XPANND: MULTI-PROCESS, COMBINED PRESS LINE
With the launch of Xpannd GIDUE completely changes the perception of the major printing process in the self adhesive world. Obtaining a product, which is complementary to the digital technology, is possible, thanks to the introduction of servo remote-controlled Intelligence, that guides the advanced inking section of the new Xpannd Offset head. Easiness in gaining excellent results, standardization leading to the products’ repeatability and availability on a global level, digital workflow and important saving in the purchase of the consuming material: these the main advantages of GIDUE new offset technology.
Offset is the most demanding printing process in the industry for the mechanical parts of a printing unit. While the Flexo process needs limited printing pressures, Offset needs very heavy loads on the cylinders to enable ink transfer. The tolerances of manufacturing and assembly, and the robustness of an Offset print unit are crucial to the final print quality, together with the ink train design and the ink management system. Vertical structure: the majority of the Offset print heads in the market (for sheet-fed or web fed presses) are manufactured based on the vertical development of the structure, to help the robustness and the stiffness of the structure, for the best print result. This is the configuration chosen for the Xpannd Offset head. Mechanical manufacturing: on the final print quality of an Offset print unit, the manufacturing process plays a dramatic role.
An efficient manufacturing process developed for the Xpannd new Hi-Offset unit (launched at the end of 2007) performs a total control during the entire process. High print quality for both fine process and heavy solids are possible, due to the 22 rollers in the ink train, the over dimensioned rollers, and an innovative fully automated ink management system for full anti-ghosting control, fast ink reaction from the ink tray to the substrate and consistent quality during production (sheet-fed offset Print Quality European Certificate by SID available). The temperature control is ensured through water-cooled oscillating rollers inside the Hi-Offset print unit that keep the printing consistency unchanged at any speed. High speed productivity is possible, without affecting the print quality, due to the inner robustness of the Hi-Offset unit and to the redesigned ink train.
The Offset printing process in the label and in the packaging industry is often perceived as producing high quality of printing, with a lot of drawbacks in the efficient and cost-effective production of short runs, especially if compared to the Flexo process. This should be considered generally true for most of the Offset print units today offered in the market. The Xpannd Offset head makes significant steps to successfully address the short runs issue.
Printing at slow speed
Most of the Offset print heads in the market start to achieve an acceptable print result at press speeds of over 30 to 40 meters per minute, and good and consistent quality over 50 meters. This set up speed can be very critical in case of short runs due to the high amount of wasted substrate. The Xpannd Hi-Offset head achieves good and consistent print quality at the unprecedented speed of 12 mt/min! The wasted substrate during set up gets very close to that generated by the Flexo process. This result has been obtained by completely redesigning the ink flow geometry inside the ink train, and it is one of the most distinguishing achievements of the Xpannd head for the label and packaging industry.
The Xpannd ink management system
While in the Flexo process printing pressure adjustments are an important key for the printing process control, the print result of an Offset unit, specifically in the case of wet Offset, is mainly affected by the performance and by the control on the ink flow and of the ink-water balance. The philosophy of Intelligence has been transferred to the advanced inking section of the Xpannd Offset head. A PC based interface controls all the parameters inside the ink train, and adjustments can be automatically performed by the main control panel through automated servo remote controls. The Ink Management System is able to store all the data for the inking process and reproduce them, for job storage purposes in case of repeat jobs or presetting purposes in case of new job. Waste and time during set up is thus greatly reduced, as all the inking parameters are under control, and can be reproduced.
The ink fountains
The keys of the ink fountain are motorized as a standard, and are remote controlled to adjust the ink flow to the image, through the width of the print unit. In case of a new job, automatic presetting of the ink fountain is possible, by in-putting the original data file of the printed job. The keys will be automatically pre-set up based on each separation on each printing plate. The motorised keys of the ink trays are remotely controlled (CIP 3, CIP 4 softwares available on request) and so the inking and dampening functions to ensure low wastage at set-up. The data per job of all the inking functions (ink tray keys and ink/water balance) are stored to ensure minimal waste during set-up of repeat orders and the maximum printing consistency during production.
The fast responding ink flow
The quantity of ink given by the ink train to the substrate is controlled by the proprietary inking parameters developed for the Xpannd Hi-Offset head, which make the ink flow and the ink-water balance adjustments simple to operate, and with a quick response to the printed substrate. This greatly reduces waste during set up, as the action on the ink flow gives immediate responses on the printed substrate. The fast responding ink flow technology developed for the Xpannd™ Offset head is another strategic achievement to reduce costs for the production of short runs on an Offset press.
