Genius_Tronic is an anthropomorphic robot for changing any sleeve (direct printing sleeves, intermediate sleeves or anilox sleeves) in an automatic way without any intervention of the operators, no matter if they are heavy or not, no matter if we want to change the unused decks while others are printing, no matter the number of colors, Genius_Tronic will make the job in the fastest and more efficient possible way.

Genius_Tronic is a game changer when we talk about job changeover time and when talking about machine productivity and uptime.

Genius_Tronic will increase your productivity up to 40% on average, when you compare with the traditional solutions of having a trolley and platforms when changing sleeves

High quality printing goes together with minimum dot gain, in order to obtain minimum dot gain you must have minimum pressure between the blades and the anilox.

Genius_Doctoring is the solution of the pipeless doctor blade made in two parts to allow a full change of the doctor blade chamber (no more cleaning and changing blades onto the machine while the machine is stopped), in less than 1 minute without disassembling pipes and with a minimum weighing chamber.

Genius_Doctoring is a very stable, rigid and precise system:

• A solid and robust bar with a flat surface where the doctor blade stands
• Forward-backward movement over linear guides
• Low friction pistons that keep the doctor blade in place but with the minimum pressure, so allowing the doctor blade to move together with the anilox as they were single piece

The highest printing quality requires a robust and stable machine with the latest developments in materials and software tools. With Genius_Tech we have a full range of mechatronic approaches for the main flexo challenges related to printing quality: 

• Minimum and stable dot gain
• No bouncing effects
• Perfect intercolor registration

Genius_Run is the mechatronic combination of the high robust frames with the monoblock concept, mandrels with an extensive use of carbon fiber, bearing supports with preloaded linear guides and ball screws, and all together with an intelligent software that understands the printing and adapts the response of the motors to the printing conditions.

 Genius_Drive is our patented technology of the Virtual Master together with its exclusive and also patented Direct Encoder (Encoder directly fitted on the shaft instead than rear the motor) that allows us to offer the highest longitudinal register tolerance of the market, with a value as good as ±25µ 

Genius_Print is our best-in-class system due to its high adjusting precision, both for pressure, where we can assure a maximum overpressure between 20µ to 70µ, and for register (based in the PDF and so in the whole printing) with a deviation <50µ

• Totally automatic system (operator only has to push a button) without dedicated marks
• Printing and register adjustment based on the 100% of the print
• Register adjustment through the comparison against the digital file (PDF) used to create the plates
• Average waste around 150m depending on repeat, number of colors and machine model

As the Genius_Print is using the 100% inspection camera from AVT, when having it we have also the 100% inspection and quality assurance of the printing results.

Genius_Dot is our automatic impression and register system for optimal combination of waste and quality.

• Pressure and register adjustment based on a 1.5mm dot that appears at the end as a black dot
• Average waste around 120m depending on repeat and machine model

As the Genius_Dot is using the matrix camera from AVT, when having it we can easily upgrade (just software) to add the statistic inspection and quality assurance of the printing results

Genius_Set is our automatic impression system for minimal waste.

• Pressure adjustment based on detecting the kiss point between substrate/plate/anilox by means of the torque of the motors
• Average waste around 70m depending on the repeat and machine model

As Genius_Set is only for pressure adjustment, it is perfectly complemented with the Genius_Reg to make the register adjustment

Genius_Reg is our register system where the operator locates manually a characteristic area of every color at the same place (drag&drop) on the video touch screen

• It does not need any specific mark, but specific marks (dots, microdots, register cross...) can also be used
• Average waste around 30m as once the characteristic area has been selected and zoomed the process can be finished with the machine stopped

As Genius_Reg is only for register adjustment, it is perfectly complemented with the Genius_Set to make the pressure adjustment.

Genius_Color provides the necessary tools to minimize waste and time required to achieve color match. When the job is already in the machine, and you are not able to find the right color, these tools will help you to calculate and prepare the quantity and composition of the ink that must be added to each color so you can match your samples with the required ∆E.

Genius_Flow is the system that manages the ink supply to the print, and cleans the ink chamber, the anilox, ink tanks and connection hoses in the circuit. This is a compact inking and cleaning system focused in minimizing the solvent consumption while enhancing the cleaning results.

There are different versions of the Genius_Flow, and multiple options to adapt to any specific need:

• Stainless steel execution for Water-Based inks or EB inks
• Ink cooling or heating with or without external chiller integration
• Clean and dirty solvent tanks that can be connected to an external distillatory
• Ink viscosity and/or temperature adjustment without need to have neither the anilox nor the chamber installed

Genius_Flow

• Pneumatic Inking system that features both the inking for printing as well as the cleaning of the system itself, the ink hoses, doctor blades and anilox sleeves.  
• The system is based on having an asymmetric pneumatic ink pump for each deck that enables both the ink supply and the ink return to the ink bucket and a manual valve with two positions (fill/empty) that allows reversing the circulation in the circuit to remove the ink from the chambers back to the ink buckets. 
• System is valid either for Solvent or Water-Based Inks

Genius_Flow Prime

• Pneumatic Inking system that features both the inking for printing as well as the cleaning of the system itself, the ink hoses, doctor blades and anilox sleeves. 
• The system is based on having an asymmetric pneumatic ink pump for each deck that enables both the ink supply and the ink return to the ink bucket and pneumatic valves that allow reversing the circulation in the circuit to remove the ink from the chambers back to the ink buckets

Genius_Dry is a mechatronic solution to improve the efficiency of the drying system. It combines new intercolor & tunnel nozzles, with a software that adapts the system to the real job requirements. Genius_Dry has 3 working modes LO-MI-HI depending on job characteristics in order to optimize energy consumption, air flow to exhaust and solvent concentration.  The different working modes adapt the flow rate by changing the fan speed and recirculation valve opening.

Genius_Job is the option for 10 color machines to make job changeovers while the machine is in production for those units that are not used. It combines perfectly with the Genius_Flow option to prepare and conditionate the inks for the next job even if the anilox or the doctor blades are not yet in place.

Genius_Touch is the new HMI with intuitive and easy to use touch screens from where you can do any operation for the machine, and where you will find all data and the connection to Comexi Cloud. There are different touch screens in the machine, you can find the main one in the operator desk, but also there are in the unwinder and rewinder and in the inking system.

Genius_Touch is the interface, but when we want to manage any data of the machine either if it is a data related to a job or if it is a data related to the use of sleeves, blades, inks, or whatever you may require, then we go through our Genius_Data which is a powerful SQL database where everything is stored. 

Functionalities of Genius_Data are among others:

• Data base of all printing and anilox sleeves
• Data base of all parameters of current job, and also historical data of all jobs
• Production control for current job and historical data of all jobs
• Within the production control it determines the status of the machine (job change – adjustment – production) automatically
• Possibility to have a detailed report of the current job or between dates report of production (only as a pdf file)
• Connectivity to Comexi Cloud to extract the values and connect to customers ERP systems

Genius_Ink gives the information related to the amount of ink and solvents used to run a specific job. This information is obtained by placing a scale under each inking pot, with flowmeters in the viscosity and cleaning lines, along with a specific software that makes all related calculations.

Genius_Energy gives the information related to the energy used to run a specific job. This information is obtained by adding required measurement devices (flowmeters, temperature sensors…) for the different energies required, and with a specific software that makes all related calculations.

Genius_Cost gives the information related to the cost associated to a specific order. This information is obtained from the machine when the machine is equipped with the respective Genius_Ink and Genius_Energy, together with the other information provided from the machine to the Cloud (material, meters, number of colors…)

This module is Cloud based, so it requires internet connection and a valid Cloud license.