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Labelexpo Europe 2015 – Gallus presents explosion of innovations

Gallus at LABELEXPO Europe 2015

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Gallus at LABELEXPO Europe 2015

The new Gallus DCS 340 - The first Industrial Digital Converting Solution

St. Gallen, September 2015 – Labelexpo 2015 in Brussels launch of the new Gallus DCS 340 digital label press. The digital converting system, developed in a joint project with Heidelberger Druckmaschinen AG, is equipped with latest-generation inkjet print heads and prints in a quality that was previously only achieved on offset presses. The special thing about this machine system besides its unique print quality is the integration of inline finishing modules and conventional postpress operations. The Gallus DCS 340 prints digitally from reel to die-cut label in a single pass. 

The new Gallus DCS 340 offers flexibility and efficiency of digital printing combined with the benefits of inline finishing, embellishing and converting modules

Digital printing in offset quality
The new Gallus DCS 340 has been developed to meet the requirements of markets that are changing faster all the time. Its high resolution and precise print and embellishing quality are winning features. This machine system based on digital UV inkjet printing units enables label printers to achieve an unprecedented level of print quality matching that of high-resolution offset printing. With its high native resolution of 1200 x 1200 dpi, the Gallus DCS 340 is particularly impressive when it comes to small characters, fine lines and gradients down to zero percent. The unique, shaped inkjet print head also makes it possible to achieve seamless head stitching, resulting in a smooth print across the entire web. In addition to this superior inkjet technology, the Gallus DCS 340 also has conventional production units taken from the Gallus ECS 340, which is tried and tested a hundred times over. The Gallus DCS 340’s user-friendly HMI, which controls both conventional and digital modules, ensures that label printers manage and control their entire machine system with the same operating philosophy.

Conventional meets digital
The new Gallus DCS 340 also offers label printers the flexibility they expect from a digital press system. With its innovative integration concept, it combines digital printing with conventional printing, postpress and embellishing in a single system. From reel to high-finish die-cut label, everything is done inline in the Gallus DCS 340.
The eight-colour capability of the UV inkjet printing system extends the colour gamut without having to switch to spot colours. The integrated Prinect software from Heidelberg makes it easy for operators to transfer data from virtually any standard MIS system and provides a system interface for data handing that benefits from straightforward and intuitive operation, whether changing the arrangement of labels on the web or making subsequent colour corrections. Such operations are quick and easy for any operator thanks to this integrated software. That and the possibility offered by a job container of producing several jobs without stopping the press boosts any company’s production potential many times over.

The Gallus DCS 340 also impresses with its adapted and consumption-dependent ink business model. Thanks to this customer-friendly model, ink prices are at a level appropriate for the market and are based on the actual consumption.

The many different functions of the Gallus DCS 340’s digital front end deliver benefits for print shops across the board. Conventional functions are used precisely where they are needed for the efficient production of short runs with minimal setup times. Thanks to the unique design of the Gallus DCS 340 digital machine system, the converting systems normally located downstream for postpress operations are no longer required, which in turn leads to more efficient and cost-effective label production.

Gallus ECS 340 – the global bestseller in its class
Since its initial launch in 2010, the Gallus ECS 340 has been the top-selling narrow-web label press. And now the tried-and-tested Gallus ECS 340 has had a makeover. This new and improved machine system is equipped with the latest technologies and is being unveiled at Labelexpo 2015 in Brussels. The integration of flexographic printing units with enhanced performance levels ensures optimum productivity combined with top quality.

The new and improved Gallus ECS 340 is equipped with the latest technologies

The Gallus ECS 340 enables cost-efficient label production of the highest standard
The improved Gallus ECS 340 offers users the possibility of even more cost-effective commodity label manufacture. The consistently high production quality delivered by the machine is one of the key aspects of the Gallus ECS 340. From the manufacturing stage onwards, the focus was on the most important factors for optimising print quality while also maximising the speed and minimising costs. Thanks to its granite core, the Gallus ECS 340 benefits from a particularly long service life and excellent precision. A further impressive feature is that it is quieter than any other machine in its class. The shortest web path in the label industry – 1.1 metres between printing units – and the efficiency of the Gallus ECS 340 reduce the amount of waste generated during production, which maximises the profitability of operations for printers. Further attractive benefits of the Gallus ECS 340 are its short setup times and fast job changes thanks to sleeve technology and chambered doctor blades. These features ensure top quality at all times combined with consistent reproducibility and excellent resistance to ageing over the entire service life.

The impressive new features of the Gallus ECS 340
The grand unveiling of the Gallus ECS 340 equipped with these latest technologies will take place at Labelexpo 2015 in Brussels. The addition of the new high-performance matrix stripper gives the Gallus ECS 340 an extra feature that further boosts this machine’s productivity and cost-efficiency.

