Tech Watch

Eagle Systems’ Golden Eagle Package (Cold Foil and Cast and Cure)

December 10, 2024

By Jeff Peterson, editor-in-chief, PostPress

Eagle Systems has introduced a ‘game changer’ for the industry with the recent installation of its Eagle Systems’ Golden Eagle Package, which includes two separate Eagle units on one offset printing press.

The new installation, which took place at Carlson Print Group, Eden Prairie, Minnesota, includes a Cold Foil unit at thesecond tower of an 8-color Koenig & Bauer 106 with a double coater and a second separate Eagle Casting unit on a final station of the press to apply Cast and Cure™. This allows Carlson to apply cold foil, 4-color lithography plus PMS and Cast and Cure all in one smooth pass at full press speeds.

Pictured: Mike King, president of Eagle Systems, and Darren Carlson, president of Carlson Print Group

“When you can apply both processes inline, you can create a piece that really pops without handling it through multiple passes,” stated Carlson Print Group President Darren Carlson. “That ability increases throughput, decreases costs and protects the piece from being handled multiple times.”

The Golden Eagle Packages are fully networked machines, allowing inter-communications for various functions within both Eagle units. With this system, it constantly can monitor all the functions, and any alerts immediately are sent back to Eagle Systems. In the case of the two units installed at Carlson, both Golden Eagles have cameras on their network, with presets allowing constant monitoring at the delivery for both machines. In addition, each unit has a Human-Machine Interface (HMI) for normal operational functions such as run, jog and reset, eliminating mechanical switches and buttons.

The Eagle unit does not have separate tension controls because it maintains tensions and speed through its multi-tasking environment and the proprietary algorithms needed to smoothly run. The consistent tension on the Eagle System units also provides less foil dust around the printing press. Excessive foil dust can cause problems on-press and with the printing process. So, having proper tension eliminates foil dust problems.

Eagle also offers its foil sync technology for cold foil, utilizing air shafts so the foil floats and helps eliminate damage to the foil. Cold foil can be fragile, especially with narrow webs. This technology for indexing can allow narrower webs to be used vs. a large foil roll and can save a significant amount of foil costs, depending on the final layout of the sheet.

“With our foil sync technology, it is not necessary to always use a large foil roll that is installed across the entire press sheet to apply cold foil inline on the offset press,” commented Mike King, Eagle Systems’ president. “If the layout allows, our Eagle units can run several smaller webs, potentially saving the customer thousands of dollars in foil costs – down to 2-inch-width rolls and any combination up to eight webs to the full width of the printing press abilities.”

Lastly, Eagle units run on an “eco platform,” which means both units use minimal power to run. The unwind is driven a slight percentage less than the press blanket speed. The slightest of tension creates a pulling effect constantly on the unwind, which then generates enough power to almost run the rewind. The faster the press runs, the less power is drawn with the internal generated power from unwind to rewind. The savings can be significant and create a more sustainable process.

Carlson Print Group made the decision to install the double Eagle unit on its newest offset press to take advantage of the greatest efficiencies when applications call for cold foil, printing and Cast and Cure. Applications include packaging, posters, comic book covers and trading cards that use embellishments to add even more collectability.

“Currently, we are working on R&D with the combined foil and Cast and Cure in areas of security/fraud prevention for companies,” stated Carlson. “This is an area that lots of companies struggle with that needs a solution that is not easy to copy but is easy to recognize, without specialized equipment in the field.”

The new Eagle units on the Koenig & Bauer 106 have opened all types of opportunities to add embellishments for Carlson Print Group and provide a unique competitive advantage.

“The opportunities allow us to apply different embellishments/tactile coatings all in one pass,” concluded Rod Franson, Carlson Print Group’s technical sales manager. “This has created a higher quality, finished product and improved efficiencies at a more competitive price.”

Tech Watch: Scodix SHD and ART

April 9, 2024

Edited by Erin La Row, editor, PostPress

Scodix Inc., with US headquarters in Saddle Brook, New Jersey, has released two technological breakthroughs for digital embellishments that offer finer detail and a wider range of usable substrates: Scodix Smart High Definition (SHD) and Scodix Anti-Static
Reflective & Transparent (ART).

