Edition 39 / September 2014

Gallus Screeny – innovative screen printing

As a pioneer in rotary screen printing and the world’s most important label press manufacturer, Gallus has made something of a habit of setting standards and introducing innovations in combination printing with screen printing. Gallus Screeny Genuine Plates are just one example. They are the perfect one-stop solution from a system supplier in the label printing business (press, screen printing unit and screen printing plate from a single manufacturer). New standards will once again be set at the Gallus Innovation Days from 23 to 25 September in St. Gallen, when Gallus will be presenting the new Gallus Screeny A-Line and providing a live demonstration of the unique metallic doming combination printing process (screen-printing/hot-foil embossing effect). It will also be actively tackling the “Tempo 120 rotary screen printing” challenge.

Gallus Screeny Advanced (A-Line)

As an OEM, Gallus has always been committed to delivering the highest standards in terms of quality, safety, performance, reliability, responsibility and technological advances for its Gallus Screeny Genuine screen printing plates. The result of this commitment is now being seen with the presentation of the new Gallus Screeny Advanced Line (A-Line).

The main feature of the new A-Line is its exceptional robustness, which is particularly advantageous when handling screen printing plates both inside and outside the press. The Gallus Screeny A-Line is therefore ideal for maximising the number of times plates can be re-used. This higher re-utilisation rate is also the quickest way to significantly cut costs per screen-printed label.

However, robustness is just one of the requirements a good screen printing plate needs to satisfy. Excellent print results, optimum image resolution, a wide range of possible applications, a perfect ink flow and straightforward final checking of the imaged screen printing plate are further factors that have been taken into account during the development process.

All this makes the Gallus Screeny A-Line the best and most cutting-edge screen printing plate currently available on the market. Visitors to the Gallus Innovation Days will be able to see samples that demonstrate just what the new Gallus Screeny A-Line is capable of.

Close-up of the Gallus Screeny A-Line

Metallic doming – the unique metal relief effect

Metallic doming is a unique combination printing process in narrow-web label printing that embellishes rotary screen printing with metal foil. The first step is to apply the print image using rotary screen printing. A metal foil is then laminated onto the screen print. At the Gallus Innovation Days, this combination printing process will be demonstrated live to label printers for the first time on the Gallus RCS 330.

The special feature of metallic doming is that it imitates a metal relief effect on transparent self-adhesive materials or tube laminate. An embellishing effect of this kind on monomaterial or clear material is a true innovation and has previously been technically impossible on transparent self-adhesive materials and tube laminate on narrow-web label presses. This unique application will give users of Gallus label presses a vital competitive edge, with technology that enables them to stand out from the competition. Naturally, metallic doming can also be applied to all standard self-adhesive paper substrates.

Relief effect of metallic doming for text

Further benefits of metallic doming for label printers are the time it saves and its flexibility. Once the special tool for metallic doming has been purchased, they no longer need to order in tools and wait until they are finally delivered. With the appropriate in-house equipment, it is possible to produce the print motif for metallic doming and start the process on the press within 30 minutes. This makes planning the production of print jobs extremely flexible for label printers, and urgent jobs can be produced and delivered at short notice.

Relief effect of metallic doming for solid areas and lines

“Tempo 120” – rotary screen printing at 120 metres per Minute

How can rotary screen printing be made more cost-efficient for label printers and compete with flexographic printing? Gallus has repeatedly raised this question with customers and the conclusion was clear – production needed to be quicker.

A large number of the label printers using rotary screen printing currently operate at production speeds of between 30 and 60 metres per minute. If the production speed matched that of flexographic printing, greater use could be made of the productivity potential of inline production on a label press while also benefiting from the embellishing effects of screen printing. But what kind of production speed is needed for the rotary screen printing process to match flexographic printing? Initial customer feedback indicated a speed of 120 metres per minute, which led Gallus to initiate the “Tempo 120” project. The aim of this project is to fully exploit the press’s performance potential in terms of achieving the maximum speed in screen printing.

The project is currently still in its initial stages. As a supplier of system solutions, Gallus has set itself the task of performing thorough tests to establish the perfect combination of all relevant print parameters for this project – from the design of the press and screen printing unit all the way through to the screen printing plates, inks and drying system.

At this year’s Gallus Innovation Days, the company is looking to hold more in-depth discussions with its customers about “Tempo 120” and is expecting further key contributions from them that can be incorporated into the project.

The aim of the “Tempo 120” project is to print at a speed of 120 metres per minute in rotary screen printing.

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