Labelexpo Americas 2022 - ancillary products

Artificial intelligence (AI) to check for printing errors? Affordable UV LED curing that drastically cuts energy costs? The ancillary suppliers at Labelexpo Americas 2022 responded to the challenges of today with an array of innovations.

 

From more cost-effective versions of older technology to completely new concepts, read on to learn more about the most exciting inspection, cleaning, LED curing, and anilox innovations featured at

Labelexpo Americas 2022.

 

 

The latest inspection equipment innovations tout higher speeds, artificial intelligence, more accuracy and an improved ability to scan white and clear materials.

 

Rosas Maschinenbau highlighted its AI inspection technology at the show. The new Infinity 4K line scan camera is designed for rewinders that handle web widths of up to 520mm (20in). It features new AI-based print inspection technology.

 

‘It works like a human with decades of experience,’ says Davis Rosas Wolf, owner of Rosas Maschinbau.

 

The system works with automatic setup software and capabilities such as PDF master check and roll map with PDF proof report.

 

It can inspect a wide variety of label types, including labels with variable or holographic backgrounds and reflective surface materials such as gold embossing.

 

Code reading and logging are also part of the system, which comes complete with reflection-free illumination, screen and CFK encoder roller. Designed for Rosas’ Cheetah 500 and Leopard tabletop rewinders, the Infinity 4K line scan camera can also be installed in other industry label converting and printing machines.

 

Techkon’s latest innovation can quickly check the levels of Optical Brightening Agents(OBAs) in paper.

 

Its new SpectroDens4 spectrodensitometer – the latest in its series of continuously evolving all-in-one (combined densitometer and spectrophotometer) handheld color measurement instruments – features OBA-check. Optical Brightening Agents are frequently used in paper production, and they can affect how paper looks under different light conditions.

 

 

SpectroDens 4’s OBA-check provides precise information about the amount of Optical Brightening Agents used in a particular paper substrate. The company says this is extremely useful in today’s print market, when the paper industry faces supply chain issues that often result in companies sourcing from different suppliers. Being able to easily check to make sure all the suppliers are meeting the printer’s standards leads to a more uniform output.

 

An ergonomic design makes for one-handed operation. It also includes visual opacity measurement functions and rolling wheels for scanning.

 

Erhardt+Leimer’s latest inspection equipment can check clear labels and run PDF comparisons to masters. The company’s Smartscan 200 percent print inspection system uses UV illumination to detect defects on clear labels and it can scan with speeds of up to 800ft/min. The company says it’s the first 200 percent inspection system in the world dedicated for the label industry. It also uses intelligent classification to detect print defects, missing labels, unremoved matrix, splices and flags. 

 

Applied Rigaku Technologies showcased its NEX LS, an in-line silicone coating analyzer for real-time process control.

 

NEX LS software provides a clear visual representation of the process. Its analytical head sweeps back and forth across a moving web and displays real-time data as a graphical cross-direction and

machine‑direction profile.

 

The company also offers an at-line benchtop unit for measuring very low silicone coating weights and metal catalysts in silicone coatings.

 

Both benchtop and process systems feature energy dispersive X-ray fluorescence technology, a standard, nondestructive technique used in the paper and film industry for determining silicone coating

thickness and composition.

 

 

When it comes to cleaning, the newest innovations offer companies more sustainable options without sacrificing results.

 

Eaglewood Technologies’ new Sitexco Label L10 Anilox Cleaning System has been developed to make laser anilox cleaning technology more accessible for the label industry, according to Peter J. Mulheran, VP and GM of Eaglewood Technologies.

 

The slimmed-down version of its Sitexco Laser Anilox System 5 was specifically designed for narrow web printers, while also featuring a more accessible price point. 

 

The system offers cleaning times between five to 15 minutes, and it works on any type of ink chemistry, including water-based, energy-curable (UV/LED), solvent-based, adhesives, varnishes, and coatings.

 

The laser cleaning system offers an alternative to liquid cleaning technologies by using lasers to abate the ink off the parts and then collect it with a filter. He claims the process is more sustainable than liquid cleaning as it doesn’t require chemicals, water, and it does not generate any water waste.

 

 

Mulheran says it’s also much easier to operate than liquid cleaning systems because there are no pre-cleaning or post-cleaning processed involved. In addition, he claims rolls are 30 percent cleaner compared to liquid systems technologies. 

 

‘Our customers tell us the rolls look brand new every time,’ Mulheran adds.

 

FlexoWash also showcased laser cleaning equipment at the show.