Scodix SHD
Scodix SHD gives users the ability to achieve quality and detail that rivals conventional foil stamping and can be applied underneath lamination.

“Scodix SHD tops off our offerings, giving customers more effects in a single platform than any competing technology on the market today,” said Paul Furse, director of channel sales, Americas. The ‘Smart’ in Smart High Definition utilizes a unique artificial intelligence to identify fine lines and edges of objects to both reduce polymer consumption as well as produce the same flawless appearance as could be expected from analog methods. Furse said what this means for customers is finer detail at a lower cost.

Scodix ART
Scodix ART expands the gamut of usable substrates by opening up synthetics and thick laminates (anti-static); reflectives, such as foil board, metallic laminates or substrates that already are metalized in some way; and synthetic transparent (clear) medias.

“With Scodix ART, customers can utilize Scodix embellishment technologies as they would any other substrates in the production process when using medias that would be exceptionally laborious to impossible with other digital embellishment technologies or conventional stamping methods,” Furse said.

Overcoming challenges
Because of the heat, pressure and overall process of conventional analog stamping technologies, Furse said it is exceptionally challenging to hot foil stamp both small text or
thin lines as well as large surface areas in a single run.

“With digital embellishment technologies, this has been virtually impossible, requiring multiple passes as well as additional polymer and foil usage to ‘balance’ the sheet, with hours of set-up to even attempt it. Scodix SHD uniquely offers the ability to do fine lines and large solids both in a single pass on both B1 & B2+ sheets, at a lower cost than historical digital embellishments,” he added.

Scodix SHD produces high-margin work in print economically, productively and sustainably through minimal polymer usage, no dies, plates or screens and with significantly reduced set-up and run times. Working with plastics and PVCs is challenging, and working with transparencies can be even more challenging. Adding conventional embellishments to metalized surfaces is common but challenging for digital systems because of reflectivity back into optical sensors, cameras or scanners.

“Scodix has developed a unique sensor system that, when combined with our existing encoder and registration technologies, can achieve the same industry-leading registration accuracy our customers trust and respect on these challenging materials,” Furse said. “This
opens the gamut of usable substrates in the digital process. It’s a big win for our customers and for the industry as a whole.”

Both Scodix SHD and Scodix ART are available with new Scodix Ultra presses, and Furse said there are options for legacy customers to upgrade older presses.

Customer response
According to Furse, Scodix ART officially launched in January 2024, and customers already utilizing this technology have shown that productivity of what were challenging medias has skyrocketed. Plastics and metalized substrates now are being run like any other conventional media in the production process.

Furse said that all Scodix 6000s, the company’s flagship B1 press, sold in the past 12 months have been purchased with Scodix SHD, and many companies have upgraded to the
technology. Additionally, part of the technology behind Scodix SHD is a newly developed polymer that replaces three historically used Scodix polymers.

“For our most versatile customers, we’ve eliminated what may have been three changeovers, once again leading to even higher productivity, higher sustainability and lower economics,” Furse said

Scodix SHD and ART

March 18, 2024

Edited by Erin La Row, editor, PostPress

Scodix SHD

Scodix SHD gives users the ability to achieve quality and detail that rivals conventional foil stamping and can be applied underneath lamination.

Scodix ART

Scodix ART expands the gamut of usable substrates by opening up synthetics and thick laminates (anti-static); reflectives, such as foil board, metallic laminates or substrates that already are metalized in some way; and synthetic transparent (clear) medias.
“With Scodix ART, customers can utilize Scodix embellishment technologies as they would any other substrates in the production process when using medias that would be exceptionally laborious to impossible with other digital embellishment technologies or conventional stamping methods,” Furse said.

Overcoming challenges

Because of the heat, pressure and overall process of conventional analog stamping technologies, Furse said it is exceptionally challenging to hot foil stamp both small text or thin lines as well as large surface areas in a single run.

