F1

More SKU’s diversity and reduced job lengths are punishing machine OEE (Overall Equipment Efficiency), so we need to look for alternatives that increase machine uptime.

• Increasing job lengths by printing multiple sku’s
• Reducing change-over time

Printing multiple SKU’s lead to wider machines and so heavier and more difficult to operate sleeves, today’s health and safety regulations are punishing the manipulation of big sleeves (which has always been a problem for big repeat sleeves), so the way to go is one step ahead in automation that permit to making job change-overs faster and without the operator’s intervention.

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

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

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.

Changing sleeves is not the only operation in the job change-over, it is the most important and it is carried out in every job change, but we still need to change the doctor blades from time to time. In the F1, like in the F1 cars, you can make a Pit-stop change of the doctor blade thanks to our Genius_Doctoring solution of the PIPELESS doctor blade in two parts that allow to make a full change of the doctor blade chamber (no more cleaning and changing blades onto the machine with machine stopped) in less than 1 minute without disassembling any pipe and with a chamber weighting around 15Kg.

This is combined with the Doctor blade platforms located in front part of the decks where you will have the spare chambers already prepared and from where you will make the change without having to climb any steps, even if you are in deck 10.

The highest printing quality requires a robust & 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” printing and adapts the response of the motors to the printing conditions. 

All mandrels are made in carbon fiber, with the highest possible diameter to help minimize bending, and with hydraulic fixation of the intermediate sleeves (also made in UHM carbon fiber) to maximize the rigidity of all the elements that are primarily absorbing vibrations.

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 of at the rear of the motor) that allows us to offer the highest longitudinal register tolerance in the market, with a value as good as ±25µ

Genius_Doctoring allows for the minimum pressure between the blades and the anilox that will give you minimum and more stable dot gain.

• A solid and robust bar with a flat surface where the doctor blade stands
• 3D-verified doctor blades with the highest precision
• Forward-backward movement over linear guides with Low friction pistons to keep the doctor blade in place but with the minimum pressure, therefore allowing the doctor blade to move together with the Anilox as they were a single piece

Automatic Set up systems to have the best quality job adjustment

More SKU’s diversity, reduced job lengths and lack of skilled operators lead to the need to make machines with a high level of automation that permit making faster job change-overs and adjust the next job with the highest possible quality and without the need of an expert printer. 

In this scenario, we have a full range of Genius_Tech solutions to improve the quality of the job set-up while reducing both time and waste, and more important, without being dependent on the skill of the operators.

All our pressure and register set-up systems are automatic, based on real print (not based on theoretical calculations that in at the end depend on machine calibration, but are based on visualization of the real printing) and enhanced with the use of “big data” through Industry 4.0 solutions, which allow for the best quality (minimum overpressure) and minimum waste.

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 100% AVT camera inspection, when using it we take advantage of also having 100% inspection and quality assurance systems with a first level brand.

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

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

As the Genius_Dot is using the AVT matrix camera, we can easily upgrade (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 manually locates a specific area of every colour in  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 pressure adjustments

Genius_Flow, excellence with the most efficient inking system

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

• Only one asymmetric pump (Pneumatic) or two electric pumps (electric)
• Reduced pipe lengths
• Pressurized pulse dampener
• Integrated Vibration viscosimeters (in-line)

The exclusive Asymmetric Pneumatic Pump allows for both pumping and sucking ink to and from the doctor blade, It is controlled via PLC in order to adapt the flow rate to the specific running needs of the machine, therefore helping save compressed air and increasing the life of the membranes.

Genius_Flow is built into the actual machine frame. Its ergonomic arrangement provides for easy operator access and facilitates maintenance tasks for all elements.

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 Prime

• Pneumatic Inking system 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 ink supply and ink to return to the ink bucket and pneumatic valves that allow reversing the circulation in the circuit to remove remaining ink from the chambers back to the ink buckets.
• System is operated from 2 touch panels located in the CI covers, in the vicinity of the pumps and the decks, with visual control of both.
• The touch panels it can be set and you can control any parameter of the inking system, not just pumping, but also viscosities, temperatures, maintenance control (life time of the membranes), …
• There are 3 pre-set cleaning programs to optimize the time and waste for cleaning, depending on the color change needs.
• It can be connected to 2 tanks of 400l each (optional), one for clean solvent and one for dirty solvent.
• System as std is valid  only for Solvent Based Inks, there is the option for Water Based inks as well

Genius_Flow Electric

• 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 2 electric ink pumps for each deck that enable both ink supply and the ink to return to the ink bucket and which are controlled by drivers.
• System is operated from 2 touch panels located in the CI covers, in the vicinity of the pumps and the decks, with visual control of both.
• From the touch panels it can be set and controlled any parameter of the inking system, not just pumping, but also viscosities, temperatures, maintenance control (life time of the pumps) ...
• There are 3 pre-set cleaning programs to optimize the time and waste for cleaning depending on the color change needs.
• It can be connected to 2 tanks of 400l each (optional), one for clean solvent and one for dirty solvent.
• System is only valid for Solvent Based Inks, there is no option for Water Based Inks

Genius_Touch is the new HMI with intuitive and easy to use touch screens from where you can carry out any machine operation, and where you will find all data and the connection to Comexi Cloud. There machine has different touch screens, you can find the main one on the operator’s desk, but there are also 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 can 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