Frame Structure

Distinctively designed and precisely machined, strong and sturdy, steel frame structure completely machined on CNC-VMC, maintains accuracy over long dependable life and ensures less vibration even with optimum line speed.

Control system

Unwinder, rewinder, common for all print units, in-feed and out-feed are individually driven by servo motors-drives controlled and supervised by the high performance PLC/PPC having its own intelligent software.

‘Fiber optic bus system’ used for maintaining tight synchronization between all the drives by providing fast, reliable and jitter-free communication.

Operator interface

Master operator control panel mainly consists of touch screen operator interface located at rewind side and remote operator control panel located at unwind side, facilitates easy operation from both the end Electro-electric Edge Guiding System with Ultrasonic edge sensor and PMDC motor.

Unwind group

Unwind Web Tension Control by using latest generation AC servo motor and drive. The system maintains the set tension precisely through out the reel run. The system mainly composed of AC servo motor and drive, pneumatically loaded low friction dancing roller assembly and load cell for tension feed-back. Pneumatically expanded shafts and safety chucks to hold the reels.

In-feed system (Draw unit)

The system maintains set tension between in-feed and first printing unit precisely and isolates the printing unit from tension disturbance of the unwinding zone. The system mainly composed of matt chromium plated steel roller, AC servo motor and drive, load cell and rubber covered nip roller with pneumatically adjustable pressure.

Print unit control panel

Each print unit control panel consists pneumatic controls for drying hood, doctor blade and impression rubber roller & electrical controls for manual length and side-lay registration setting, temperature display for drying chamber and emergency stop.

Idle Rollers

Specially designed, dynamically balanced low friction-low inertia idle rollers made of Aluminum alloy, mounted on low friction bearings, enhance rotational smoothness.

Out-feed System

The system maintains set tension between last printing unit and out-feed precisely and isolates the printing units from tension disturbance of the rewinding zone. The system mainly composed of matt chromium plated steel roller AC servo motor and drive, load cells and rubber covered nip roller with pneumatically adjustable pressure.

Rewind Group

Rewind web tension control by using latest generation AC servo motor and drive. The system maintains the set tension precisely through out the reel run. The system mainly composed of AC servo motor and drive, pneumatically loaded low friction dancing roller assembly and load cell for tension feed-back.

Pneumatically expanded shafts and safety chucks to hold the reels.

Transmission

Five drive servo driven automatic web tension control systems : Load cell and or dancer based closed loop Servo motor control & drive on (1) Unwind (2) In-feed System (3) Printing Station (4) Out -feed System (5) Rewind.

Automatic Register Control System

Automatic length and side-lay register control system with full colored touch screen operator interface facilitates automatic mark centering and recognition. Automatic selection of different control parameters during machine speed changes and control parameters individually configurable to different materials for easy operator selection.

Doctor blade group

Designed to ensure a straight profile of the blade resulting in lesser blade pressure, better printing quality and longer cylinder life. The blade locking by eccentric rod without tools.

The group allows horizontal, vertical and angular adjustment for the doctor blade position on engraved cylinder. Pneumatic doctoring pressure with adjustment possibility from the unit control panel.

Drying System

Ink drying is obtained by blowing hot air on the web through air nozzles. The optimized airflow minimizes heat consumption and avoids solvent retention in the printed substrate.

The system mainly composed of single hood drying chambers, ventilation modules, connection ducts, central exhaust system.

Ventilation Module suitable to send and re-circulate the process air. The module composed of AC frequency drive controlled centrifugal fan, thermal oil or electric heat exchanger and necessary controls and feedback device for temperature.

Connection Ducts and piping for the delivery and re-circulation between drying chamber and ventilation module. Adjustment of air balancing by means of manually operated dampers.

Central Exhaust System

composed of AC frequency drive controlled heavy-duty centrifugal fan to collect solvent contaminated air from all the printing units through central duct. The ducts fitted with manual adjustable dampers.

Impression Rubber Roll

Pneumatically operated impression rubber roller raising lowering on precision linear bearings. The precision linear bearings ensure smooth and precise displacement.

Pneumatic working impression controls with independent pressure adjustment for both the sides.

Motorized web video inspection system

Motorized web video inspection system consists of high quality CCD color camera, Industrial PC & Monitor (facilitates sequential inspection of the lateral and entire print repeat of the web).

Motorized Ink Pump

Speed variable, air motorized Ink pump on each station with ink flow/pressure adjusting valve

Lay–on Roller Assembly

Pneumatically operated lay on roller assembly complete with pressure gauge and regulator for control of the pressure on the rewind reel.

OPTIONAL ATTACHMENTS

Turret System
Turret system with flying splice facilitates automatic reel change-over without stopping the machine. The whole function is controlled and supervised by the high performance PLC/PPC.

The system mainly composed of push button initiated motorized rotating disc, pneumatically loaded automatic splicing arm, PU covered pasting roller and cutting blade assembly etc.

Pneumatically expanded shafts and safety chucks to hold the reels.

Thermic Fluid Heating System 

Oil or gas fired Thermic Fluid Heating System (instead of electrical heating system) : The system consists of main Boiler & Radiator (heat exchanger) on each printing station with necessary valves, fittings, etc...

Viscosity Control System

An individual system for each printing unit measures and controls the viscosity of the ink. The system is having features like Automatic calibration of the viscosity, Automatic rinsing, Programmable process parameters, Synoptic display of the alarms, Function chronometer at the unit, self cleaning operation etc.

Trolley System

For quick change of engraved cylinder & the whole inking group facilitates fast and easy job changes. Trolley consists of hollow type cylinder mounting shaft assembly with quick locking check nut, double ink basin and speed variable air motorized Ink pump.