System to Compose

Modularity for maximum flexibility and future-proof operation

In a market characterized by changing requirements and increasing complexity, adaptability is key. With its modular approach, the System to Compose combines the advantages of conventional and digital printing processes to produce high-quality labels efficiently and economically.

The System to Compose is not just a concept—it is a modular system that keeps you one step ahead in the dynamic label printing market while maintaining perfect harmony between performance and profitability.

Five components – Perfect interaction

The System to Compose combines five modular components that are perfectly coordinated with each other: From press and ink to workflow solutions and services. Thanks to the consistent plug-and-play approach, each solution can be individually customized and flexibly expanded - tailored precisely to the requirements of your company.

Platform

The System to Compose uses the proven Gallus Labelmaster carrier modules as a reliable platform for your printing success. These enable customer-specific requirements to be met with tailor-made solutions and are available in three printing widths – 340 mm, 430 mm, and 570 mm. The platform serves as the basis for integrating all necessary printing, finishing, and processing units. It enables perfectly coordinated label production and is a robust foundation for versatile and future-proof performance.

Process units

The System to Compose offers unparalleled flexibility, allowing customers to seamlessly add, remove, or replace a wide range of conventional and digital printing modules, finishing units, and secondary rail and die-cutting solutions. This high degree of modularity allows customers to tailor their solutions to their needs while retaining the freedom to adapt as their operations grow and evolve. This dynamic scalability makes the System to Compose a truly future-proof investment that grows with the business.

Inks

The high-performance Heidelberg Saphira UV02 and UV05 inks, developed jointly by HEIDELBERG and Gallus, are designed to integrate perfectly into the digital printing unit (DPU). They deliver vibrant colors, high white coverage, and consistent print and color quality. Thanks to the modular ink system, flexible configurations are possible – from 4-color and 6-color printing to the optional integration of white. This ensures maximum adaptability for different label applications.

Workflow

With the System to Compose, all key systems can work together seamlessly. At its heart is a standardized human-machine interface (HMI) that is used on all Gallus machines. It has been designed so that the most important information is visible at a glance. This uniform interface simplifies operation and reduces complexity. All hybrid and digital printing presses can be operated via the intuitive and transparent Heidelberg Prinect®, which ensures maximum machine efficiency and productivity. For added flexibility, Prinect is also compatible with most third-party workflow systems.

Service

Gallus offers outstanding sales and service support with flexible service packages and on-demand training. Through its global sales and service network, which is operated in close partnership with HEIDELBERG, Gallus brings its service expertise directly to the customer's site. The Heidelberg World Logistics Centers (WLC) ensure particularly fast and reliable delivery of over 10,000 original Gallus spare parts and consumables. In addition, the Gallus Print Academy offers comprehensive training courses to enable your employees to achieve the highest quality in every print job.

Processing Units

Printing, embellishing, and converting solutions

Our printing, embellishing, and converting modules are seamlessly integrated into the Gallus machine platform. By combining conventional and digital printing modules, you can leverage the strengths of both technologies — without compromise. This holistic integration was developed to optimize efficiency, increase production flexibility, and create measurable added value for your business.

Printing and embellishing solutions

Digital printing unit
  • 1200 x 1200 dpi
  • Available in 340 mm and 430 mm print widths
  • The specially developed automatic cleaning system increases productivity by reducing downtime, ensuring consistent print quality, minimizing manual cleaning, and reducing ink consumption.
  • The Vision System ensures the highest print quality at all speeds and on all substrates through register adjustments at the touch of a button, live visual checks, and automatic compensation for nozzle errors and density fluctuations.
Flexographic printing unit
  • Servo-driven printing cylinder ensures first-class print quality and precise register accuracy
  • Short rail length of 1.4 m between units minimizes material consumption
  • Omega track run on large cooled pressure cylinder optimizes substrate conditioning and substrate diversity
  • User-friendly design enables quick setup and easy operation
Screen printing unit
  • High-resolution relief coating up to 300 μm
  • Fully integrated screen printing unit
  • Quick changeover and flexible positioning of the printing unit
  • High user-friendliness and automated functions
  • Comprehensive screen printing solutions and services portfolio from a single source
Gallus MatteJet
  • Print speed of up to 50 m/min ensures high productivity
  • Matte effect at the touch of a button (in digital inkjet printing) without changing the look and feel of the substrate
  • High cost efficiency, as no additional printing inks or special varnishes are required
  • Inline integration into the Gallus One

