IMPACT OF REEL LIFTING AND LABEL CONVERTING TECHNOLOGY ON YOUR PRINTING BUSINESS

Every industry from Automobile, FMCG products, Electronics etc. are going through a lot of advancement. Shorter product life cycle and increasing demand for new features are leading to new innovations in each field. It has also impacted the Label printing industry in a positive way and also surfaced new challenges for Label printers and converters. Demand has increased for Label printers but there is an increase in short runs jobs and orders delivery are more time bound. To succeed, Printers need to be more automated in their functioning and have to find new smarter ways to achieve the desired goal. Reel Lifting and short run label converting are the new trending technologies and both have an important part to play in successful journey of a Printer/Converter.

REEL LIFTING TECHNOLOGY

Reel Lifting doesn’t sound important to most press owners as because of the high cost of automatic roll lifters and no return on Investment. But Printers can invest in manual roll lifters which are easy to operate and are less expensive.

Reel lifting has an important role to play, even if it doesn’t produce ROI but it can save the already invested amount in paper rolls. It improves the manual handling operations of loading/ unloading/

transportation of rolls and helps to reduce workplace injuries. The high cost of Raw material and it’s fragile nature makes mechanization in reel handling all the more essential.

LABEL CONVERTING TECHNOLOGY

With all presses, whether Flexo, offset or digital getting geared up to produce short runs, converting systems are also needed to catch up. These machines can be setup inline or offline to the printing press and perform all the functions such as slitting, rewinding, die-cutting and other key embellishments. We would like to list some of the key advantages of the short run converting equipment:

 Reduced Total Cost of operation (TCO)

The most important factor while investing in any machinery is the total cost of operation. Good converting equipment ensures a lowest TCO irrespective of the printing process.

 Set up time

How much time do your operators waste on setting up the machine when they do a job change? As jobs are short run and changes are frequent, set up time becomes a key cost center. Also, this time is a significant portion of the total production time in case of Digital and hence impacts costs and well as job delivery turnaround times (TAT)

 Make Ready Waste

As digital is normally used for short runs, the make-ready waste also needs to be minimum. Keep in mind that the cost of printing per square meter of a digital process is much higher than conventional processes, hence any make-ready waste contributes significantly to the job cost and hence must be kept to a min. Finishing makes ready waste for a good digital finishing equipment should not exceed 8 to 10 linear meters.

 Turnaround time

When it comes to turnaround time (TAT), as a digital printer you will experience less time due to the need of plates, repeat formats etc. If you finish on the line itself everything in 1 pass, the TAT is even shorter. Customers expect a TAT of max 2 working days for labels workflow and hence the finishing process also needs to be quick and should not become a bottleneck in the workflow.

 Quality of Finishing

While using conventional finishing machines, there are some limitations when it comes to intricate die-cutting or generating pop-up features while cutting and creasing. But digital finishing including laser die cutting systems eliminate these limitations and provide an exceptional finishing to the packaged product or label.

 Variable Data Personalization

Often companies want to sell a limited edition of their products and services resulting in lesser copies. So, when they sell them, they send personalized products to end consumer for brand engagement. So in digital finishing, you can run lesser copies for VDP which is an added advantage.

 Laser Die-Cutting

With laser die-cutting, converters save thousands of dollars over the year as it completely eliminates the need for hardware tooling and die-making. Die-making is usually an outsourced function in the press room and it takes three to four days to get the die and you cannot even start with your job resulting in a delay.

 Low Investment on Manpower

With conventional finishing, converters have to invest in a number of operators. With the advancement of technology, connected stations, and more automated functions, digital finishing systems require lesser manpower. As many operations are automated and job storage and recall facilities exist, human labor requirement is much lower.

Investment in training an operator is very less. As a pressman operating conventional systems, it requires years of experience to handle machines effectively. But with digital machines, you can train an operator in 6 weeks as fewer functions are there to operate. All you need is that your printers know how to click, drag and drop.

 Advanced software capability

With no die required and software set-up, a converter can easily upload the design file into the machine and start producing its print job. Usually, the print workflow can be extended to the Finishing as well which reduces set up time, errors and enhances end product quality.

WHAT TO CONSIDER WHILE INVESTING IN RIGHT SLITTER REWINDER FOR LABEL FINISHING?

Global Label market is staggering at $35 billion and millions of printers & converters are competing with each other to increase their market share. But only some of them make it big in the long run because they believe in providing value added solutions with superior quality & functionality to their customers.