The new Gallus RCS 430 – more than a technical evolution
The success of the Gallus RCS press series is based on the unique combination of its modular design. This enables maximum flexibility in the selection of printing methods and an exceptionally high level of automation. The large number of Gallus RCS presses installed worldwide provides impressive proof of the great trust label printers around the globe place in this machine system. The Gallus RCS is being unveiled to the public in a new form and with new technology.
The new Gallus RCS 430 has been equipped with state-of-the-art control technology so as to be ready for the future.

Maximum process flexibility without any compromises
The Gallus RCS 430 promises label printers unrivalled application and process flexibility. This press can handle any substrate with ease and combines optimum profitability with maximum flexibility. The machine system supports six printing methods and defines the future of label printing. Offset, flexographic and screen printing units and hot foil embossing units – to name but a few – can easily be located anywhere along the press in just a few minutes without having to separate the web. This means that secondary processes such as cold foil embossing, laminating and reverse-side printing are quick and easy to incorporate on the secondary rail.

The new Gallus RCS 430 – a leader in UV offset printing
The Gallus RCS 430 promises label printers top-quality print results without any compromises in terms of output or cost-efficiency. Its robust design, state-of-the-art servo drive technology and intelligent user interface ensure optimum print quality. The quality of the offset printing results achieved by the Gallus RCS 430 is equivalent to that of sheetfed offset printing. The offset printing unit can be deployed anywhere in the Gallus RCS 430 process units. It can be combined freely with flexographic printing, screen printing and hot foil embossing. This ensures the printing units are used cost-effectively and in line with actual needs. Label printers thus benefit from an extremely flexible system that can respond quickly to changing market requirements. The highly automated Gallus RCS 430 also demonstrates its strengths in offset printing. It is equipped with the latest direct servo drives, which can be configured with the relevant settings to ensure continuous production. Thanks to optimum end-to-end automation, the Gallus RCS 430 maximises users’ operational cost-efficiency through extremely short job changeover times, fast ink changes, reduced setup times and minimal waste. The motorised printing units are quick and easy to adjust, which ensures consistent and precise reproduction of print results.

Gallus Screeny – 30 years of tradition, precision and innovation
For 30 years now, Gallus Screeny has been synonymous with innovative screen printing. The latest innovations from Gallus Screeny A-Line, metallic doming and Tempo 120 are being presented at Labelexpo 2015 in Brussels.

The latest innovations from Gallus Screeny
When it developed its own screen printing plates for rotary screen printing, Gallus also undertook to continuously develop and improve the technology behind the “Gallus Rotascreen” system solution. Tradition and precision are the cornerstones that have been helping Gallus to keep this innovation promise for 30 years. For example, the Gallus Screeny A-Line was launched midway through 2015 and is the most stable screen printing plate on the market. The metallic doming process is also currently being introduced in narrow-web label printing. This new and unique combination printing process from Gallus is based on rotary screen printing. In addition to this, the Tempo 120 project group has been founded with the aim of printing at a speed of 120 metres per minute for defined applications in combination printing (screen/flexographic printing).

Swiss precision – close-up of a Gallus Screeny A-Line screen printing plate.

Gallus Services – the decisive added value for our customers’ success
“Gallus Services” plays a key role in securing more success for the label printer. The technical availability of a press has a major impact on output. This year, during LabelExpo 2015 in Brussels, the company will be presenting two additional innovations – new doctor blades in a range of qualities and the self-adhesive Twinlock cylinder.

Three new types of doctor blade available as Gallus consumables
The squeegee or doctor blade is a key element in flexographic printing. High-precision, high-quality doctor blades are vital to ensure stable ink transfer and avoid premature wear on the anilox roller and all kinds of printing difficulties. Gallus offers three different high-quality doctor blade types for all Gallus presses.  

The Basic doctor blade: This doctor blade is very attractively priced. The Classic doctor blade is a top-quality doctor blade that benefits from additional hardening for an above-average lifespan at maximum printing speeds. The Premium doctor blade combines exceptional stability with a unique finish, which means it is used to counter printing problems such as ink spitting.

Polymount Twinlock cylinder
In flexographic label printing, the flexible printing plate is normally applied manually to the printing cylinder using foam adhesive tape. This tape has a huge impact on the print result and needs to be replaced at regular intervals. To achieve high-quality print results, it is advisable to apply new tape for each job. This takes time and costs money. What’s more, it is not unusual for incorrect application of the tape to cause quality problems. The revolutionary full-area and thus seamless self-adhesive Twinlock printing cylinder coating solves all these problems, because it dispenses entirely with the need for flexographic adhesive tapes and all the associated drawbacks. A solvent can be used to restore adhesion at any time. If used correctly, the manufacturer guarantees adhesion for an unlimited period.

The new Twinlock coating is available in three different levels of hardness for the full range of Gallus print cylinders and sleeves.