Die cutting solutions

RDC Top
  • Top-load rotary punch
  • Up to 200 m/min
  • Optionally available with cutting depth adjustment
RDC Quick
  • Very robust front-loading rotary die cutter, optimized for thin liners
  • Up to 200 m/min
  • High degree of automation with fast punch cylinder change and short setup time of less than two minutes
  • Optionally available with cutting depth adjustment
SDC ABG
  • Semi-rotary die cutter for 13.4 inches print width
  • Up to 70 m/min (depending on format)
  • Quick cutting plate replacement – no need to replace the cutting cylinder
  • Optionally available with cutting depth adjustment
SDC Pro
  • Semi-rotary die cutter for 430 mm print width
  • Up to 100 m/min (depending on format)
  • Quick punch cylinder change – no need to change cutting rollers
  • Optionally available with cutting depth adjustment

Movable secondary rail solutions

Cold foil unit
• Enhanced appearance thanks to metallic effects
• Pneumatic spindle displacement for holding up to four spools of cold foil
• Quick change thanks to easy handling
• Suitable for mono-lamination
• Flexible positioning on the secondary rail
Cold foil unit Pro
  • Enhancement through metallic effects
  • Precise winding thanks to motorized unwinder and rewinder
  • Pneumatic spindle displacement for applications with multiple films
  • Quick change thanks to easy handling
  • Suitable for mono and PS lamination
  • Flexible positioning on the secondary rail
Mono laminating unit
  • Surface protection of printed products through lamination
  • Suitable for monofilms
  • Manual tension control and side adjustment
Lamination unit
  • Surface protection of printed products through lamination
  • Suitable for mono films and pressure-sensitive laminates
  • Lateral adjustment
  • Motorized unwinder and rewinder for optimized film transport
Web turn bar
  • Precise double-sided printing, including reverse printing on glue
  • Microporous ridges prevent scratching of the substrate
  • Easy alignment of material paths
MR touch
  • Matrix rewinder for high production speeds of standard and complex label shapes
  • Compatible with all Gallus die-cutting modules

Heidelberg Saphira ink set

Two different ink sets are available for the digital printing unit (DPU), which were developed jointly by HEIDELBERG and Gallus. These sets determine the printing speed of the machine and impress with their vibrant colors, high white coverage, and consistently high print and color quality.

Heidelberg Saphira UV02 & UV04

The Heidelberg Saphira UV02 and UV04 ink sets were developed specifically for Gallus inkjet machines and enable printing speeds of up to 70 m/min. The 100% solvent-free UV inks ensure high abrasion resistance and good hardness. The very long nozzle opening time ensures reliable print quality and stability on a wide range of label substrates.

Printing speedUp to 70 m/min
CMYKUp to 88% PANTONE®
Optional O+VUp to 95% PANTONE®
Optional whiteUp to 85% opacity
DryingMercury vapor lamp (UV-Hg)

Heidelberg Saphira UV05

The Heidelberg Saphira UV05 ink set was developed specifically for the Gallus Five and enables printing speeds of up to 100 m/min. The new inks are characterized by first-class conformity with the latest industry standards. In addition, they offer unparalleled color brilliance and vivid pigmentation even at full production speed. The ink set also covers the most common spot colors in packaging printing with minimal ΔE.

Printing speedUp to 100 m/min
CMYK, O+VUp to 95% PANTONE®
Optional whiteUp to 85% opacity
DryingUV LED (LeoLED)

About the printing systems

Print widths: 340 / 440 / 570 mm

Gallus Labelmaster

The Gallus Labelmaster takes conventional label printing to a new level. The machine system combines maximum flexibility and simple handling with optimum cost efficiency.

Print widths: 340 / 430 mm

Gallus One

The Gallus One is a future-proof investment that combines maximum automation, modularity, and flexibility, thereby reducing the total cost of ownership for digital label production.

Print width: 340 / 430 mm

Gallus Five

Experience a new dimension in label printing with the Gallus Five – powerful, flexible, and innovative. Developed for label converters who demand high speeds of up to 100 m/min, precision, and uncompromising quality.

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