A lot of factors decide while supplying quality label solutions, some of them are affordability, value-addition, longevity, reliability, quality of print and substrate etc. But the label finishing plays the most important part of all as it depicts how perfect the label looks after printing. If not properly slit or die-cut, the printed label will lose its feel or will not dispense correctly onto the product hence reducing the appeal of the product. To obtain perfect finishing, converters have to invest in right slitter rewinder for finishing of labels.

What is a Slitter-Rewinder?

Slitter rewinder machines that are used to finish large rolls of printed material into smaller rolls of the slit, inspected and counted rolls which may be on a smaller core size to make them usable on automatic label dispensing systems on high-speed filling/bottling lines.

When choosing the precise slitter rewinder for the finishing purpose, converters should focus on the following:

 SPEED

The machine should be able to slit and die-cut on high-speed. Typical mechanical speeds vary between 200 to 350 Mts/min.

 WASTE

Some machines are cheaper, but they produce a large amount of waste which can affect the profit margins. Set up waste for each job must be below 5 mts and the time required to set up below 10 mins. Offline Vernier systems and removable shafts add to the efficiency of the whole process and improve the accuracy of the finished product. Automatic Set up slit stations are also available on European machines now.

 INSPECTION

A good label inspection system is required to find faulty and missing labels with 100% accuracy. By not having proper inspection system, inferior quality material may be dispatched to the customer

 Type of Slitting;

Typically slitting can be done by 3 processes

a) Scissor Slitting with top and bottom knives

b) Razor Slitting with Razor blades

c) Crush Cut Slitting rotary blades working on a hardened anvil

For Normal Label stock with Paper release liners, Scissor slitting is preferred. For cutting films or Self Adhesive materials with a Filmic liner, Razor slitting is preferred while when cutting thick papers or paper boards the crush cut is the preferred system.

Machines which can have the flexibility of having more than one slitting system installed should be preferred as they offer a wider flexibility of substrate use.

 Paper and Print Width

Depending upon their orders, a printer should invest in a machine which will accommodate all sizes. By not complying with this, the printer can lose orders which require higher print/slit width.

 Automation

It also plays an important task; a machine should have a mechanism for less operator interference. Systems with Auto-slit knife settings, offline knive settings. A wider HMI control integrating all operating functions and job storage etc. add to the reduction in human effort and better repeatability of jobs

 Upgradable

The machine should be upgradable to other finishing process such as die-cutting, inkjet, camera inspection, Lamination, embossing etc. depending upon the requirement.

 Service & Support

While investing, a printer should also consider the brand value and service support; he can avail from the manufacturer or supplier. Without an active service support, no system can provide optimum output.

What has VINSAK to offer?

To help printer/converters with the latest labeling technology and providing a solution to their specific requirements so that they stay at forefront of competition, VINSAK provides a different range of customized printing and finishing solutions to suit their job requirement.

Some of the advanced solutions are:

A) ABG OMEGA SRI 350/430/530mm

VINSAK provides Omega SRI (Slitter Rewinder) from ABG International better known for perfect handling, highest productivity with rewinding speed up to 350 m / min, latest servo technology, and an innovative SPS/PC operating system.

The Omega SRI fulfills all your label converting and web finishing requirements. It is having fully integrated fleyeVision inspection control with screen operation to detect faulty and missing labels connected with an integrated workflow for waste processing.

Key Features:

 Adjustable web clamps allow a variable splicing area to glue in even large labels without a problem.

 An arrangeable splicing table after the rewind with an operating stroboscope simplifies the visual control.

 Pneumatic expandable mandrels, for unwinder and rewinder

 Roll diameter at the unwinder up to 800 mm

 Roll diameter at the rewinder up to 500 mm (600 mm as an option)

 Efficient web tension control during highest acceleration at unwinder and rewinder site

 Electronic web guide including an ultrasonic sensor for paper and clear on clear material

B) VINSAK USAR 250 to 530 mm

The USAR(Universal Slitter Rewinder) is flagship product from VINSAK. Along with high speed precise slitting with rewind and unwind option, it can be upgraded to provide the die-cutting unit with servo re-register (10”-24”), 100% inspection system and inkjet unit for barcode, QR-code, and variable data.

Benefits:

 Automatic stop of complete roll; at diameter: at label count or meter count.

 Electronic web guidance with ultrasonic sensor suitable for opaque and clear substrates.

 Max. Rewind up to 450 mm & efficient web tension control.

 Adjustable splicing table with pneumatic clamps for removal of the waste product.

 Quick release/removable nip roller with pneumatic pressure control.

