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Hotspot for Digitalisation and Packaging Technology

Vishnu Rahma
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Hotspot for Digitalisation and Packaging Technology

  • Arburg host computer system: All trade fair machines interlinked
  • High-speed: Four IML containers in around 5.5 seconds
  • Screw caps: High-quality and reliable production

During Plástico Brasil from 27 to 31 March 2023 in São Paulo, Brazil, Arburg will be showcasing application examples of digitalisation and efficiency enhancement in the series production of plastic parts at stand I040. The focus will be on the packaging sector. In addition to the production of screw caps and IML cups, the potential of the Arburg host computer system (ALS), which is used to interlink both exhibits, will also be demonstrated live during the trade fair.

“Plástico Brasil is the most important plastics trade fair for Brazil and the whole of South America,” says Alfredo Fuentes, Managing Director of Arburg Ltda. in Brazil. “Now, after a break of four years, the fair is giving us the opportunity to reconnect with existing and potential customers again.”

According to Fuentes, the application areas of packaging, household goods and medical technology have seen very dynamic growth in the Brazilian market in recent years. “We have expanded our portfolio accordingly, so that we can offer world-class manufacturing solutions for these industries.”

Assistance systems support set-up technicians and operators
On the stand, an Allrounder 570 E Golden Electric will be producing PP screw caps in an 8-cavity mould with a clamping force of 2,000 kN. The moulded parts have a diameter of 63 millimetres and a weight of 16.5 grams. The Multilift Select robotic system is used to remove the components. The machine is equipped with Arburg’s “4.set-up” assistance system, which has a wide range of features to simplify set-up and conversion. aXw Control ScrewPilot ensures a stable filling process by regulating the position of the screw, which in turn results in a reliable process and high product quality.

The Allrounder 570 E Golden Electric produces PP screw caps in an 8-cavity mould at Plástico Brasil.

Another Arburg exhibit at Plástico Brasil is an Allrounder 630 H with a clamping force of 2,500 kN. The machine can produce IML containers with a capacity of 220 millilitres in a cycle time of around 5.5 seconds. The IML robot is provided by the Brazilian manufacturer G3 Automation Machinery Industry and Trade. The machine’s Gestica controller features a host of assistance functions offering set-up technicians and operators maximum convenience and extensive support. For example, aXw Control FillAssist automatically calculates the processing parameters based on the component model. This expedites the set-up process and helps to avoid errors during machine set-up.

Both machines are interlinked with the Arburg host computer system (ALS), meaning that visitors can experience first-hand the benefits offered by ALS. For example, indicators relating to current orders, shifts and production quality can be obtained at any time, making it possible to identify where targeted improvements can be made to the production process. This increases product quality and the availability of the system in the long term.

The Arburg host computer system brings transparency to production. With the mobile ALS functions, all important information is available anytime and anywhere.

Further information about Arburg can be found at www.arburg.com

 

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Neste, Borealis, Uponor and Wastewise Group Enable Chemical Recycling of Hard-to-recycle Plastic Waste Into New High-Quality Plastic Pipes

Vishnu Rahma
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0

Neste, Borealis, Uponor and Wastewise Group Enable Chemical Recycling of Hard-to-recycle Plastic Waste Into New High-Quality Plastic Pipes

  • First production of cross-linked polyethylene (PEX) pipes based on feedstock from chemically recycled PEX waste
  • Project demonstrates chemical recycling can process hard-to-recycle waste plastic into high-quality polymer products
  • Partners to evaluate further cooperation to expand waste material pool as well as recycled volumes

Neste, Borealis, Uponor and Wastewise have successfully produced pipes made of cross-linked polyethylene (PEX) which was based on feedstock gained from chemically recycled post-industrial waste plastic from PEX pipe production, using an ISCC PLUS certified mass-balancing approach. The partner companies believe this project is among the first implementations of chemical recycling of PEX.

