In-Line Flexographic Press

When the Focus Design Team decided to develop a new generation of Converting Presses they had a single goal in mind. To produce a truly modular high performance machine to meet the new demands of printing & converting the ever increasing range of substrates used in today's packaging industry.

Take a closer look at Focus label Flexographic Solutions

Webflex flexographic printer

Design

When the Focus Design Team decided to develop a new generation of Converting Presses they had a single goal in mind. To produce a truly modular high performance machine to meet the new demands of printing & converting the ever increasing range of substrates used in today's packaging industry. To satisfy that demand Focus have produced a standard press that is packed with advanced features that are only available as options on other equipment. The Webflex is a truly modular press designed to meet tomorrow's converting demands.

Webflex flexographic printer

Webflex flexographic printer

Converting and Quality

High productivity and consistent quality are essential in today's market and the new Webflex has been designed to meet your production quotas head on. As with all Focus Presses, quality of components, design, construction and reliability are built in as standard. The close customer relationship valued by Focus will ensure you benefit from future advances in tomorrow's technology.

Heavy duty construction
To convert such a wide range of materials, new construction techniques have been incorporated.

• Solid Floor Supported Double Sided Frames with shear plates and Compression Tubular Tie Bars for reduced vibration.
• Fully CNC machined Print Modules for absolute precision assembly and perfect pinned alignment on installation.
• A unique Drive Line designed by Focus incorporating torsion resistant links with zero backlash couplings to reduce register errors during changes in press speeds.
• A high precision, enclosed Spiral Bevel Gear Box with phase shift for 360° registration adjustment.
• The central location of the Motor Drive reduces accumulation of load, improving performance and reducing vibration and torsional errors. The motor is sized on configuration and future considerations.

Advance Electrical Design

The Webflex is a complex machine system controlled by the very latest technology. The ‘PLC’ (Programmable Logic Control) System ensures precise sequence control of every function of the press at all stages of production. This level of control is combined with the 3 Zone Total Tension Management system (TTM). Both systems can be customised for individual requirements and will ensure increased productivity and reduced wastage.

STANDARD FEATURES

• Unwind
• Splice Table
• Web Guide
• 3 Zone Digital Controlled Tension System (TTM)
• In Feed/Out Feed Roll
• Print Stations / Cartridge Option
• Super Light Anilox Rolls
• Doctor Blades
• Individual Dryer Units (Variable/Proportional Temperature Control)
• Die Module
• Slitting Module
• Waste Rewind
• Rewind Module
• Central Drive Motor
• Advanced PLC Sequence Control
• Independent Module Controls

FEATURES
Printing Modules

Superior stability over traditional cantilever design is obtained through true double side frame construction with shear plate incorporated for reduced vibration. New features include an Anilox Throw Off system to allow selfcleaning of the printing plates during press stops. We introduce the latest Quick Release Print Cartridge combining Ink Fountain, Metering Roll, Doctor Blade and Super Light Anilox Rolls. Complete job changeovers can be completed in minutes, without the need for special tools. In addition, Print Cartridges are completely interchangeable, allowing colours to be exchanged instantly. All rolls have hardened journals in precision heavyduty bearings for long & trouble free operation with reduced down time and maintenance.

Toolless Changeovers also extend to Print Cylinders and Gears, where revolutionary construction ensures perfect print quality by eliminating eccentric rolling error. Individual operator panels allow full control over the features of each colour station, including Plate Throw Off, Constantly Turning Anilox Rolls & Anilox Throw Off, Drying Functions, Print Cartridge Release, Run & Jog features, etc.

Dye station module

Each module is heavy duty, all Steel Construction with hardened and polished Anvil Rolls, designed to cope with the most difficult applications. Each unit is supplied with a Removable Anvil to allow front & back die cutting, creasing, folding, cross perforating and sheeting for a wide range of substrates, including Label Stock, Tags, Board, Foils & Films, etc. An additional benefit is that Tooling is fully reversible, increasing Tool Life and eliminating errors when ordering special shapes. Provision has been made within the first Die Module for the addition of a Video Inspection System. (Separate detailsavailable).