Scodix SHD produces high-margin work in print economically, productively and sustainably through minimal polymer usage, no dies, plates or screens and with significantly reduced set-up and run times.

Working with plastics and PVCs is challenging, and working with transparencies can be even more challenging. Adding conventional embellishments to metalized surfaces is common but challenging for digital systems because of reflectivity back into optical sensors, cameras or scanners.

“Scodix has developed a unique sensor system that, when combined with our existing encoder and registration technologies, can achieve the same industry-leading registration accuracy our customers trust and respect on these challenging materials,” Furse said. “This opens the gamut of usable substrates in the digital process. It’s a big win for our customers and for the industry as a whole.”

Both Scodix SHD and Scodix ART are available with new Scodix Ultra presses, and Furse said there are options for legacy customers to upgrade older presses.

Customer response

According to Furse, Scodix ART officially launched in January 2024, and customers already utilizing this technology have shown that productivity of what were challenging medias has skyrocketed. Plastics and metalized substrates now are being run like any other conventional media in the production process.

Furse said that all Scodix 6000s, the company’s flagship B1 press, sold in the past 12 months have been purchased with Scodix SHD, and many companies have upgraded to the technology. Additionally, part of the technology behind Scodix SHD is a newly developed polymer that replaces three historically used Scodix polymers.

“For our most versatile customers, we’ve eliminated what may have been three changeovers, once again leading to even higher productivity, higher sustainability and lower economics,” Furse said.

THERM-O-TYPE NSF Excel Mark II

December 11, 2023

Edited by Erin La Row, editor, PostPress

Requirements for foil stamping, embossing and diecutting equipment using metal dies have changed over the past few years. Productivity, automation, ergonomics and safety issues are compelling many plants to replace outdated equipment.

The NSF Excel Mark II, offered by THERM-O-TYPE, located in Nokomis, Florida, has been specifically designed to meet the latest industry requirements.

“The THERM-O-TYPE NSF Excel is the result of over 36 years of experience designing and manufacturing high-speed production foil stamping, embossing and diecutting presses in our plant in Florida,” said Chris Van Pelt, president at THERM-O-TYPE.

Typical Excel applications include packaging, greeting cards, business cards, stationery, invitations and announcements, embossing braille and commercial letterpress work, as well as diecutting and enhancing digital output.

The Excel can run up to 5,500 impressions per hour, far exceeding the running speed of older platen presses. “While printing plants across the country struggle with staffing shortages, the requirement for higher levels of productivity is critical,” Van Pelt said.
The Excel uses a full-color touchscreen, interfaced to a Windows computer control, to simplify and automate the press. Touchscreen controls are intuitive and easy to use. Sensors monitor and automatically react to double- or skip-feed conditions, paper jams, low air pressure or lubrication. Auto job set-up and paper jam detect/interrupt functions are provided.

Set-up information can be stored and recalled for up to 500 programs. Stored information includes paper registration, foil draw, paper jam sensors, die temperature, running speed and impression pressure settings. While this level of automation is helpful in day-to-day operation, it especially is important when the equipment is being run by less skilled operators during peak production periods.

The Excel design is ergonomically efficient. Paper loading height, the position of machine controls and adjustments, mounting foil rolls, accessing the chase and makeready plates, and product delivery all are designed to enhance productivity and safety while minimizing operator workload and stress.

The Excel is equipped with dual foil-support shafts, dual programmable foil draws and four waste-foil rewinds. To minimize foil waste, embedded software simplifies pattern-repeat foil-draw set-up. Up to 7″ diameter foil rolls can be used, and draw length can be adjusted while the press is running.

The Excel meets internationally recognized safety standards and currently is certified by TUV. Safety certification is an important issue with plants today, and most legacy foil stamping, embossing and diecutting presses do not meet current safety standards.
Up to eight impression positions can be programmed along the length of the sheet. When foil stamping, embossing or diecutting small-quantity orders, printed multiple-up, a smaller (less expensive) die can be used, with a simplified (faster) set-up. This capability especially is popular with customers who are diecutting and scoring small boxes.