PEX pipes are an important contributor to energy efficient heating and safe plumbing due to their robustness, temperature resistance and longevity, yet the interconnected polymer chains make them nearly impossible to recycle with conventional recycling technologies. The project shows that chemical recycling can close the circularity loop for hard-to-recycle waste plastic, turning it into high-quality polymers feedstock and enabling the consecutive manufacturing of products with quality and properties identical to those in their previous life.

The cooperation sees Wastewise use their novel pyrolysis-based chemical recycling technology to liquefy industrial waste from Uponor’s PEX pipe production, breaking the polymers down back into their building blocks, which creates an oil-like recycled intermediate. This liquid is then co-processed in Neste’s oil refinery in Porvoo, Finland and upgraded into recycled Neste RETM, a high-quality drop-in feedstock for the production of new polymers. Borealis is feeding this raw material into their steam cracker and consequently polymerizing it into polyethylene as part of the company’s BorcycleTM C, chemical recycling portfolio. Finally, Uponor is using the polyethylene to create new PEX pipe systems, which can then be used in the construction sector for heating, plumbing and cooling purposes once more – eligible even for sensitive applications with high requirements, for example those used for drinking water systems. The whole value chain is traceable via ISCC PLUS certified mass-balancing.

“We are very excited about this collaboration as it gives us a head start on our transition to circular materials,” says Thomas Fuhr, Chief Technology Officer at Uponor. “PEX is by far the material that has the most versatile application uses, from building water supply systems to efficient radiant heating and cooling systems, thanks to its superior properties for the construction industry. At Uponor we have just celebrated the first 50 years of our PEX piping, and now our new long-term goal is to use 100% of our PEX waste as raw material through closed loop recycling.”

“Hard-to-recycle waste plastic as input and high-quality polymers as output are not in contradiction anymore,” says John Webster, Global Commercial Director Infrastructure at Borealis. “In fact, we are able to integrate chemically recycled PEX pipe waste plastic as a raw material into our established manufacturing processes. It doesn’t require additional tests, approvals or validation. It’s a drop-in solution ready to use even for drinking water applications.”

“The successful project demonstrates not only that recycling of PEX is possible via chemical recycling, but it also shows that it’s actually possible with high yields: some 80% of the PEX production waste can be added back to the circle,” says Kaisa Suvilampi, Managing Director and Partner at Wastewise. “Through our processes, we were able to turn PEX into pyrolysis oil of sufficient quality to use it as input for a refinery, which in turn can process it into a high quality cracker feed. This project strikes certain PEX off from the list of materials giving recyclers a headache.”

“The curtain is opening for chemical recycling,” added Mercedes Alonso, Executive Vice President Renewable Polymers and Chemicals at Neste. “It will still take time to reach large-scale operations, but this project is providing the blueprint for circular value chains for polymers via chemically recycling. It’s pushing the technology from the promise to the delivery phase. Further, it shows the importance of bringing the right partners together to cooperate.”

Due to the involved parties’ commitment to pushing circular solutions for polymers and the solution’s drop-in character, the partners were able to establish the value chain in a rather short period of time. Little more than six months passed between the start of the project and the production of the first pipes made with chemically recycled PEX waste.

The partnership holds potential for further cooperation beyond production waste: The PEX pipes made by Uponor have already been optimized from a resource efficiency point of view by reducing their wall thickness and increasing lifetime. At the end of their long life, mechanical recycling is so far the first recycling option, but it also means downcycling the materials, e.g. into other construction materials or items such as hockey sticks. With chemical recycling, though, the PEX waste pipes can be turned into fully functional PEX pipes again. Moving forward, the partners will evaluate further opportunities for cooperation. Aside from broadening the waste material pool, this may also include higher recycled volumes.

www.neste.com

 

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New Flex Option for DIEFFENBACHER’s Fibercon Consolidation System

Vishnu Rahma
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0

New Flex Option for DIEFFENBACHER’s Fibercon Consolidation System

Flexible sheet simplifies geometry- and thickness-independent consolidation

A new Flex option for the DIEFFENBACHER Fibercon system expands customers’ application possibilities by making consolidation possible independent of the tape layup geometry and layup thickness. This option is available as a retrofit or as part of a new Fibercon system.