Automatic Wash-up system
Automatic plates wash-up at every stop and restart of the press to remove the ink in excess and reduce waste during set-up and start/stop operations is provided. Automatic ink train wash-up with washing liquid automatic dispenser is provided. An automatic doctor blade and tray holder washing cycle management for fast and automated ink colour change is also provided.
The press Supervising System
All the press functions are controlled from one single location: video-inspection, ink trays, ink/water balance, multi-process press operation, etc. The PC-controlled Intelligence, using a supervisor licensed by Wonderware®, can be easily connected to any printing company’s Management Information or Execution System (MIS and MES). Job orders, job planning and production data can be exchanged by means of a user-friendly program interface using a touch-screen video and compatible with Microsoft® platforms and Ethernet® protocol.
Easy handling of the Offset print cassettes
Often Offset print units are associated to time consuming and cumbersome operations. The Xpannd print cassette is designed based on a two cylinders cassette concept (plate and blanket cylinders). No print pressure adjustment is needed when changing cassette, neither to break the web. The cassette is light and easy to handle and the change takes only a few minutes. The help offered by Gidue Organizer is strategic in this respect. The Organizer, running along the entire length of the machine, provides a storage facility for the offset cassettes and for all the handling and lifting instruments needed to operate the press. A cart moving along the machine allows the easy replacement of the Offset cassettes. The Organizer promotes a ‘lean’ working environment and the philosophy of the press ‘built around the operator’, avoiding unnecessary movements, heavy and dangerous loads lifting and involving great time savings. The ORGANIZER becomes fundamental for the management of heavier 450 offset cassettes, thus reducing the workload and the time waste for the operator.
Plate mounting
Offset plate mounting on an Xpannd cassette has considerable advantages over Flexo plate mounting. There is no need of cushion tape mounting, neither of manual plate positioning on the tape. The combination of, in a fixed position, clamping bars, and a pin positioning device make plate mounting fast and accurate. Plate diagonal register is possible too directly on the press, without dismounting the plate, by operating on the clamping bars of the print cylinder, to avoid wastes due to incorrect plate mounting.
Access to the Xpannd Offset head
The head is fully accessible on both sides, as it allows front and rear complete man path. All the functions of the Xpannd print unit are accessible and visible, for press operations, inspection and maintenance. The Xpannd Hi-Offset unit is accessible from right for: comfortable rubber roller cleaning, fast offset plate change directly on the machine, access to the printing group automatic wash-up and asier clean-up of the ink tray. It is accessible from left for: inspection and control of the mixing unit and ease of manual web path feeding.
Flexo+Offset combination
The Xpannd Hi-Offset units are combined in line with the full servo Flower™ (no need of adjustments, no performance decay, low maintenance costs) flexo heads now boasting a new design and ensuring a perfect tension and print lenght control. In combination with the tension buffer (available on request), the use of delam/relam and the printing on adhesive up to 2 colours on self-adhesive filmic substrates is now possible.
Xpannd excels in Register capabilities
The Xpannd boasts the revolutionary ‘mark to mark’ Multi-camera Intelligent Register system with cameras (not photo-cells!) positioned on each print unit able to recognize the register pattern. The register is fully automatic at set-up (pre-register) and during production (register); the register verifies the printing pressures; the operation is totally independent from the operator’s abilities. The Xpannd register system ensure exceptional performances on self-adhesive substrates with a tolerance of ± 0,02mm at the highest speeds, on the most subtle colours!
Xpannd extreme converting
The high-end converting equipment of the machine, entirely positioned on rail, includes a new, gearless hot stamping unit, which can be equipped with both standard engraved brass cylinders or magnesium plates, flatbed or rotary embossing, silkscreen and cold foil. The Organizer, GIDUE special storage area in front of the machine, has been extended to include the new hot stamping changeover.
Universal Platform Concept
GIDUE introduces the new Universal Platform Concept, a modular printing station for the rapid and effortless interchange of the Flexo, Hot Stamping, Silkscreen, Gravure and Die-cutting processes for fast adapting of the press to highly dissimilar print runs. The print module of the Universal Platform lies on a slide that, along with the same cart allowing the cassette change of the Xpannd Hi-Offset groups, make the printing unit easily glide out of the press and onto the Platform. This simple movement requires no hard work by the operator who gently extracts the process head from its print position and accompanies it to its final parking location. When the interchange is complete, an efficient plug & play system provides the instantaneous plug-in of the group in the machine, which is immediately ready to print.