 Standard Scissor slitting unit including 3 sets of knives

 Matrix stripping section, Air mandrel, Matrix break sensor, Bulk Waste Rewind and Venturi trim extraction (16mm max)

C) ABG Vectra ECTR Turret Rewinder 330/430/530

The other slitting solution is ECTR Turret rewinder ideal for slitting and rewinding of standard self-adhesive labels. The ECTR with closed loop servo drive is capable of handling a huge range of substrates including delicate, perforated or punched products. The turreter has auto roll eject system and adjustable core stop with constant torque tension control. All these features lead to web speed of 100m/min with 25-38mm diameter mandrels and 150m/min with 40-76mm diameter mandrels.

Conclusion

“A RIGHT INVESTMENT ALWAYS PAYS HIGH RETURNS IN FUTURE”

A printer/converter has to invest in slitter rewinder to provide optimal label finishing and they should invest after considering volume & type of job orders they are fetching from the market. They should think of finishing solutions which have less wastage, high speed to reduce job time, inspection system, and automated solutions with less operator interference, value added solutions and active service & support for their machines.

WHY INVEST IN SECURITY INKS?

Security of important documents and packaged products is becoming a necessity for Brand owners. As without the proper security measures, paper as well as products, both are prone to tampering or forgery which amounts to brand implication, financial & information loss.

Due to this advance efforts to protect, track and authenticate the document/ products are becoming more critical for both printers and their customers to stop security infringements.

A useful and efficient anti-counterfeiting measure is the entire range of Security inks that Vinsak has to offer.

Security Inks are having complex information encrypted into their DNA. They are designed to reduce or even eliminate the fraudulent use of products/documents. Security Inks are having excellent covert anti-counterfeiting features which make it difficult to gauge by a naked eye whether the item is printed by security ink.

Advanced counterfeiters who can locate the image of the security print, still find it difficult to replicate as they wouldn’t be able to access the codes stored in Ink’s DNA.

Security Inks can be used for applications such as Degrees Diplomas, transactional, govt. documents, passports, cheques, labels, product packaging etc. Theses inks can be printed using most commonly used printing processes such as Flexo/offset/digital/Gravure/Intaglio.

To help printers/converters fight counterfeiting, VINSAK-one of the prominent player in world’s printing and packaging industry is supplying a range of security inks such as

Water Fugitive, Fluorescent, Erasable, Phosphorescent, Inactinic, Photochromic, Iridescent, Pearlescent, Watermark, Sympathetic, Thermal, Black-paint, Seri-Paint, Coin-Revealable, Conductive, Numbering, Magnetic, Invisible, Thermochromic and Reactive Inks

The security inks supplied by VINSAK are the preferred choice for Printers & Converters because of the following reasons: Cost Efficiency, Compliance with all printing technologies/ Substrates and Capabilities such as Overt, Covert, Forensic, track & trace features.

We wish awareness about security infringements and its measures should increase in the packaging industry and more people should opt for secure packaging for their products.

About VINSAK

VINSAK is a pioneer in manufacturing and supplying printing and packaging solutions in India, Africa, and the Middle East. VINSAK has enabled many businesses to succeed financially by providing them customized solutions that were well integrated and supported. These include manufacturers of print that extend from large and well-established brands to entities that are in their nascent stage of growth. The vision of VINSAK has brought solutions that were innovative, high quality and more critically an ideal fit for businesses to succeed in today’s competitive environment. These and the commitment to serve the customer’s business interested have enabled VINSAK’s growth that now spans extensively across the nation

Label Expo India 2016 will witness demonstrations of total label print solutions from Six Major Industry Leaders in Packaging Industry

Much awaited Label Expo India is approaching in the mid of November 2016. Every year Label Expo brings new ground-breaking technologies from companies providing Equipment, substrates, and solutions to the Label manufacturers. This is the sole reason why visitor’s attendance increases every year resulting in higher sales at stands. As Label Expo America was a huge success this year compared to earlier label events, so a lot will be expected from Label Expo India 2016.

Brand owners, converters, and printers across continents will be keeping their eye on new technologies and innovation to be revealed in Label Expo to enhance their products, prints, and services. With growing demand in Asian countries and increase of private Label and organised retail ,the label market is growing leaps and bounds in this region.

VINSAK, a leading manufacturer of Label Printing and security solutions is going to participate for the record 20th time in Label Expo and every year VINSAK brings something new for visitors. In the last Label Expo India 2014, VINSAK has showcased its LVPI, LSR and DSR machines capable for Digital Label Printing and Finishing. VINSAK have received an overwhelming response from buyers for these machines.

To continue its legacy of showcasing latest innovations in Label Expo Editions, this year VINSAK in the expo and will display their most watched USAR machine equipped with slitter, rewinder and 100% inspection system for label finishing. Being a modular machine, it can be equipped with die-cutting, variable data printing and, adjustable splicing table with pneumatic clamps for removal of the waste product.