The DIEFFENBACHER Fibercon system consolidates tape layups into near-net-shape laminates with excellent quality and porosity of less than 1%. Fibercon achieves exceptionally good material properties for high-quality components, making it ideal for large-scale production of individual component-specific tape layups. It’s even possible to process high-performance thermoplastics without further adaptation.

Vacuum consolidation of the tape layups in the standard Fibercon version takes place between two frames with transparent glass inserts. In the new Flex version, the upper frame comes with a flexible sheet that automatically adapts to the contour of the tape layup.

Many applications, especially in the sports and leisure and automotive industries, can benefit from the new Flex option, explains Marco Hahn, Director Sales of the Forming Business Unit at DIEFFENBACHER. “In manufacturing bicycle frames and rims with high component diversity, for example—for which the Fibercon is extremely well suited—the new Flex option simplifies production.” Variable layup thicknesses and geometries of up to 4 mm can be consolidated with very high quality but without
component-specific tools.

With a temperature range of up to 250°C, the Fibercon Flex option is the ideal consolidation system for all PP and PA6 applications, regardless of the type of fiber used. Compared to conventional laminating presses, the Fibercon delivers significantly higher product quality, as thickness variations in the component are preserved, and neither squeeze flow nor fiber ondulations occur. Unlike permanently heated laminating presses, the Fibercon heats the product directly, without any peripherals and only during actual consolidation. In this way, pause and set-up times are bridged without energy input or long heating processes. This makes the Fibercon
consolidation system many times more energy-efficient and resource-saving.

“Each Fibercon is equipped with three pairs of frames as standard. With the new Flex option, each customer can choose how many of these frame pairs to equip with the standard glass insert and how many with the new flexible sheet. This ensures maximum flexibility,” says Hahn. “Existing installations can also be retrofitted with the Flex option at any time and with minimal effort.”

DIEFFENBACHER Fibercon

www.dieffenbacher.com

 

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Clariant Wins 2022 Anglo American Supplier Awards

Vishnu Rahma
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0

Clariant Wins 2022 Anglo American Supplier Awards

  • Clariant wins four awards including Outstanding Supplier 2022
  • Other prizes recognize performance, optimization and contributions to social projects
  • Awards demonstrate Clariant’s innovative customer solutions and commitment to sustainability

For the second year running, in 2022 Clariant has been named Outstanding Supplier by Anglo American. The award recognizes the partnership between the two companies.

Clariant was also recognized in the ‘Optimization’ category for its FLOTIGAM silica collectors, which enable a mine to separate silica from iron ore with minimal iron loses. Clariant customizes the collectors for each mine to achieve the maximum possible iron recovery while achieving or improving upon the required iron ore concentrate grade.

In the ‘Performance’ category Anglo American acknowledged Clariant’s ongoing support to enhance the silica collectors for reverse iron ore flotation and in other applications beyond flotation to help optimize operations.

In the ‘Sustainability/Social Projects’ category, Clariant was recognized for its work with nearby local communities. Clariant sponsors a project to promote sports activities among students, which expanded in 2022 to include one additional public school as well as classes for adults. The company also supports several other initiatives with students. This project has already benefited hundreds of people in the last six years and will continue in 2023. It’s the fourth time that Clariant and this important social initiative have been recognized by Anglo American.

“We are proud to receive the Outstanding Supplier Award from our customer Anglo American for the second year in a row. Additionally, being recognized again for our contributions to sustainability and social responsibility really shows our commitment to living out our purpose – Greater Chemistry, between People and Planet,” said Anna Dacar, Head of Business Segment Mining Solutions.