Slitting/Sheeting Module Pneumatic Crush Slitters are supplied as standard with on the run lateral register. These are easy to set & maintain and can be used for Slitting, Perforating and Creasing applications. A high friction Tension Roll ensures excellent Print to Cut register stability.

Unwind Module

The Double Side Frame construction provides rigid support of all rollers and ensures accurate web tracking. Standard features include Air Core, Inflation Gun, Slack Roll Festoon for accumulation of loose wound rolls, Web Guide, Splice Table with Pneumatic Clamps and Tape Dispenser. An Automatic Roll Lift is available on request. The Digital Tension System allows accurate tracking of any substrate, enabling recording for future reference.

Drying Systems

Each print module houses its own Progressive Drying System with variable temperature control. The latest system combines infrared and controlled impact airflow over the substrate with the waste volume air extracted. Temperature at each module is increased proportionally to the speed of the press, making this latest system ideal for any combination of ink and substrate. U.V. Dryers are supplied as an option. The Webflex press incorporates a unique system, which allows each U.V. drying unit to slide clear of the working area, quickly reverting back to a conventional Flexo Press or to provide a combination of drying possibilities.

Operator Controls

Years of experience in machine design have ensured the Webflex has been manufactured with the operator in mind. Clearly identified controls are provided at each independent module, enabling effortless control of the press. Production conditions such as tension can be monitored and recorded for future repeat runs to ensure those same conditions are repeated, reducing set up time and wastage.

Rewind Module

The heavy duty Rewind Module allows a maximum roll of 800mm diameter. The open cantilever design enables easy access for fast roll changes. Air Operated Core Holders are standard features with a Sensor monitoring the Diameter of Roll for constant tension regardless of press speed. Independent tension controls can provide hard or soft roll capability and an additional Rewind Turret can be supplied as an option.

Total Tension Management System (TTM)

The unique design of the Focus TTM System ensures that in all situations the tension is monitored and controlled to ensure the best possible conditions for high quality printing & converting. The system provides digital monitoring of tension information, feed back and recording for future repeat orders enabling identical conditions to be reproduced and therefore reduce set up time and wastage.

The Focus Design Team have created 3 separate Tension Zones all controlled independently. The Unwind Module provides optimum control for any substrates through a Dancer Arm, which compensates for eccentric or loose rolls and through acceleration and deceleration.

The accuracy in register of many ‘In Line’ presses can suffer under acceleration and deceleration. The Webflex development team considered this and designed ‘TTM’ in as standard. This system controls the Printing Zone Tension even through changes in press speed, reducing waste.

The Print & Die Zone tensions are isolated from the Unwind & Rewind. This eliminates any cutting to printing registration error. The Rewind Zone provides constant tension through a Sensor and tension can be adjusted so that hard or soft rolls can be produced depending on the material. Accidental Web Breaks can be detected and the press will be automatically stopped.

Quick Change Cartridge

Never has it been easier to make complete job or colour changes with the new Print Cartridge System. Toolless Interchangeable Units effortlessly slide out and can be exchanged within seconds. A special Mobile Carriage offers further benefits, as additional cartridges can made ready without interrupting planned production. Cartridges can be cleaned offline, ensuring the press continues producing throughout the operating shift, without long periods of down time.

OPTIONAL FEATURES

• Pacing/Impression Rolls (For Different Thickness of Materials)
• Additional Print Modules
• Ink Pumps
• Additional Ink Fountains
• Super Light Ceramic or Chrome Anilox Rolls
• Additional Doctor Blade Units
• Mobile Cartridge Carriage
• U.V Dryers
• Web Cleaners/Antistatic Units
• Corona Discharge System
• Video Web Inspection System
• Additional Die Module
• Rotary Die Adapter
• Crush Slitters/Perforation Slitters.
• Male/Female Sprocket
• Hole Punch (24'' System)
• Laminating Unwind
• Delamination/Relamination Unit.
• Additional Waste Rewind
• Edge Trim Extractors
• Stacker/Conveyor
• Fan Folder
• Turn Bar
• Reversible Print Unit for Reverse Printing
• Additional Rewind Module
• Roll Lift

Technical Specification