Apart from VINSAK, it's Lombardi and ABG International machines will prove their mettle in the show. Where Lombardi will be demonstrating its new Synchroline 430 UV Flexo press known for its versatility and printing on the wide gamma of materials. SYNCHROLINE is equipped with printing groups governed singularly by brushless motors and the setting and maintenance of the printing register of the whole press are governed by the electric board with a system of register control. This ables to correct in real time the deviation from the register due to the extensions of the material.

ABG International, one of the leading manufacturers of Label Finishing Solution also wants to make most out of world’s largest Label Expo. They are showcasing their turret rewinder-VECTRA ECTR 430 which is fully upgradable with a wide range of options. These options include servo technology upgrades, allowing the ETCR to produce a range of finished rolls from a wide spectrum of substrates. The ECTR is also fully compatible with automatic core loading options and finished roll label application options. The ECTR, with its wide range of optional extras including automatic core loading, is fully compatible with A B Graphic International Ltd.’s own 100% camera inspection system.

Besides watching live demonstrations of machines, buyers will have an opportunity to explore products of Lead Lasers, Iwasaki International, Schober, and Petrel. Each of our strategic associates will provide sample, brochures and related information about its products and most of all; managers from each company will be present to guide them about nittygritty of their machines.

Lead Lasers will focus on promoting its unique hybrid direct laser engraving machines Printmaster hybrid used to produce high-quality laser engraving on plates and sleeves ranging from 1 mm to 7000 mm. The HYBRID can start with 2 small lasers for imaging flexo sleeves and plates, up to 250 m2/year. By adding shifts and laser power capacity can increase to 8.000 m2.

When it comes to Offset Flexo Press, it’s IWASAKI International which has created a big repo in the international market with Intermittent Press TR2 UV offset flexo printing machine with 5 offset print station and 3 flexo printing stations. TR2 is available in web width of 100 to 330 mm and speed of 30-250 rpm.

Visitors will also have the luxury of knowing about brand protection solutions from Petrel known for world class security inks, fibres, and thread. Petrel Security inks are printable by offset, silk-screen, flexography, gravure, and are used for protecting documents against falsifications and counterfeiting.

Lastly, it’s Schober USA Inc., largely known for its world class equipments for Punching and Cutting of Labels and other extensive materials. Schober develops, manufactures and supplies a wide range of tools, modules or complete processing lines for the manufacturing of longitudinal, cross, contour and half cuts as well as perforations by proven technologies. Schober Punching equipments provide clean and burr-free punching with a web width of up to 2000 mm and speeds of up to 600 m/min.

Buyers can meet major industry experts under one stand with in-depth knowledge of Label Printing Industry to provide them best of the solutions to enhance their print capabilities. Buyers visiting Label Expo India 2016 can find VINSAK and its strategic partners at K5 & K8 stand in Hall No. 5 at India Expo Centre, Greater Noida. Please mail us at info@vinsak.com to book your meeting with VINSAK officials.

HOW HIGH-SPEED VARIABLE DATA PRINTING HAS REVOLUTIONIZED PERSONALIZED LABEL PRINTING

Currently, VDP market is a staggering $12 Billion and expected to reach $ 22.7 Billion by 2021 due to the advent of global brands, rising consumerism, and growth of the packaging industry. Marketers all over the world are focusing on Digital Printing with Variable Data Printing technology to increase their engagement with the customers to make them loyal customers towards their branded products. The main reason behind this is most of the printers are getting orders in small quantity and to lure customers, clients ask for the more personalized and customized data to print as opposed to traditional shotgun campaigns. This market possesses high growth due to potential Growth in the end-use sector and packaging printing industry, demand for inventory tracking and tracing solutions, product differentiation, and technological advancements in the printing industry are some of the drivers for the growth of the Variable Data Printing Market in labels. This is why printers prefer digital printing and high-speed variable data printing over offset printing.

It helps in better brand engagement as customers appreciate if they receive personalized mailer and chances of opening it and buying the next product increase by four times whereas normal mailers are mostly going unopen leading in wastage of money and effort.

Today’s marketing is very complexed, in order to increase customer base , companies have to make target based marketing strategies and to communicate their message effectively, they should know something about the customer for using VDP For example, Amazon- the leading giant in global E-commerce industry use Label personalization and track and trace technology while delivering its products to end customers.On every shipment, Amazon prints the end user details with QR code. Amazon continues to tailor each shipment because doing so generates enough additional sales and customer loyalty to create a positive ROI & WOM.