Clariant offers a wide portfolio of innovative, customized solutions to the mining industry, supported by a highly qualified team of experts and a robust global footprint, including application laboratories and competence centers in many of the major mining regions in the world. Clariant delivers sustainable solutions to the mining industry, including its Tailings Management Program to help mine operators reduce the amount of tailings they generate and improve their tailings storage practices.

www.clariant.com

 

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Standardised HASCO Colour Table for Tolerances in The 3D Model

Vishnu Rahma
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0

Standardised HASCO Colour Table for Tolerances in The 3D Model

In 3D-CAD design in mould and tool making, defined colours are frequently employed for the identification of tolerances. With the aim of using uniform colour schemes to create an easy-to-use standard to make the work of the designers as easy as possible, HASCO – as a leading manufacturer of high-quality standard mould components and customised hot runner solutions – worked with various cooperation partners to produce the industry standard as part of a joint project.

Standardised colour tables simplify CAD design

A standardised colour table for mould and tool makers has been developed making it possible to easily and quickly identify tolerances of workpieces in 3D design. The result is a standardised colour table (VDWF Guideline 2020-1) for tool and mould making that is now available on the HASCO website and makes it possible to unambiguously label tolerances through defined colours. The CAM systems conventionally used can directly read in 3D models, automatically recognise the colours, and, from this, derive the tolerance.

Colour table standards simplify process automation

Misinterpretations when converting from a 2D drawing can be effectively avoided. ACTUAL dimensions are automated through corresponding measuring systems and can be compared with the 3D model. This simplifies process automation. Furthermore, this tool can be used for easy exchange of models for production at other locations.

Simply download the standardised HASCO colour table at www.hasco.com/en/hasco/cad, and take advantage of the benefits.

www.hasco.com

 

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HASCO Update – CAD Native Data for SolidWorks

Vishnu Rahma
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0

HASCO Update – CAD Native Data for SolidWorks

Standard mould units in the CAD system can do a great deal more than just replicate the geometry. Parameter-controlled native standard mould units offer the designer numerous advantages.

With the latest update of the SolidWorks Database, HASCO is providing its customers with an exclusive tool with around 100 further products. The parametric data allows simple and precise working.

In addition to the geometry of the component, the standard elements also contain information about the cutting geometry. Through Boolean operations, the cutting elements can be removed from the mould plates. This considerably facilitates installation of the mould units in the mould.

Native CAD data with installation spaces for ultra-short design times

The fully parametric data also have decisive advantages if any changes are made, since the relevant parts automatically adapt to the corrections. A new parts list is then generated, guaranteeing very high process reliability and completely eliminating the risk of incorrect orders. The largely automated ordering process ensures punctual delivery for the start of assembly and rounds off the overall process in a perfect manner.

Maximum process reliability through automatic parts list generation

If the design data, with the added value of the installation geometry, is channelled directly to the machining centre, further savings can be made at the downstream CAM stage.

The CAD specialists at HASCO are always available to assist SolidWorks users in implementing the database in their own systems.

www.hasco.com

 

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Precise and Easy Control with HASCO Control Units

Vishnu Rahma
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0

Precise and Easy Control with HASCO Control Units

Temperature control has a major influence on the quality of the mouldings. For around 35 years now, HASCO hot runner has been intensively involved in the further development of hot runner control units and offers a variety of different units for customised applications.

Basezone H1250/…

The basic control unit H1250/…, available in 1, 2 and 4 control zones, allows a high level of reliability in production. This reliability is ensured by the improved, self-optimising control characteristics, soft-start mode and LED displays for target/actual temperature, control parameters and an unambiguous alarm diagnosis. This device stands out for its simplicity, being designed as a plug-and-play controller and dispensing with additional features. It merely has the classic boost and stand-by functions and the possibility to switch over to manual mode.

Clickzone H1270/…

The module controller H1270/… allows 3-6 modular units to be fitted. Self-optimising control characteristics, a soft start for gentle drying of the heating unit, LED displays for target/actual temperature, control parameters and reliable error messages are some of the features of this controller. A two-colour LED strip shows the operating status. For flexible injection moulding production, the controller can also be replaced quickly and easily if necessary during operation.