 

Its new FW 850 series models clean up to two narrow web rolls in one cycle and can be installed without water supply, drain or safety equipment.

 

Operators are required to place the aniloxes as-is on the traction stations, then a high-frequency laser cleans the anilox with a precise, defined pulse, which ensures an even distribution of energy.

 

The extraction system then removes all dust and fumes, making sure no nanoparticles enter the room. The program automatically stops when the cleaning and extraction process is finished.

 

The laser is automatically adjusted to the size of the anilox roll, making the process fast, user-friendly and safe, according to the company. In fact, there’s no need for safety goggles or other safety equipment.

 

‘The FW 850 series is available in the company’s Laser X Series, which cleans twice as fast as the company’s regular laser anilox cleaners,’ says Patrick Potter, president at FlexoWash. 

 

Alphasonics showcased its Ultrasonic Press Room Cleaning Systems.

 

According to the company, these devices use high-frequency sound waves transmitted through liquid to clean away any ink residue and contamination to an incredibly low level.

 

Designed to clean anilox rolls, sleeves, and gravure cylinders, the Ultrasonic Press Room Cleaning Systems can help reduce setup times, minimize downtime, and optimize print quality.

 

The range of ultrasonic anilox roll cleaning systems can be used for flexography, gravure and offset. They are fully automated and can be tailored to specific cleaning requirements.

 

Meech’s launched its latest web cleaning equipment Its Clean-R is a non-contact web cleaner for narrow web machines that does not require adhesive rolls.

 

‘Eliminating the need for the adhesive rolls, which must be regularly replaced, can help companies save up to 3,200 USD a year, assuming they would have used 28 adhesive rolls annually,’ says Matt Fyffe, VP and general manager of Meech.

 

To clean without adhesive rolls, the web first passes through a cloud of ionization at the entry point of the CyClean-R head, which neutralizes any static charges on the web. Then, a blast of turbulent air breaks the boundary layer on the web and losens any contamination. A negative airflow then draws the contamination away from the web, filtering it through the air handling unit. As the web exits the CyClean-R head, it passes through a second cloud of ionization to prevent re-contamination.

 

‘The non-contact nature of the machine makes it suitable for paper and film,’ says Fyffe.

 

Available as a single-sided or double-sided cleaning configuration, it delivers consistent removal of dry, unbonded contamination from any web material – even as small as 0.5 microns.

 

Graymills showed its PrintClean 554/654 ink pump and bid washer, which was specifically designed for HP Indigo digital technology. Designed with assistance from HP Indigo experts, it offers fast, easy cleaning of BIDs and ink pumps with minimal labor and mess.

 

Twin filters also extend the life of imaging oil and minimize redepositing of pigment on parts after removal.

 

It also uses HP imaging oil, which means it creates no new waste streams. And an extra-long, stay-put flexible metal flush hose allows for directed, hands-free flushing.

 

 

LED was the star of the curing systems on display during Labelexpo. Innovations are making it easier and more cost-effective to install LED UV systems while rising energy costs mean companies are

quickly seeing a full return on investment.

 

GEW showcased its air-cooled UV LED system AeroLED, which is now ArcLED compatible.

 

‘UV LED is not a niche technology anymore. It’s completely mainstream,’ says Robert Rae, managing director of sales at GEW. He adds that it now accounts for about a third of what GEW manufactures.

 

‘Dramatic increases in global energy prices have created an unprecedented demand for low-energy, sustainable LED systems,’ Rae explains. In Europe, some of GEW’s customers are paying 900 

percent more for energy costs compared to a year ago.

 

The surge in prices motivates companies to switch to UV LED, which can reduce energy costs by 50-70 percent when compared to a conventional UV arc system. The significant energy price increases

have meant companies are seeing a return on investments in less than a year.

 

‘We’ve even seen ROIs as low as four months after retrofitting,’ Rae adds. ‘The energy savings are huge.’

 

GEW’s AeroLED is a high-power system for full cure, printing, coating and converting applications up to 60cm wide. During Labelexpo, the company highlighted a design update that also makes AeroLED compatible with GEW’s ArcLED system. Using the same fan and ducting arrangement as the industry standard E2C, customers have the flexibility to switch between arc and LED curing on any station.

 

‘It’s very, very simple for an operator to use, and it’s very, very simple to maintain,’ Rae says.

 

Maybe most notable though, customers with GEW’s Rhino/RLT power supply platform can upgrade to LED within a matter of hours. They simply have to change the cassettes and run a software upgrade.

