In a market environment characterized by rising cost pressures, shorter lead times, and an ever-increasing variety of product variants, one factor above all else determines competitiveness: productive efficiency and flexibility while maintaining consistent quality. With a printing speed of up to 100 m/min, the Gallus Five enables fast turnaround times and high production volumes —without compromising on precision or color intensity.
Designed specifically for medium to high print runs , it shifts the economic break-even point for hybrid label production from 5,000 to an impressive 10,000 running meters. This means maximum productivity at lower unit costs and a significantly improved TCO (Total Cost of Ownership).
Thanks to its modular architecture and seamless integration into the to Compose system, the Gallus Five is ideally suited to adapt flexibly to changing production requirements. Based on the proven Gallus Labelmaster platform, it can be configured with either a 340 mm or 430 mm print width.
Its future-proof, modular design allows for easy configuration and future expansion with printing, finishing, and die-cutting modules. This makes the Gallus Five the perfect solution for companies that want to stay one step ahead in a dynamic market environment.
In addition to all the advantages of the System to Compose—such as physical modularity, well-designed workflow solutions like operation via HEIDELBERG Prinect, and a modular service offering—the Gallus Five stands out thanks to innovative components that further boost efficiency and performance. These include the newly developed Heidelberg Saphira UV05 ink set, the high-performance SDC Pro semi-rotary die cutter for a print width of 430 mm, and the new, energy-efficient LED drying unit.
All components are perfectly matched to ensure maximum uptime and efficiency.
The new Heidelberg Saphira UV05 ink, developed in collaboration between HEIDELBERG and Gallus, complies with current regulations for safe inks. It is therefore particularly suitable for demanding and sensitive applications, such as those in the health, beauty, and cosmetics sectors.
In addition, the ink set (6C + white) delivers unmatched color brilliance and reduced ink consumption even at full production speeds, thanks to its high pigment concentration. The Heidelberg Saphira UV05 also covers the 32 most common PANTONE® spot colors used in packaging printing with minimal ∆E.
The new high-performance SDC Pro semi-rotary die-cutter is designed for maximum efficiency. It enables die-cutting at a width of 430 mm and speeds of up to 100 m/min. Its innovative design ensures quick die plate changes without the need to replace the die cylinder, which significantly reduces setup times.
The Gallus Five is equipped with advanced LED pinning and curing technology. The integration of GEW LeoLED reduces power consumption by up to 50%, resulting in significant savings on energy costs. In addition, customers benefit from the durability of LED technology, which not only increases efficiency but also enables sustainable and resource-efficient printing operations.
From significant time savings thanks to simple operation and automated functions, to an impressive printing speed of up to 100 m/min, to substantial energy savings thanks to innovative LED drying. The Gallus Five impresses from the very first print with outstanding Gallus quality and makes hybrid label printing faster, more efficient, and more cost-effective.
Whether you produce labels for healthcare and beauty products, household goods, technical products, or pharmaceutical and OTC products, the Gallus Five is up to the challenge. It is the perfect solution for large print runs that require a high level of finishing, delivering impressive results with every run.
| 340 | 430 | |
| Max. mechanical speed | 100 m/min. 328 ft/min. | 100 m/min. 328 ft/min. |
| Max. print width | 340 mm 13:39 | 430 mm 16.92 in |
| Productivity | 2,040 m²/h (21,948 ft²/h) | 2,580 m²/h (27,771 ft²/h) |
| Max. web width | 345 mm 13:58 | 445 mm 17.5 inches |
| Splice inspection | automatically | automatically |
| Teknek Rail Cleaning | on both sides | on both sides |
| Coronavirus | Front side or both sides | Front side or both sides |
| Anti-static system | Passive or active | Passive or active |
| Carbon-neutral | Yes | Yes |
| 340 / 430 mm | |
| Printing method | UV Piezo DoD - Inkjet (Fuji Dimatix) |
| Print resolution | 1200 x 1200 dpi native print resolution with a droplet size of 2 pL, optical resolution 2400 x 2400 dpi |
| Ink | Heidelberg Saphira UV05 |
| Colors | CMYK (Cyan, Magenta, Yellow, Black), Orange, Violet |
| White (optional) | 85% opacity |
| Pinning | Single-color pinning / Air-cooled UV LED |
| UV Curing | LED Curing (GEW LeoLED) |
| Automatic cleaning system | contactless; additional ultrasonic cleaning system for intensive cleaning |
| Vision System | Automatic display of pressure on the HMI |
| Digital Print Control | Automatic nozzle error detection and compensation / Density unevenness detection and compensation |
| Substrate qualification | Automatic inline qualification (100% system-supported) |
| Automatic Digital Register | Yes |
| Industrial Variable Data (iVDP) | Industrial Variable Data (iVDP) included; Full FDP optional |
| Insetting | Optional |
| 340 / 430mm | |
| Installation | On-premises or cloud-based |
| Digital Front End (DFE) | Server/Client Architecture |
| Server | Hardware or virtualized |
| Ink consumption | Cost estimate |
| 340 / 430 mm | |
| Monofilm | yes |
| Paper | yes |
| Composite materials | yes |
| 340 / 430 mm | |
| Tension | 380–415 V / 50 Hz |
| Power connection | Depending on the machine configuration |
| Compressed air | 6 bar, oil- and water-free |
| Exhaust air | Depending on the machine configuration |
| Conformity | CE, GS (UL upon request) |
| Network connections | Secomea for Remote Maintenance, Prinect & GEW Support |
| Cooling system | Air cooling for UV lamps and pinning |
| Water | Water for UV LED lamp heads, electronics, and the conveyor (cooling roller) |
| room temperature | 20–25 °C (68–77 °F) |
| Humidity (relative) | 40–60% |
| Air pressure (location) | 700–1,060 mbar (10.5–15.37 PSI) |
| 340 / 430 mm | |
| Dimensions | Depending on the machine configuration |
| 340 / 430mm | |
| Supply | 1,500 mm (59 in) |
| Issue | 1,500 mm (59 in) |
| Front | 1,500 mm (59 in) |
| Rear | 1000 mm (39 in) |
| Flatness | ± 1 cm over a length of 10 m |
| Load-bearing capacity | 1,600 kg/m² (2,275.7 psi) |
| All technical data, descriptions, and illustrations are provided without warranty and are not binding. Subject to change. |
In an industry where precision, efficiency, and innovation are key to success, in-depth expertise is the most valuable asset. The Gallus Print Academy’s training program was specifically designed to help print shops make the transition from conventional printing processes to digital and hybrid printing.
In keeping with the principle that “modularity is key,” the training program is also structured in a modular format. This allows customers to customize their program and receive training from our printing experts directly on their production floor.