For customers who focus on diecutting, the Excel can be equipped with an optional, inline waste stripping attachment.

“The ability to diecut and inline strip finished products dramatically reduces operator workload while increasing productivity,” Van Pelt said.

Additional technical details
The NSF Excel Mark II has a 3-horsepower main drive motor. It handles a maximum paper width of 18.5″ and length of 20.5″. The maximum image area is 12.125 x 17.625″ with a maximum impression pressure of 20 tons.

Sakurai Introduces the ScreenFoil™ LQM Series Inline Hot Foil Stampers

September 10, 2020

Edited by Lara Copeland, contributing editor, PostPress

Sakurai, a global leader in sheet-fed screen printing technology located in Schaumburg, Illinois, has launched the ScreenFoil™ LQM Evolution series, a cost-effective solution for inline hot foil stamping. Now available in two sizes, the new LQM 105 accepts sheet sizes up to 41 ½ x 30″, and the new LQM 76 accepts sheet sizes up to 23 ½ x 21 ½”.

“Sakurai is very pleased to introduce the new ScreenFoil™ hot foil stamper series to the North American market,” said David Rose, vice president, Sakurai USA, Inc. “The redesigned, full-featured LQM series offers our customers the ability to increase profits with an in-house solution for hot foil finishing.”

The new LQM 105 Evolution series was introduced at the Sakurai Graphic Systems Corporation Factory Open House in Gifu, Japan, last April and was scheduled to make its North American debut, running live, inline with a Maestro MS-102AX screen press, Natgraph dryer and stacker – at Sakurai USA’s exhibit at Printing United in Atlanta in October. Sakurai’s screen press line, as described, allows the operator to screen print, dry, screen foil and stack in a single pass.

The LQM Evolution is able to precisely apply foil in a variety of area sizes – as small as 10 mm or as large as the whole substrate length and in narrow bands or across the whole width of the substrate. The precision provided by these two functions ensures the minimum of foil waste.

The ScreenFoil™ LQM 105 brings a new level of flexibility, quality and performance when combined with any size or vintage Sakurai screen press. It is perfect for PSP, folders, leaflets, business cards, loyalty cards, magazines, book covers, packaging, promotional items, labels, roll-to-roll, greeting card, automotive, appliance and plastic card applications.

The LQM series has many new features to increase productivity. An alignment conveyor transports sheets. After the UV varnish is cured, the sheet is transferred to the foil unit via infeed rollers and automatically is registered by a lateral side registration bar. The machine automatically locates the front edge of the sheet and begins applying foil based on the job parameters. When the job does not require foil, a bypass function allows the sheet to pass through at the same speed as the press, acting as a transport mechanism. Additionally, the job-setting parameters for foiling easily are entered, edited and stored via a user-friendly touchscreen panel. It can be retrieved by the operator at any time, allowing repeat jobs to be set up instantly.

“The use of the screen printing press to deposit the image in registration allows the heated foil to be applied in any size or image configuration. No dies – just print the image you want foiled, UV cure and then pass through the foil applicator. Fine line, 3D coverage foil now is controlled by the screen press,” Rose added. “If you are looking for greater use of your Sakurai or other existing screen press, add foil to your list of services to the graphic arts industry.”

Sakurai new and used presses, LQM hot foil stampers and Natgraph dryers are distributed in the US, Canada, Mexico and Central and South America by Sakurai USA, backed by responsive customer support, service, replacement parts and training.

Technical details

Both the LQM 76 and LQM 105 have a maximum speed of 30m/pm during the foil application process. The bypass speed with no foil is 55m/pm for the LQM 76 and 65m/pm for the LQM 105. The internal core diameter is 3″ for both sizes.