Valuezone H1252/…

The multi-zone control units H1252/… are available in two versions with 6 and 12 control zones. A programmable soft start, a constant power display, unambiguous alarm diagnosis and permanent signalisation of the operating state via an LED strip ensure maximum reliability in production. The control accuracy of <1 °C under optimum conditions and switch-over temperature sensor are further features.

Primezone H1281/…

With the new generation of innovative control units, Primezone H1281/…, HASCO hot runner has made an important addition to its hot runner product portfolio. This range boasts outstanding control accuracy, intuitive ease of operation and comprehensive diagnostic functions. The touch-screen display and the latest software technology enables simple and intuitive operation just like a modern smartphone. With the three table-top sizes, it is possible to control between 6 and 48 zones precisely and reliably and, with the mobile version, between 64 and 96 zones.

All the control units allow a high level of production reliability and offer unique user friendliness, control accuracy and long service life. Apart from that, the new, smooth-running Co-Cart H1200/… transport trolley from HASCO hot runner allows perfect and secure positioning of the devices directly next to the mould.

www.hasco.com

 

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Elastomer Entrepreneur Michel Baulé Passed Away

Vishnu Rahma
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0

Elastomer Entrepreneur Michel Baulé Passed Away

With great sadness Covestro and its employees learned about the death of Michel Baulé, entrepreneur in the cast polyurethane industry, who has passed away January 13th at the age of 79.

“Our thoughts and condolences are with Michel’s family,” said Thomas Braig, Head of Elastomers at Covestro. “We will forever and fondly remember the entrepreneur, the exceptional man and our friend who was at the origin of Covestro Elastomers.”

Graduated with a PhD in chemistry, the native of Cavaillon, France embarked on entrepreneurship in 1976 at the age of 33 by creating a molding company for cast polyurethane parts in Romans-sur-Isère, France. Fate, circumstances and his passion for innovation made him establish a second business in 1983, specializing in the formulation of cast elastomers systems. Together with companions such as Philippe Jeantin, currently Head of the Machines business at Covestro Elastomers, Antonio Alvarez and Mauro Modugno he then founded even another business in 1987, dedicated to the design and manufacture of low pressure dispensing machines.

These businesses became a leader in its realm as a cooperation. It later divested its molding entity to its executives to become EXSTO, while Baulé, combining the material formulation and the machines manufacturing, successfully established a Joint Venture with the MaterialScience division of the Bayer company in 2008. In 2012, this turned into a merger, and Baulé’s former business became officially part of the Bayer group. In 2015, it became part of the carve out of Covestro from its parent company Bayer. Today, this business finds its heritage in the Elastomers Business Entity of Covestro, still headquartering in Romans-sur-Isère.

“We pay tribute to genius that was Michel Baulé, for inspiring dozens of innovations in the cast polyurethane industry, among them the development of three-components systems with quasi-MDI-prepolymers and many innovative processing concepts that lead us to maintain and promote the brand Baulé for our machine technology. He will be missed dearly,” Abdel Arhzaf, Managing Director of Covestro Elastomers SAS, added.

After a valuable contribution to the growth of the cast polyurethane industry, Michel Baulé developed a family office called EXIMIUM which has maintained all its entrepreneurial culture through acquisitions and participations while developing financial activities and support services. Until his last days he remained very active and energetic in his entrepreneurial role.

www.covestro.com

 

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Print & Digital Convention Shows the Future of Multi-Channel and Dialogue Marketing

Vishnu Rahma
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0

Print & Digital Convention Shows the Future of Multi-Channel and Dialogue Marketing

About three months before its kick-off on 16 May, the PRINT & DIGITAL CONVENTION 2023 is on a very positive course for success: the bookings received so far already exceed the previous year’s levels. Numerous international industry players will be represented again making the Düsseldorf congress trade show the trendsetting platform for multi-channel and dialogue marketing. The Ticketshop is open as of now.

