One of the more noticeable trends was towards inline finishing with just about all of the digital machines shown with some kind of finishing capability. Some of these relied on conventional finishing units with a limited number of truly digital finishing solutions.
However, Xeikon is hoping to address this with a new concept called Fusion. This basically means adding modules to a standard Xeikon print engine for features such as inline cutting, varnishing or foiling, which can be slotted in as needed. But the key thing is that these are all digital rather than conventional modules. Wim Maes, CEO of Xeikon, believes that we’ll see more web to print in the label sector that will need a completely digital production line.
Meanwhile, HP has worked with a number of finishing companies to ensure that there are solutions available to work inline with its Indigo roll-fed presses, many of which were demonstrated at the show. Thus Tresu showed off its iCoat varnishing system, which is basically a flexo system that can offer fast changeovers for short runs with both aqueous and UV varnish. It can handle substrates from 180gsm to 500gsm at a rate of around 5000 B2 sheets per hour. There’s a version specifically for the B2 Indigo 3000, called the iCoat 3000, designed for folding carton.
Comexi also showed its new laminator, the Nexus L20000, which has been designed to work alongside the Indigo 20000 for flexible packaging. It uses water-based adhesives and can turn a package around in 24 hours, which is both faster and better for the environment than solvent alternatives. It includes an automatic cleaning system and can refill the adhesives in ten minutes.
Domino showed an interesting collaboration with GraphiMecc that used two of its inkjet heads on a foiling machine. The first head printed black ink, while the second jetted adhesive, which combined with the foiling for a really effective variable data security solution.
Prati has developed a finishing unit specifically for short run digital presses. The DigiFast One is still being developed, though Prati did manage to sell at least one at the show. It can run at up to 80 mpm and promises waste of just 18 metres for each run, with changeovers of around eight minutes.
Neryos has developed a label finishing system capable of laminating, cutting, matrix removing and slitting. The DLF2000 is quite a compact unit that can run at 10 mpm and is designed to work with both conventional and digital label presses. It uses software that automatically detects the cutting shape and can generate it directly on the system, and can then drive the knives for a cut on demand solution.
Then there were curing options
Several companies showed off new hybrid UV curing systems that can handle both conventional and LED curing. The main benefit is to future-proof the press should you want to convert to LED inks, with a growing number of companies doing just that. But it also means that the curing modules can be swapped around as needed, which is useful if, for example, you have LED pining lamps on individual units together with Arc lamps for a final cure.
GEW showed off its ArcLED hybrid UV curing system. Essentially, it allows customers to use arc technology now but with the option to upgrade later to LEDs using the same lamphead casing and the same power supply and control. The system can automatically switch from the AC required for Arc lamps to the DC power needed for LEDs.
IST Metz also showed off a hybrid system, the MBS. There are three versions, all air-cooled: one for UV lamps that can be upgraded to LEDs; one for LEDs that can be upgraded to UV lamps; and a hybrid system that uses both UV lamps and LEDs. They use the same electronic power supply and both UV and LED lamps can be air cooled.
IST Metz has partnered with the British company, Integration Technology Limited, which used the same stand at the show to demonstrate its Solidcure 2 N, a slim system designed to fit into tight spaces for full cure or pinning of high density colours. ITL also showed its Pincure 2 system for high speed pining for LED UV curing, which now has an improved housing to prevent contact with the media.
In conclusion, there's no longer any doubt that digital will play an increasingly bigger role in the label sector, despite being better suited to short runs. There’s still plenty of room for improvement; most of the hybrid presses struggle to integrate the digital and conventional halves, while some of the digital presses still need to find the right balance between cost, speed and image quality if they’re to go beyond more than a handful of installations. But it’s clear that the industry accepts that there is a need for short run labeling and this sector will continue to grow.