Eagle Systems’ Cold Foil Module

March 10, 2020

by Lara Copeland, contributing editor, PostPress

Nearly all types of lithographic printing presses, six towers or greater, can be adapted to include a cold foil module and realize the effects that can be achieved with cold foil and 4-color overprinting in one pass. The Eagle Cold Foil Module from Eagle Systems, Ocean, New Jersey, can be retrofitted to almost any new or existing offset press without altering or interfering with the functions or electronics of the existing press.

With more than 40 years of experience with foil machinery and process, Eagle Systems always has strived to improve upon its machinery and add technological developments to its Eagle products – specifically engineering highly productive equipment to meet the need of the printing industry and the needs of the environment. Recently, Eagle Systems has added new and exciting features for cold foiling with the introduction of its Eagle Low Profile (LP), Eagle High Volume (HV) and the new Eagle Foil Sync.

The multitude of new features on these Eagle cold foil units offer several advantages for users. Eagle LP is perfect for companies that do not have the appropriate ceiling height in their production areas to accommodate the cold foiling unit and crane. The LP unit can offer the same cold foiling technology with the ability to be installed and fit into much less space and height.

Eagle Systems also has introduced the Eagle HV, which offers fewer foil changes to companies that have extremely high-volume runs with the ability to hold foil rolls as large as 32,000 meters. Newly installed units also include the Non-Telescoping System (NTS) that helps simplify the winding and rewinding of the foil on the cold foil unit.

The third introduction from Eagle Systems – Eagle Foil Sync – is added to its cold foil modules when the area that is to be foiled is in a smaller, specific spot on the sheet. This new feature allows one web of foil to be used several times by syncing the position where the foil is applied in each run, which can result in major foil savings. Finally, the Eagle Cold Foil Modules now include the new Eagle Information Center (NEIC) that is totally informational and mounted near the delivery of the machine.

All the features above save time, money and create less downtime, which can translate into a greater return on investment. The new internal features of the Eagle make it easier for set-up and allow for less operator involvement. This provides more time to work on the printing process instead of cold foil concerns. Furthermore, the new NTS feature is either on or off and is no longer adjustable, so the operator is either using it or not, providing less for the operator to be concerned with when moving from a cold foil job back to a printing job. In addition to being an information center, the NEIC includes a video feed and an error/error history screen for press operators.

The goal for these new additions to the Eagle Systems Cold Foil Module is to create a unit that is easy to set up and run. Many of the changes and additions come about by listening to press operators and applying those suggestions. Eagle Systems’ Cold Foil Modules will be on display at drupa on stand 16C16, June 16 to 26, Dusseldorf, Germany.

Brausse Group’s 1050SFi Foil Stamper and Diecutter

June 12, 2019

by Lara Copeland, contributing editor
PostPress

Brausse Group, a member of the Bobst Group since 2012 and headquartered in Vancouver, Canada, provides machinery that now incorporates proven group technology, delivering an excellent product at an affordable price. With over 30 years of experience in design and manufacturing of its diecutting and folder-gluer machines, the company’s Brausse 1050SFi foil stamper and diecutter comes with a number of high-end features.

“With Brausse being a member of Bobst Group, proven group technology and existing technology in electronics engineering and functionality can be seen throughout the press,” said Matthew Sharp director of sales and marketing at Brausse Group North America. The foil stamping and diecutting controls are easy to use on the computer’s touchscreen, and “with our Advanced Foil Control System (AFCS), which provides reliable and precise foil-advancing controls, the operators can make any adjustments during operation,” he added. The press includes a pneumatic, push-button die chase locking mechanism to ensure safe and operator-friendly die changing, which eliminates the use of a wrench to remove the chase. A slanted feed table allows for stable and accurate registration, especially for lightweight paper at high speeds. The sheet stretching air blower included in the delivery section lets the operator add air as needed to help the sheets to lay flat. “This helps during fast speeds,” Sharp commented.

The 1050SFi assists operators in reducing downtime during runs. “This piece of equipment allows the operator to make a number of important changes to the machine while it still is running, which helps reduce downtime,” Sharp said. Additionally, with both an automatic feeder and delivery section, the press does not have to stop when adding more material or removing finished product.