 

In an AeroLED system, air is extracted by a single centralized fan situated away from the press. There is no need for integrated fans or electronics in the individual lamp heads, which eliminates the high-pitched noise and the associated risk of failure. AeroLED features the same LED chassis and core components as GEW’s LeoLED lamp head, for proven reliability. As with LeoLED, the lamp head has tough watertight seals to protect the LED modules from moisture ingress and to make cleaning easy and safe. Every aspect of the design has been carefully considered to deliver robust performance and long-term reliability.

 

According to GEW, two AeroLED systems have a lower electrical supply requirement than just one conventional arc UV system.

 

‘The opportunities are huge, and we are convinced that LED will soon become the dominant technology in the narrow web market,’ Rae notes.

 

Phoseon Technology featured its Nexus One sustainable UV LED curing products for flexographic printing applications. Nexus One premium UV LED curing lamps deliver maximum power and a dose of UV energy for the flexographic markets where high performance is a key requirement.

 

The technology increases press uptime, reduces scrap by increasing yields, and features easily replaceable protective glass plate.

 

Prime UV showed its MiniMax, which minimizes UV cassette size while delivering maximum UV energy. Prime’s RadMax Series provides proven reliability coupled with advancements in UV curing

technology. The equipment features positive pressure air filtration system (PPAF), a simple-to-use control panel, and easy-to-remove cassettes.

 

 

Updated anilox roll geometries offers more print consistency by reducing variations in ink transfer.

 

Harper’s new Xtreme Channeled Application Technology (X-CAT) was on display, marking the first time label converters had the chance to look at the geometry up close.

 

‘Customers were able to use a microscope to see the new patent-pending engraving geometry on an anilox roll on display. Says Josh Sigmon, Harper’s VP of sales, ‘The new shape allows for a combination of a consistent pocket structures that creates a channel flow while providing the consistency and performance of a closed cell.’

 

Developed to combat ink spitting, moiré, trail edge voids (TEV), ghosting, and ink re-solubility at high speeds, it also makes the anilox easier to clean and allows particles to pass through rather than being trapped behind the blade, which reduces or eliminates scoring.

 

 

X-CAT works with UV, water-based and/or solvent inks and performs well in applications including process printing, the 60-degree hex, UV narrow web, solvent wide-web, UV mid-web, and water-based

narrow web.

 

Anilox specialist Apex International showcased its GTT 2.0 enhanced anilox geometry.

 

The product of nearly 10 years of development, GTT 2.0 anilox, is specifically engineered to reduce liquid turbulence and create a calm liquid surface, the company says.

 

The improved anilox geometry creates up to a 50 percent reduction in cell wall surface area across the anilox while also decreasing the required channel depth by an average of 25 percent.

 

The new design saves on ink usage and delivers higher opacity and print quality. The engraving is available in a variety of volume options and can be used in multiple print applications, from fine print to flood coat.

 

Applied Laser Engineering (ALE) featured its Twin Track laser engraving technology.

 

The new hardware and software interface for ALE engraving machines is particularly effective when they’re used to engrave high-volume cell structures.

 

 

Enercon is joining those incorporating AI into their machines. The company’s CoronaFlex corona treaters, specifically designed for high-speed flexographic presses and digital printing applications, improve the bond between ink and coating. 

 

The machines include Enercon’s trademark Compak Pro software, which uses AI to automatically track fault logs, maintenance logs and event logs, capturing a detailed snapshot of operating data.

 

The company says it’s the equivalent of having a service technician monitoring the system with advanced diagnostic tools.

 

A USB port also allows users to download the data, and share it with Enercon service engineers to quickly resolve any issues. Operators also have the option to connect to real-time remote support and monitoring. The feature makes it easier for Enercon to service machines remotely, which has been even more highly requested since the pandemic.

 

Flexo Concepts, which is known for its bright orange TruPoint doctor blades, showcased a new gray TruPoint Keon doctor blade during the show.

 

Julie Saad, senior marketing manager of Flexo Concepts, says: ‘It’s a safer alternative to steel and it also holds its shape.’

 

Used for high speed, high temperatures and aggressive chemicals, it’s 0.03in thick and has a maximum width of 1.575in. It can be cut to length and it’s food safe.

 

Yazoo Mills, Inc. showcased its cores during Labelexpo, highlighting the fact that they are made in the United States. According to Chris Evans, Yazoo’s North American sales director this has helped

the company serve customers despite a tumultuous global supply chain.