F2 MC

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 to make the job changeovers faster 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 the 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 in the real impression (not based in theoretical calculations but based on real printing) and enhanced with the use of data through Industry 4.0 solutions to have 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 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 & 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 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

More SKU’s diversity and reduced job lengths are punishing the OEE (Overall Equipment Efficiency) of the machines, so we need to look for fast changeover machines with the highest ergonomics.

The F2MC has 8 decks located around a central drum of 1.5m that allow to a small overall machine height, where you only need a two steps ladder when you want to change sleeves in decks 1 or 8, while all other operations are made at floor level.

When the machine is in 10 colors an easy to handle movable platform is supplied to facilitate the sleeve change for the upper decks. 

The plate cylinder and anilox sleeve changeover takes a couple of minutes. The covers are opened manually, in a quick, simple way.

Ergonomics has also been applied to the Doctor blade, with the Genius_Doctoring solutions for the PIPELESS and magnetic doctor chamber.

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 just 12Kg!

And once you have changed the entire doctor blade and you have the machine printing again, then you can clean and change the seals and blades without the need of any tool thanks to our patented magnetic fixation of blades.

More SKU’s diversity doesn’t necessarily mean that jobs are totally different one from the other. Several times only 2 or 3 plates may change while the others remain the same, so given the case of having a 10-color machine it would be possible to change the free stations (if there are) in order to prepare for the next plates, minimizing the time dedicated to the change-over.  When you combine the Genius_Job with the Genius_Flow options to prepare and conditionate the inks for the next job (even if the anilox is not yet changed)  the stop time is minimized even more.

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

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

Genius_Run is the mechatronic combination of the high robust machine 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_Doctoring allows for the minimum pressure between the blades and the anilox that will give you the 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 doctor blade in place but with the minimum pressure, so allowing the doctor blade to move together with the Anilox as they were only one piece

Genius_Flow, excellence with the most efficient inking system

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. It is composed by:

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

The exclusive Asymmetric Pneumatic Pump allows for both pumping ink to and sucking ink from the doctor blade, and is controlled via PLC in order to be possible to adapt the flow rate to the specific working of the machine, so helping to 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 the 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:

• 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.
• 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 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 the ink supply and the ink 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

The drying equipment is made-up of two totally independent circuits, one for intercolor drying and the other for the final tunnel. Each circuit has its own fans for blowing and exhausting and work totally independently one from the other, in order to be possible to optimize the performances depending on the job printed.  It is blowing hot air at high speed to completely evaporate the diluents (solvent or water) contained in the ink and to guarantee no residual diluent in the final product.

First circuit has 7 intercolor drying boxes easy to rotate for maintenance, with an inspection door at the exhaust part of the drying box to be possible to clean from any particle sucked from the material.

Second circuit corresponds to the drying tunnel, which in this machine is 5 m long and with sixteen nozzles that can be easily dismantled without any need of tools for cleaning.

The tunnel is accessible from the upper platform, it includes a specific opening for maintenance and cleaning, a chain for the web threading and belt driven rollers to maintain the web speed without influencing the web tension.

Genius_Dry is the new software to improve the efficiency of the drying system by adapting it 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.

Following the ergonomic design, there is a big upper platform all over the machine where all electronics, fans, heat source, video, etc. are located with easy and convenient accessibility for any maintenance requirement, including an opening to access the CI for cleaning purposes.  This avoids any maintenance work at a height using a ladder, so it is complying to the most demanding safety standards.

Together with the upper platform, you will find several details that highlight this machine as the best solution in terms of maintenance: its easy handling and doctor blade access, filter change, greasing points, decentralized electronic panel, and others.

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