More updated components of the machine make the 1050SFi something operators can use with ease, resulting in efficiency. A redesigned platen offers a more leveled impression to reduce makeready time, while a precision ground 15 mm-thickness insulation plate located behind the heating base optimizes heating efficiency and maintains constant temperature. A sandwich plate with micro-adjustment in both running and cross direction allows for quick set-up and facilitates effortless makeready. The push and pull side lays (OS and OOS0 with photo sensor sheet arrival control) are easy to use as well. A self-diagnostic touchscreen detects the location of an alert and provides information on how to repair or clear an error. The pneumatic one-push, button-activated safety doors are operator-friendly. Finally, the machine comes equipped with a tape inserter that has a counter which allows the operator to pre-set and insert a piece of paper tape to mark the load.

“We are extremely happy with the 1050SFi,” Sharp exclaimed. “By utilizing proven group technology, we have brought a very advanced press to the market at a very reasonable price point.” In fact, customers already are responding positively to the new technology. Sharp said that due to the price point of the press and all the improved features, “the response has been fantastic.” Operators also are pleased.

Technical Details

The Brausse 1050SFi foil stamper and diecutter features a max speed of 7,500 sheets per hour. The machine also offers 300 tons maximum cutting pressure. Folding carton stock range is 90g/m2 to 600g/m2. Corrugated stock range is maximum 4 mm
(B Flute).

THERM-O-TYPE’s Glue-Tech SA-1420

March 11, 2019

by Katy Ibsen, editor, PostPress, and Chris Van Pelt, THERM-O-TYPE

THERM-O-TYPE Corp., Nokomis, Florida, introduced the Glue-Tech model SA-1420 sheet-to-sheet gluing machine at PRINT 18 last fall. Glue-Tech provides a unique alternative for printers producing thick printed products with cohesive papers or manual gluing.

Most digital printers can only print on sheets up to 18pt thick. This makes production of products thicker than 18pt – such as premium business cards, announcements or reinforced end sheets – impossible using a single sheet. In addition, some products require multiple layers, not necessarily to increase product thickness, but to encase RFID chips/antennas or to enhance the product by inserting a colored layer between exterior sheets.

Traditionally, options have included cohesive paper or manual gluing; however, both come with limitations. Cohesive papers are effective, but expensive – often costing four to five times the price of non-cohesive sheets – and are only available in very limited sheet sizes, thicknesses, colors and finishes. Manual gluing uses relatively inexpensive equipment and materials while offering flexibility regarding sheet sizes, thicknesses, colors and finishes, but is a very slow and labor-intensive process during operation and clean up.

Using affordable, water-soluble, cold glues, Glue-Tech can bond a wide range of materials including papers, chipboard, magnetic sheets, micro flute board and some synthetics at speeds up to 1,500 glued sheets per hour using a single operator.

Glue-Tech uses an offset press-style suction feeder, with double sheet detect/interrupt, to feed bottom sheets onto an alignment table. After sheets are accurately aligned to an adjustable side guide, they are fed into a pair of pinch rollers that advance the bottom sheet through the glue application section of the machine. A sensor-activated pump automatically maintains the glue reservoir level and the quantity of glue applied to the bottom sheet can be accurately adjusted and controlled.

After glue has been applied to the top surface of the bottom sheet, the sheet is advanced to a headstop. The operator hand feeds the top sheets into a feed tray, with each sheet aligned to the headstop and side guide.

When sensors confirm the correct top and bottom sheet positions, the sheets are gripped and advanced through a pair of squeeze rollers to remove any air pockets and to evenly distribute the glue between the sheets. If the top and bottom sheets are not positioned correctly, the Glue-Tech will automatically stop and an error message will be displayed.

If the product requires three sheet thicknesses, two sheets would be glued together and then the two glued sheets would be bonded to the third sheet in a second pass. A large, full-color touch-screen, interfaced through a Windows computer core, is used by the operator to adjust and control the Glue-Tech.

Functionally, the Glue-Tech provides advantages and flexibility of manual gluing but with increased productivity, glue application control and sheet-to-sheet alignment consistency.

