishing, Breit Technologies and Azul Sistemi. It demonstrated the Refine 17in‐wide Compact 2 finishing system, with features such as a semi‐rotary flexo unit, UV LED curing system, cold foil lamination, semi‐rotary die‐cutting and semi‐automatic turret.

Jurmet exhibited its Langer3 inspection machine, suitable for wraparound labels and other monofoil, linerless as well as linered labels. The machine is equipped with a 100 percent inspection camera, has a working width of 520mm, and can operate at speeds of 500m/min.

Labeltech highlighted the Ortles slitter rewinder equipped with the new E+L Smartscan MIS2 4K inspection system and an upgraded version of the Lavaredo automatic knife positioning system, for both razor and rotary knives.

Labeltech also debuted Reit, a small versatile rewinder available in several configurations (bidirectional doctoring machine, slitter rewinder, inkjet printer). The machine is designed to meet the growing demand for small‐batch productions.

The latest version of the Stelvio modular converting machine, with Lombardi flexo unit for printing/varnish, UV‐LED curing, cold foil lamination, full/semi‐rotary die cut and Vajolet semi‐automatic turret rewinder was on display.

LemuGroup launched the MA 350+GTU for premium finishing of digitally printed labels, and the fully automatic GTU 440 with a boxing system that can automatically pack label rolls. MA 350+, connected to a GBS turret, is targeted at the production of premium finishes for digitally printed labels in the wine, cosmetics and pharmaceutical markets.

Martin Automatic displayed an MBS automatic unwind butt splicer and an LRD transfer rewinder. Both machines had been sold to German label printer Krämer Druck and were to be installed directly after the show. These machines save space, can be installed directly against walls at either end of the press and still allow access for maintenance and roll loading and unloading.

Nepata Systems presented new products from its Saga Label brand – an all‐in‐one machine for processing labels after digital printing. The LC30 PRO label finisher combines five functions in one device: laminating, contour cutting, trimming, slitting and winding.

The Label Finisher provides variable production of labels in small to medium runs. The contour cut enables the production of labels with complex contours and the simultaneous production of various shapes and sizes in one pass, without any cutting die.

The Saga Label SALF‐350, a roll‐to‐roll label printing, laminating, slitting and rewinding machine, features an integrated four‐color Epson Colorworks printer.

Pantec showed the Rhino S, an embellishment system with a new RSD tool change system for improved machine uptime. This enables the time‐consuming set‐up process to be done outside the Rhino to increase machine up‐time.

Polar showcased the LabelSystem DCC‐12 die‐cutting system, designed for automated in‐line production of die‐cut labels made of compressible materials. The system is designed for highly automated in‐line production of banded die‐cut labels made of compressible materials, such as OPP foils for in‐mold, and allows for remote maintenance and diagnostics, and integration into the digital workflow.

Prisma introduced the modular LF‐350 finishing line for self‐adhesive labels. The line is configured with a flatbed silkscreen unit, hot stamping/embossing, a flexo station, and semi‐rotary die‐cutting and rewinder. The machine operates at 50m/min in semi‐rotary mode.

Reborn showed its RBJ‐Ares 350 digital plotter. The machine is equipped with three blades, 350mm width, 980mm repeat length, and 500mm unwind/rewind diameter. It can automatically register and adjust cutting pressure by inputting the thickness of liners. Label converters just need to input/transfer their cutting artwork in AI/DXF/PDF format, without any die tooling.

Rhyguan showcased a compact fully digitally controlled finishing machine with corona, full rotary flexo (flood varnish), digital die‐cutting and automatic slitting. The machine is designed for the efficient finishing of short‐run jobs without any tools and is prepared for a JDF workflow and standard QR code scanning for automatic set‐up. For wine labels, the modular Plus330 was shown with a new fast silkscreen unit, Silkfoil, and a heavy‐duty hot foil module with dual heating zones. For longer runs, Rhyguan showed a machine with 50 percent improved productivity by increasing the semi‐rotary die‐cut speed from 60m/min to 90m/min.

Rosas Maschinenbau demonstrated its third‐generation Gazelle high‐speed bidirectional rewinder for imprinting a variety of labels. The new Gazelle III 6‐color digital imprinting machine features an unwind diameter 650mm, web widths from 40‐330mm, print width up to 200mm, corona treatment, a flexo primer station, Graph‐Tech’s EZ 202 DOD color inkjet head based on Epson S3200 technology, double white DOD UV inkjet with 600 dpi, a 4C DOD UV inkjet with 600 dpi, and an LED UV curing unit.

Also shown were two of Rosas’ tabletop rewinders: the Cheetah 500 with AI technology for label inspection with an advanced RFID HF and UHF tag serialization module; and the Leopard 300, with a Smartscan label inspection system, 2k resolution, and 180m/min inspection speed. Two Cheetah 500 inspection rewinders were sold during the first two days of the show, according to owner David Rosas Wolf.

Rotocontrol EMT presented a portfolio of finishing machines for label slitting, rewinding, inspection, die‐cutting, overprinting, digital and booklet printed labels.

Sermar Machines presented a compact vertical fan folder and showcased the new sheeter range models Smart Cut and Easy 2 Cut with electronic guillotine size change size. Sermar Machines also presented a new label converting unit in line with a spiral fan folder, the model SP‐508‐E, which operates at speeds up to 150m/min.

Starfoil Technology presented the Value Line 1300SXL spooling/slitting machine featuring a higher speed of 250m/min and larger diameter rolls up to 350mm. It also introduced the CLC‐600XLR, a cantilevered, compact model.

Vicut released a series of roll label cutters and a new model DTF cutter VFC90 with an auto‐feeding conveyor table. It is compatible with Cadlink RIP software.