System to Compose

Modular platform for maximum flexibility

Instead of investing in a rigid machine configuration, label printers using Gallus’s System to Compose benefit from a scalable printing system that adapts flexibly to market changes, new applications, and increasing production volumes, and can be further developed over the long term.

The ideal solution for anyone looking to optimize their printing operations cost-effectively and make future-proof investments .

Five components—perfectly coordinated

A holistic printing concept

What sets Gallus' System to Compose apart from other modular printing solutions in label printing is that its modularity doesn't stop at the press. Five perfectly coordinated components— platform, processing units, ink, workflow solutions, and service— form a comprehensive system for flexible label printing.

Every component can be customized individually, and every expansion is plug-and-play compatible. This ensures that you don’t end up with a siloed solution, but rather a printing solution that evolves alongside your company’s needs—technologically, economically, and with a view to the future.

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.

Integrated printing modules for measurably greater production efficiency

Our printing, finishing, and post-press 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 comprehensive integration solution is designed to optimize efficiency, increase production flexibility, and deliver measurable value to your business.

Printing and Finishing Solutions

Digital printing unit
  • 1200 x 1200 dpi
  • Available in 340 mm and 430 mm print widths
  • The proprietary automatic cleaning system boosts productivity by reducing downtime, ensuring consistent print quality, minimizing the need for 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
  • A servo-driven printing cylinder ensures top-notch print quality and precise registration
  • A short track length of 1.4 m between units minimizes material consumption
  • Omega web path on a large, cooled pressure cylinder optimizes substrate conditioning and substrate versatility
  • User-friendly design ensures 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 features
  • A comprehensive portfolio of screen printing solutions and services from a single source
Gallus MatteJet
  • Print speeds of up to 50 m/min ensure high productivity
  • A matte finish at the touch of a button (in digital inkjet printing) without altering the appearance or texture of the substrate
  • High cost-effectiveness, as no additional printing inks or special coatings are required
  • Inline integration with the Gallus One

Die-cutting solutions

RDC Top
  • Top-load rotary die cutter
  • Up to 200 m/min
  • Optionally available with cutting depth adjustment
RDC Quick
  • Highly durable front-load rotary die-cutter, optimized for thin liners
  • Up to 200 m/min
  • High degree of automation with quick die cylinder changes and a short setup time of less than two minutes
  • Optionally available with cutting depth adjustment
SDC ABG
  • Semi-rotary die-cutter for a 340 mm print width
  • Up to 70 m/min (depending on the format)
  • Quick insert change – no need to change the cutting cylinder
  • Optionally available with cutting depth adjustment
SDC Pro
  • Semi-rotary die-cutter for a 430 mm print width
  • Up to 100 m/min (depending on the format)
  • Quick die cylinder change – no need to change the cutting rollers
  • Optionally available with cutting depth adjustment

Removable secondary splint solutions

Cold foil unit
• Enhanced with metallic effects
• Pneumatic spindle displacement capable of holding up to four reels of cold foil
• Quick change thanks to easy handling
• Suitable for single-sided lamination
• Flexible positioning on the secondary rail
Pro Cold Foil Unit
  • Enhanced with metallic effects
  • Precise winding thanks to motorized unwinding and winding mechanisms
  • Pneumatic spindle displacement for applications involving multiple films
  • Quick change thanks to easy handling
  • Suitable for mono and PS lamination
  • Flexible positioning on the secondary rail
Single-sided laminating unit
  • Surface protection of the printed product through lamination
  • Suitable for monofilaments
  • Manual tension control and side adjustment
Laminating unit
  • Surface protection of the printed product through lamination
  • Suitable for monolayers and pressure-sensitive laminates
  • Side adjustment
  • Motorized unwinder and rewinder for optimized film transport
Track turner
  • Precise double-sided printing, including reverse-side printing on adhesive
  • Microporous ridges prevent scratching of the substrate
  • Easy alignment of material paths
MR Touch
  • Matrix winders for high production speeds of standard and complex label shapes
  • Compatible with all Gallus die-cutting modules

Heidelberg Saphira Ink Set

Two in-house developed ink sets are available for the digital printing unit (DPU). Depending on the market segment and desired print speed, label printers can choose between Saphira UV02/UV04 and Saphira UV05 ink, always benefiting from vibrant, brilliant colors, high white opacity, and consistently high print quality.

The result: labels that make an impact at the point of sale—reliable, consistent, and produced in large quantities.

Heidelberg Saphira UV02 & UV04

The Heidelberg Saphira UV02 and UV04 inks were developed specifically for the Gallus One and enable production speeds of up to 70 m/min.

The 100% solvent-free UV inks ensure high abrasion resistance and good hardness. The very long nozzle open time ensures reliable print quality and stability on a wide variety of label substrates.

Print 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 ink colors meet the latest industry standards and deliver impressive color brilliance and pigmentation even at full production speeds. Label printers who require the highest color accuracy in packaging printing also benefit from the precise reproduction of common spot colors with a minimal ΔE value—ensuring consistent brand colors across all print runs.

Print 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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