GALLUS ‘SYSTEM TO COMPOSE’

A future-oriented machine concept offers the flexibility to seamlessly integrate additional printing and finishing modules when required. Market developments and customer requirements change over time. To stay ahead of the game, printers need to consider machine systems – analogue, digital or hybrid – and the best configuration needed to meet demands.

With ‘System to Compose’, Gallus presents a platform that is geared towards precisely this flexibility. It is based on the modular system of the Gallus Labelmaster, which forms the platform for the Gallus One digital-printing system. Within this system, the Gallus One can be expanded into a hybrid system by adding analogue modules. Conversely, an existing Gallus Labelmaster can be converted into a hybrid machine by adding a digital-printing unit (DPU).

‘System to Compose’ expandable by:

• DPU with 5 colours CMYK +white
• Colour space extension DPU with orange and violet
• Flexo-printing units
• Screen-printing units
• Cold-foil transfer
• Laminating unit
• Rotary and semi-rotary die-cutting

The modular structure of the ‘System to Compose’ offers very flexible expansion options. In addition to the integration of the DPU with up to five inkjet colours (CMYK + white), there is also the option to expand the colour space with orange and violet. The DPU is now also available in a print width of 430mm, in addition to the previous standard width of 340mm.

The system’s analogue expansion options include flexo- and screen-printing units for white pre-printing, spot colour printing and varnishing. Units for cold-foil transfer and lamination, can also be added. Furthermore, 
it is possible to retrofit the Gallus One with 
a fully or semi-rotary die-cutter. This enables finishing in a single production step.

The advanced level of flexibility in the expansion options of the modular system is made possible by the highly automated, individual components. The standardised Human Machine Interface (HMI) is prepared – in terms of hardware – so that it takes over the control of the added modules after a software update. Additionally, it fully integrates conventional and digital processes. As a result, the operator receives all relevant information on the status of the machine system directly and clearly on the display. The operator can then control and regulate it from there.

In make-ready mode, the analogue-printing units set the register automatically as soon as the registration marks are in the catching area. As a result, a quick set-up can be achieved and waste is significantly reduced. In production mode, permanent register control and regulation of the analogue-printing units is carried out automatically as usual by, for example, the ‘Web-to-Web’ control system. Sensors detect the distance between the specially designed register marks and react precisely and quickly to deviations in the print image/register. 

In the DPU, the proprietary ‘Vision’ image-processing system uses a camera system to control various central machine functions. This includes automatic-register setting – triggered by the operator at the push of a button, precisely superimposing the individual colours. 

At the same time, the high-resolution camera performs essential quality assurance tasks. It detects missing nozzles and density variations (density unevenness) in solids. Compensating for these sources of error, the Vision system prevents white lines in the printed image and rainbow effects that could cause colour deviations in print areas.

The Gallus One can be expanded into a hybrid system by adding analogue modules

The Gallus One’s low ink consumption is considered an innovation. This is made possible by a needs-based combination of basic and ultrasonic cleaning. Both cleaning modes are contact-free and only take place on the outside of the printheads, so no ink is needed to flush the nozzles. Gallus states that ink savings are up to 20%.

Changes in the market can often result in the need to adapt machinery. For example, a converter’s product portfolio might consist mainly of short runs of four-colour labels that are printed digitally with short delivery times. Adaptation may become necessary with an increase in orders that might include embellishment steps. Adapting to such a premium segment makes it sensible to expand the machine technology. 

In the case of the Gallus One, the system can be retro-fitted with flexographic printing units, cold foil, screen-printing units and a die cutter. Equipped in this way, jobs in the premium segment can also be produced very efficiently and cost-effectively in a single work step.

There may be an argument for adding a DPU to the conventional machine technology in other cases. For example, when production is based on a conventional method and the product portfolio develops over time into orders with shorter production cycles and more language or colour versions. Such a hybrid machine is a more efficient solution compared to analogue production, which requires many plate changes. In the hybrid solution, solids and spot colours continue to be printed conventionally at low cost, while the variable elements are implemented digitally.

The Gallus ‘System to Compose’ has practical advantages, not only when it comes to adapting to changing job structures, but also in day-to-day business. The system brings a high level of efficiency to the production process. The ability to swap flexographic and screen-printing units in the sequence of the machine system means less investment and more flexibility. 

A process-variable machine allows jobs to be created in a single production 

The same options exist for flexographic-printing units. A machine with a fixed-printing unit constellation provides the solution for processing complex jobs in two work steps. Whereas, a process-variable machine – where units can be swapped – allows jobs to be created in a single production step.

In label printing, companies have machinery that is individually tailored to their order structure. When the market and product portfolio requirements change, existing machine configurations must be adapted accordingly. A total cost of ownership (TCO) calculator can be used to determine optimum solutions for potential new investment of machinery.

This TCO calculator provides precise information about which machine configuration – taking into account the specific acquisition and operating costs – offers the greatest cost-effectiveness for a particular order structure. For example, it is possible to determine whether it makes sense to invest in an additional flexographic printing unit for a Gallus One to print white in flexo instead of digitally. A direct comparison clearly shows when the number and length of jobs justify such an investment.

In today’s world, the flexibility of a machine platform is not just an option. It is the basis and therefore a key criterion for the future viability of a machine system. Its flexibility enables converters to react and adapt quickly to market developments and changes. This flexibility enables companies to continue to develop competitively.