VINSAK, a prominent leader in innovative print solutions have created a big storm in label personalization industry with its new Label printing machine LVPI equipped with VIS 1200 K for High Speed VDP and QR code printing for varied purposes such as Direct Mail, Transactional security printing, Tax & Excise stamps, Flexible package printing, graphics, labels, 1D/@D codes etc. It also provides security inks and software to counter brand counterfeiting.

VINSAK is currently supporting Govt. of India and private printers in India, Middle east & Africa ., to stop counterfeiting in the liquor industry by proving its machines for the personalized label and QR codes printing on liquor bottles to track and trace bottles and curb tax losses to the Governments.

VINSAK will continue to enhance its machines to provide customers with more efficient personalized printing solutions.

Two New Installations of the Iwasaki TR2 Offset Intermittent presses

Recently appointed by Iwasaki as the distributor for India and the Middle east, Vinsak is happy to announce two recent installations of the state of the art TR2 offset presses.

Mr. Naoki Ogawa, Sales Director at IWASAKI International Ltd. says IWASAKI’s main priority is to make valuable products to meet rapidly changing needs of customers. IWASAKI TR2 is next generation offset printing machine and has played a vital role in Label Printing Solutions helping wide range of industries to raise their product quality. TR2 is equipped with Printing Unit Temperature control system to maintain even temperature in the kneading and plate cylinder to assure precise control of ink temperature for high quality printing.

The first machine was installed at M/s Seljegat Printers Pvt Ltd at SIvakasi.

SELJEGAT is in the business of Label Printing and shrink sleeves from three decades helping customers from diverse industries. SELJEGAT Printers is having 80,000 square foot manufacturing facility and has grown into one of the prime pressure sensitive label manufacturers in the country.
“We have a long history of relationship with Iwasaki, said Mr V S Raveendran, the Managing Director of Seljegat Printers Private Limited in Sivakasi.” Starting from the first series of VSD
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and RUH flat bed and semi rotary machines that we purchased when we began our journey
into labels, we have grown together over the years with Iwasaki.
The latest addition has been a state of the art TR2 offset intermittent press, which puts us at
the next level of offering high quality Litho printed labels for our customers in short to
medium runs.
With the lowest cost of origination for offset, the intermittent process which offers
unlimited repeat sizes & low set up web waste, we find this process a complimentary
technology to our flexo presses and let us compete against short run digital work as well.
Ability to print on textured substrates is also a great advantage in many markets. We are
also satisfied that M/s Vinsak has taken over the sales and support of the Iwasaki range. We
have dealt with them in the past for ABG finishing equipment and find their support
satisfactory. "

The Second machine was installed at M/s WINTEK FLEXO PRINTS

WINTEK Flexo prints are having a massive manufacturing plant with state of the art
technology to produce world class products such as Self Adhesive labels which include labels
on paper, film, paper laminates and vinyl labels suitable for your application. The more the
plant is highly automated lesser it will take time to manufacture products and effects its
quality.

“The Iwasaki TR2 has been our latest investment in expanding our label printing capacity.
After a series of trials with Intermittent press manufacturers, we chose the Iwasaki TR2
press specifically for its ability to offer very high quality offset prints with all finishing
processes in line and its ability to use both convention wet offset as well as water less
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printing plates" said Mr Gururaj Ballarwad of Wintek Flexo prints , Bangalore. An Industry
stalwart of the Label industry in India, Mr Gururaj has been known for his keen technical
sense of identifying the market needs well in advance and in being able to cater to them
efficiently and economically.” With the lowest cost of origination for offset, the intermittent
process which offers unlimited repeat sizes, the lowest set up web waste, the equipment is
our answer to the demands of short run labels in the market without the high running costs
of a other technology. The offset process allows us additionally to print on textured papers
which hope to open new markets of high end Cosmetic & Wine labels for us. The in line cold
foiling as well as die cutting ensures that we get a completely finished label without the
need of a second pass of finishing which in short runs entails additional wastage of time and
material “ added Mr Gururaj. "With Vinsak taking over the sales and service of Iwasaki
equipment in the region in the last one year, our confidence has been further strengthened
in the technology and the company “were his closing remarks.
VINSAK leading distributor of IWASAKI in Asia and Middle-East have introduced its IWASAKI
TR2 for Label Printing and Finishing in Indian Market. . TR2 UV Offset Printing Machine from
IWASAKI has garnered a huge response from our customers because of its high quality and
stable printing.

We thank these two customers for their trust and support in the Iwasaki technology and the
support being provided by Vinsak. This is only a beginning of a long and beautiful journey
that we hope to have with Iwasaki In the years to come as we bring the offset technology to
the discerning label printers of the region, added Mr Neeraj Sharma, Executive director,
Vinsak India P Ltd.