The Glue-Tech has been designed for quick and easy clean up. Glue in the feed tubing can be pumped back into the glue supply container, the glue feed tubing can be flushed automatically and a suction clean up system is provided to speed and simplify removing glue from the glue metering/application section of the machine.

Sheet-to-sheet gluing applications are diverse, growing and profitable. New technology, such as the Glue-Tech SA-1420, allows printers an effective method of producing thick printed products while minimizing material and labor costs.

Technical details:

Glue-Tech features include a touchscreen computer control, 14″ x 20″ maximum sheet size, 13.5″ capacity offset press-style air feeder and full-length registration table for the bottom sheets. Top sheets are handfed into a loading tray. The system offers precise glue application, accurate registration between the top and bottom sheets, top and bottom sheet position sensors, glue level sensor and pump, vacuum clean up system and throughput speed of up to 1,500 glued sets per hour.

D&Ks Double Kote Digital

September 4, 2018

Edited by Lara Copeland, contributing editor, PostPress

D&K Group, headquartered in the US in Elk Grove Village, Illinois, manufactures print finishing and coating technologies while offering a variety of laminating films, thermal and pressure-sensitive adhesives, coated products and more. In operation for nearly 40 years, D&K offers the user-friendly Double Kote Digital.

Marketing Communications Specialist Brian Biegel stated, “D&K introduced the Double Kote Digital laminator to meet the demands of the growing digital market. This machine offers short- to medium-run digital printers an efficient and inexpensive two-sided laminating solution for digital stocks, including HP Indigo and Xerox iGen output.” It features a quick set-up and easy lamination of digital prints up to 22″ wide. The system has an automated sheet feeder with pivoting belt table, laminator and heavy duty inline guillotine cutter – accurate to within 1/16″ – all with a small footprint.

The Double Kote Digital warms up in 20 minutes for two-sided application projects of all types, including print encapsulation, decals and more. An integrated fan bank quickly cools down hot films as they exit the laminator for clean cutting and easy handling. The sheet feeder with pivoting belt table offers easy film access for fast set-ups and changeovers. An optional inline side slitting system trims film edges and collects the scrap on takeup mandrels for easy cleanup. The belt registration table accurately guides sheets and ensures straight, consistent cuts.

“This is essential for post-lamination processing that may include foil stamping, embossing, binding, cutting and more,” Biegel continued. “Consistent sheet edges allow for accurate processing in downstream finishing systems where registration and alignment are critical.” Furthermore, the digital control panel allows for precision adjustments and reduced waste. The Double Kote Digital can accommodate virtually all digital prints and is compatible with all types of thermal laminating films including PET, OPP and PVC.

The robust feeder system can hold deep sheet stacks for large volume projects. The Double Kote Digital also offers faster speeds than many other compact laminating systems. “Faster speeds directly relate to higher output per hour,” Biegel said. “It’s essential for shops to maximize output to complete jobs with short turnaround times and minimize labor costs.” He also said that fast machine speeds reduce bottlenecks in the finishing area to ensure that production flows as efficiently as possible.

Helping to reduce labor requirements, the Double Kote Digital increases shop output, since only one operator is needed from start to finish. “Many shops currently employ two people in the lamination process: one person feeding sheets into a laminator and one person on the back end to cut and stack the laminated product,” Biegel added. “Shifting one of these employees to a different station reduces the labor requirement by 50 percent and also frees up personnel for other profit opportunities within the company.”

User feedback indicates that the Double Kote Digital is easy to set up and operate with minimal training required. The low price point is also attractive to organizations that are just starting out in lamination.

Technical details:

The Double Kote Digital measures 98x43x58″ and weighs 900lbs. With speeds up to 20fpm, it can process sheets from 8.5×11″ through 20×25″ in size. It can run sheets between 80lb through 10pt thickness.

For more information, visit www.dkgroup.com.

