How is plate cylinder refurbishment quality assured in a unit-type flexo press?

A unit-type flexo press is a versatile printing press used in the flexographic printing process. It comprises modular units that can be combined and configured according to specific printing requirements. The press is made up of various components such as a plate cylinder, anilox roller, inking system, and impression cylinder, which work together to transfer ink onto the printing substrate.

Advantages and Features

Versatility

Unit-type flexo presses offer great flexibility and versatility in printing applications, as the modular design allows for easy customization and configuration of the press based on the desired printing process, substrate, and color requirements. This adaptability makes it suitable for a wide range of industries and products.

High Printing Quality

The unit-type flexo press provides precise control over ink transfer, registration, and color consistency, resulting in sharp, vibrant, and high-resolution prints. Flexo presses have made significant advancements in recent years, achieving excellent print quality comparable to other printing methods.

Speed and Efficiency

Unit-type flexo presses are known for their high production speeds. They can handle rapid printing tasks, making them suitable for large-scale printing operations. Additionally, quick setup times and fast changeovers between jobs contribute to improved efficiency and reduced downtime.

Cost-Effectiveness

Flexo printing, including unit-type flexo presses, is generally considered a cost-effective solution for medium to high-volume printing. The presses utilize flexible printing plates, which are more affordable compared to other plate types. Additionally, the ability to print on a wide range of substrates reduces the need for additional printing processes, resulting in cost savings.

Wide Substrate Compatibility

Unit-type flexo presses are compatible with a variety of substrates, including paper, cardboard, films, labels, and flexible packaging materials. This versatility allows for printing on different materials, expanding the range of applications and market opportunities.

Environmentally Friendly

Water-based and UV-curable inks are commonly used, which have lower VOC emissions compared to traditional solvent-based inks. Additionally, advancements in energy-efficient drying systems contribute to sustainability efforts.

Inline Finishing Options

Unit-type flexo presses can be equipped with various inline finishing options, such as laminating, die-cutting, embossing, and varnishing. This eliminates the need for separate post-printing processes, reducing production time and costs.

Continuous Innovation

The flexographic printing industry is continuously evolving, with ongoing advancements in technology, materials, and processes. Unit-type flexo presses benefit from these innovations, allowing printers to stay competitive and meet the changing demands of the market.

Working Principle

The unit-type flexo press works through a series of components:

Plate Cylinder

The press has a plate cylinder with a flexible printing plate attached to it. The plate cylinder holds the image or artwork to be printed.

Inking System

Anilox rollers transfer ink to the plate cylinder. The inking system consists of an ink fountain, doctor blade, and anilox roller. The doctor blade ensures an even layer of ink is applied to the anilox roller, which then transfers the ink to the plate cylinder.

Impression Cylinder

The impression cylinder receives the substrate to be printed. It presses the substrate against the plate cylinder, allowing the ink from the plate to transfer onto the substrate.

Drying System

After the ink is transferred to the substrate, a drying system is employed to evaporate solvents or cure the ink. Drying can be achieved through various methods, such as heated air, UV lamps, or infrared radiation.

Repeatable Units

Unit-type flexo presses are designed with repeatable units, which can be combined to achieve multi-color printing. Each unit consists of a plate cylinder, anilox roller, inking system, and impression cylinder. The units can be adjusted and synchronized to ensure accurate registration and color consistency.

Applications

Unit-type flexo presses are commonly used in the following applications:

  • Flexible Packaging
  • Corrugated Packaging
  • Labels and Tags
  • Folding Cartons
  • Paper Products

How to Choose the Right Unit-Type Flexo Press?

When selecting a unit-type flexo press, the following factors should be considered:

  • Printing Requirements
  • Flexibility and Customization
  • Print Quality and Registration
  • Production Speed and Efficiency
  • Substrate Compatibility
  • Inking and Drying Systems
  • Support and Service
  • Budget and Return on Investment
  • Industry Reputation and Reviews
  • Future Expansion and Upgrades

Possible Issues and Solutions

The following are some common issues that may arise during the use of a unit-type flexo press and their solutions:

Ink Smearing or Blurring

Ensure proper ink viscosity and consistency. Adjust the doctor blade pressure, and verify that the anilox roller is clean. Check for excessive plate wear or damage, and optimize drying parameters to ensure proper ink curing.

Registration Issues

Verify that all mechanical adjustments are properly calibrated, check for worn or damaged gears or cylinders, reset the plate cylinder and substrate tension, align the printing plates accurately, and regularly clean and maintain the registration sensors and control systems.

Installation and Maintenance

Proper installation and regular maintenance are crucial to the smooth operation of a unit-type flexo press.

Installation

Site preparation should ensure adequate space, ventilation, and access for the press installation, along with a level and stable foundation. The necessary utility connections should be installed as per the press specifications, and the press components should be unpacked, assembled, and calibrated according to the manufacturer’s instructions.

Maintenance

Regular cleaning, lubrication, inspection, and replacement of the press components are essential to maintain optimal performance and prevent downtime. Following the manufacturer’s guidelines and using recommended cleaning solutions, lubricants, and spare parts can prolong the life of the press and ensure high print quality.

EVER-POWER

EVER-POWER is a professional manufacturer of flexo presses. Based on the transformation and application of aerospace optoelectronic technology, they rely on precision machining and manufacturing capabilities to develop printing and packaging equipment, precision coating equipment, and special electromechanical equipment. Their core technology group includes tension system coupling modeling and decoupling control technology, equipment intelligent control technology, precision coating composite technology, high-speed high-definition printing technology, coating curing and solvent residue control technology, and multi-material adaptive winding technology.

They have obtained over 239 national patents and more than 10 national high-tech achievement awards, and have obtained ISO9001:2015 international quality system certification, SGS certification, and EU CE safety certification. Their complete after-sales service system ensures customer satisfaction.

EVER-POWER’s products are comparable to other brands in terms of quality and cost-effectiveness, making them a wise choice for customers looking for reliable and efficient flexo presses. We strongly encourage our customers to explore and purchase EVER-POWER’s products to improve their printing capabilities and increase their ROI.


Questions and Answers

  1. What is a unit-type flexo press?
  2. A unit-type flexo press is a printing press used in the flexographic printing process, designed with modular units that can be combined and configured according to specific printing requirements.

  3. What are the advantages of a unit-type flexo press?
  4. The advantages of a unit-type flexo press include versatility, high printing quality, speed and efficiency, cost-effectiveness, wide substrate compatibility, inline finishing options, and continuous innovation.

  5. What are the common issues that may arise during the use of a unit-type flexo press?
  6. The common issues that may arise during the use of a unit-type flexo press include ink smearing or blurring and registration issues.

  7. How can ink smearing or blurring be prevented?
  8. Ink smearing or blurring can be prevented by ensuring proper ink viscosity and consistency, adjusting the doctor blade pressure, verifying that the anilox roller is clean, checking for excessive plate wear or damage, and optimizing drying parameters to ensure proper ink curing.

  9. What factors should be considered when selecting a unit-type flexo press?
  10. The factors that should be considered when selecting a unit-type flexo press include printing requirements, flexibility and customization, print quality and registration, production speed and efficiency, substrate compatibility, inking and drying systems, support and service, budget and return on investment, industry reputation and reviews, and future expansion and upgrades.