Gallus Labelfire

Innovative quality of the highest standard
With the Gallus Labelfire, the engineers at Gallus and Heidelberg have succeeded in developing a highly innovative digital converting system. The compact digital production system combines unrivalled UV inkjet printing quality and maximum-efficiency digital printing with the inline productivity and speed of flexographic printing. It goes without saying that this industrial inkjet press system also meets Gallus’s high standards in terms of register accuracy.

Four- or even Seven-colour printing system for a bigger colour gamut plus digital white.

Semi-rotatry die-cutter for minimised tool costs and a wide choice of substrates.

Improved resolution and offset quality
The new Gallus Labelfire 340 digital production system enables label printers to achieve levels of print quality that match those of high-resolution offset printing. This is reflected in the native (physical) resolution of 1200 × 1200 dpi with a droplet size of just 2 pl and four different drop sizes, corresponding to a visual resolution of 2400 × 2400 dpi. The high physical resolution of the inkjet heads offers a real advantage, particularly when it comes to small symbols and characters as well as fine lines and gradients down to zero percent. The smallest droplet size in the printing industry to date results in smooth, satin-finished surfaces, improved ink adhesion and curing and minimal ink consumption. The unique shaped inkjet print head enables seamless inkjet head stitching, resulting in a smooth print across the entire web. The combination of digital white, CMYK, the colour scale enlargement colours orange, violet and green, as well as 7-colour separation mean the Gallus Labelfire 340 press system can cover a large portion of the simulated PANTONE® PLUS colour scale. All of this is made possible by the use of specially developed screen and colour management algorithms that Heidelberg has been utilising with great success in its offset prepress solutions for decades.

Inter Color Pinning ensures excellent printing quality and a wide choice of substrates.

The unique rhombic shape of the heads makes it easier to achieve a seamless fit between the heads to create a smooth colour progression.

Pinning module with light trap for ensuring dots have sharp edges.

Digital flexibility
The Gallus Labelfire is a system with an end-to-end logical operating concept that integrates digital printing with conventional printing and further processing. Labels are produced inline in a single production operation – from the unprinted roll to the matrix-stripped end product. A key benefit of the Gallus Labelfire press system is its outstanding flexibility. The digital printing unit even enables cost-effective production of runs with variable data, versioning and short runs.

Inline processing in a single step
Tried-and-tested integrated Gallus ECS modules support the digital flexibility of the Gallus Labelfire 340 printing unit in delivering top print quality. The strengths of digital printing combined with those of the inline further processing operations of a conventional label printing press optimised for digital printing open up a wide variety of possibilities. For the first time, labels can be varnished, laminated, embellished with cold foil and die-cut in a single operation. The conventional modules support the use of primer, spot colour, security or cold foil features, varnish or lamination without interrupting production, and regardless of the complexity of the label. Even before digital printing, the Gallus Labelfire is able to combine special effects such as metallic or neon colours or flexo white and add spot colours.

Maximum flexibility in substrates
The Gallus Labelfire digital press system offers label printers an unprecedented variety of substrates. There is no need for additional priming or varnishing. Coated path rollers, pressure arms and a cooling roller mean the industrial inkjet system is suitable for processing temperature-sensitive and thin substrates. The printing system also delivers high levels of flexibility when it comes to applications, with no change-over to additional digital colours being required, e.g. the use of digital white. Following prepress preparation, data for job changes is easily uploaded at the touch of a button via the integrated Gallus HMI touchscreen control panel that also controls the digital and conventional Gallus Labelfire modules with the same operating logic. Regardless of the material and die-cutting line length, most common substrates can be die-cut thanks to the semi-rotary die-cutting unit. Direct matrix removal ensures clean and constant print results, even for complex die-cutting contours of up to 70 m/min.

The proven modular system of the Gallus ECS 340 optimises the flexibility of the Gallus Labelfire.

The fully integrated Gallus HMI is the central operating station that controls the entire machine.

Optional slitter avail-able in rotary blade and/or razor blade design.

Maximum integration for ultimate productivity

As a highly efficient industrial production system, the Gallus Labelfire excels when it comes to short and medium runs and above. A single operation is all that is required from substrate to the finished roll of labels, with no need for production or machine stops for completion or further processing.

Gallus Labelfire 340: This 4- (plus optional white) or 8-color inkjet system delivers up to 94 percent of the the simulated PANTONE® PLUS colour scale in outstanding quality.
 All digital print unit configurations: A native resolution of 1200x1200 dpi ensure optimum quality at speeds up to 70 m/min.

Print functions
The digital front end of the Gallus Labelfire delivers a number of impressive practical functions including spot colour matching, the PDF Toolbox and Prepress Manager, to name but a few. All conventional print functions available meet the requirements for efficient production of short runs through optimised setup times, minimal waste and tool costs. In addition, the double rewinders enable rapid changeovers and crossed winding of small narrow rolls and also support minimal setup times.

Semi-rotary die-cutter with compensator.

The double rewinder enables interlaced winding of small reels and setup during production.

Dependable reliability
For more than 90 years, the motto at Gallus has been “success and security for the labelprinter”. Collaboration with Heidelberg, a partner with decades of experience in digital prepress and solid press engineering, created the perfect conditions for the development of a unique industrial inkjet production system in the form of the Gallus Labelfire.

The power of hybrid

The Gallus Labelfire conventional printing functions also deliver additional finishing options and inline further processing, e.g. varnishing, laminating and die-cutting. The semi-rotary die-cutting unit also delivers further benefits – printers can re-use existing die-cutting plates, meaning fewer new ones are required and thereby reducing procurement costs for these. The fair, consumption- dependent business model ensures that ink prices and service provision reflect the market and that customers benefit directly from the process optimisation achieved.

The main advantages of the Gallus Labelfire:

Lowest cost-per-label
Maximum productivity in conjunction with competitive ink prices and the efficient colour management of Prinect enable the printer to produce labels at an excellent price/performance ratio.

Quality
The best available resolution of 1200 × 1200 dpi (native) at 70 m/min* and camera-based quality assurance ensure perfect print quality. The Single Color Pinning process ensures sharp printing results even with extra fine lines and very small fonts. The 7-colour printing unit is capable of simulating up to 94%** of PANTONE® PLUS colours. Constant colour stability throughout the entire production life of the machine guarantees exact reproducibility for repeated print jobs.

Ease of use
One control panel for everything. Gallus Labelfire’s integrated register control and Human Machine Interface (HMI) stand for simple and intuitive operation. The conventional modules are controlled with the same operating logic as the digital printing unit. In addition, camera-based quality monitoring and nozzle error detection and compensation ensure the highest inkjet print quality.

From now on: "Diamond Core Series": Four models of the Gallus Labelfire are now available, concisely and clearly defined and tailored to the different market requirements. Find out more and order your print samples here!