Tech Watch: BOBST’s MASTERFOIL 106PR

September 8, 2017

by Lara Copeland, assistant editor, PostPress

More than three decades since the world’s first presses for hot foil stamping – the SP 102-BMA and SP 126-BMA – debuted, BOBST, headquartered in Mex, Switzerland, has released its MASTERFOIL 106 PR. This camshaft-driven machine is designed and built specifically for hot foil stamping, and it is suitable for carton, label and commercial print producers working with a number of end user industries, including cosmetics, pharma, food, beverages, toys and household cleaning products. “We were able to design into the machine all that BOBST has learned from the past 50+ years of producing Autoplaten® (automatic platens) for hot foil stamping and diecutting,” explained Doug Herr, director of sales, folding carton BOBST North America Inc.

Herr described several benefits of the BOBST MASTERFOIL 106PR – including improving registration, speed and the overall quality of the end product. With its Power Register II system, the MASTERFOIL ensures perfect foil-to-print register accuracy and offers the ability to register to printed marks on each individual sheet. The Power Register incorporates Registron® cameras and detects printed register marks on the print itself in addition to the sheet edge. This feature reduces feed-related production stops by at least 75 percent while also reducing downtime. These advantages ensure high-precision and excellence in foil stamping.

Complementing the MASTERFOIL’s high-quality production, BOBST also has decreased the amount of time it takes to makeready the machine, thereby increasing the net productivity. “More consistent stamping quality results in the production of fewer unsaleable sheets, Herr confirmed. Additionally, the Easy Foil system makes it effortless to prepare the foils for the next job, cutting setup times by up to 25 percent. The easy access external foil-loading cabinet means working on the foil reels inside the machine is not necessary. Simply mount the reel, feed or splice the foil and push a button to complete the job. Herr noted that, quicker changeovers and higher production speeds enable the converter to gain more business and become more profitable.” The abundance of controls and features on the MASTERFOIL can help to assure timely delivery of high-quality products to their customers.

Lastly, because foil is expensive, Herr said the company designed the machine with the ability to noticeably reduce total foil waste. “The accuracy of the foil advance has been improved, which means images can be stamped more closely together, substantially reducing the amount of foil used on many jobs.” He added, “The machine can be equipped with sophisticated software which accurately calculates the required amount of foil for a particular job, thereby eliminating errors when ordering the foil and pricing out the cost of a job.”

Customers have been pleased with the machinery. “In every situation, the MASTERFOIL has met or surpassed their expectations,” stated Herr. And on numerous occasions, “customers have placed orders for additional machines once they have experienced the advantages and benefits of the MASTERFOIL.” He continued saying that the built-in technology is a selling point, “attracting the highest skilled and dedicated operators in the industry.” Considering the pressure on suppliers to deliver perfect products as quickly as possible, BOBST has simplified makeready processes and has focused on delivering the high-end products customers desire.

Technical Details

The MASTERFOIL 106PR is 33ft long (10.00m), 24ft wide (7.30m), 11ft tall (3.30m) and weighs approximately 22 US tons (20t). Its stamping force is 0 to 100FTU, and its production speed is up to 8,000 s/h.

It offers a minimum sheet size of 15.75×13.75″ (400×350 mm) and a maximum sheet size of 41.75×30″ (1060×760 mm). The stamping and embossing maximum size is 41.25×29.2″ (1050×742 mm).

Tech Watch

Edited by Erin La Row, editor, PostPress

Edited by Erin La Row, editor, PostPress

Scodix SHD

Scodix ART

Overcoming challenges

Customer response

Edited by Erin La Row, editor, PostPress

Edited by Lara Copeland, contributing editor, PostPress

Technical details

by Lara Copeland, contributing editor, PostPress

by Lara Copeland, contributing editor PostPress

Technical Details

by Katy Ibsen, editor, PostPress, and Chris Van Pelt, THERM-O-TYPE

Technical details:

Edited by Lara Copeland, contributing editor, PostPress

Technical details:

by Lara Copeland, assistant editor, PostPress

Technical Details

by Lara Copeland, contributing editor
PostPress