They will demonstrate how print becomes an experience, how haptics sparkle and what tomorrow’s digital and online strategies will look like: the exhibitors and speakers of the PRINT & DIGITAL CONVENTION 2023 will offer countless opportunities to discover trends and be inspired. Renowned enterprises such as Konica Minolta, Canon, Xerox, RISO, and KURZ will be “on board” as exhibitors and introduce to participants their solutions and applications for a modern and sustainable media production.

“It is a great success that we have already achieved an increase of 5% in exhibitor registrations compared to the previous event at this point in time,” explains Rüdiger Maaß, Managing Director of Fachverband Medienproduktion e.V., f:mp. (Media Production Association). “What makes us especially happy is that we have currently canvassed 20% first-time exhibitors.”

One of these new exhibitors is Zaikio, a development studio that emerged from software company Crispy Mountain and Heidelberger Druckmaschinen AG. Commenting on this, Thomas Ahlrichs, advisor at Zaikio, says: “The format of the PRINT & DIGITAL CONVENTION convinces me: the atmosphere is familiar and allows in-depth exchange at eye level. I meet old acquaintances here and learn about new things. This makes the PDC a brilliant interface for the industry. We do have a bit of a weak spot for open interfaces…”

After all, the PRINT & DIGITAL CONVENTION is not only a congress trade show but also a hands-on experience and content-focused event. A concept that has also convinced Kim Niemeyer, Marketing & Communication, Ing. Fritz Schroeder GmbH & Co. KG: “The PRINT & DIGITAL CONVENTION demonstrates time and again and in many ways that the world of print is alive and diverse. The exhibitors bring print to life. We are happy to be a part of this, flagging up the opportunities offered by print processing and finishing and provided by this mix of technology, knowledge transfer and networking.”

With their innovative solutions and applications Konica Minolta are also a perfect fit for the diverse range of topics covered by this congress trade show. Confirming this, Mirko Pelzer, Offering Manager Germany & Austria at Konica Minolta Business Solutions Deutschland GmbH, says: “As a longstanding partner of the PRINT & DIGITAL CONVENTION we look forward to once again helping to shape one of the most relevant meetings of the graphics industry in 2023. In tune with the motto ‘Use your Opportunities’ we will present GLAMPRINT showing how customers can fully leverage their creative potential to turn print into a unique experience that delivers its impact on all levels.

What also makes the PRINT & DIGITAL CONVENTION so special is the presentation of innovative technologies by way of highlight projects, which not only feature individual machines or tools but practice-oriented total solutions. One of these highlight projects involves LEONHARD KURZ Stiftung & Co. KG, a global leader in thin-film technology. Elke Andersch, Marketing Manager Packaging and Print at KURZ, emphasises: “The holistic congress concept of the PRINT & DIGITAL CONVENTION allows finishing specialists KURZ to introduce to visitors a plethora of their comprehensive solutions for both analogue and digital finishing. As part of the planned highlight project, KURZ – jointly with its subsidiary SCRIBOS – will demonstrate a combination of finishing and functional security features by means of an impressive practical example. And, needless to say, KURZ will also score points in terms of sustainability here.”

Also awaiting participants here will be an extensive and high-calibre lecture agenda on both trade show days alongside exciting exhibits and in-depth expert advice at the exhibitors’ stands themselves. In addition to three parallel lecture slots focusing on the topical themes “Value Added Printing”, “Marketing Automation & Programmatic Printing” and “Sustainable Media Production” there will also be inspiring panel presentations at the “Forum Stadthalle” within the exhibition area.

www.drupa.com

 

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NDigitec Introduces Benefits of Catena Exposure Technology to the Middle East

Vishnu Rahma
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0

NDigitec Introduces Benefits of Catena Exposure Technology to the Middle East

A new ThermoFlexX Catena-E 80 exposure unit from XSYS has allowed the UAE-headquartered company to elevate its plate-making capabilities to new heights. By integrating this innovative UV LED technology, NDigitec can now supply customers with higher-quality digital flexo plates and enjoy faster processing times than before, while reducing plate waste and energy consumption.

Namma Int’l Digitec FZ LLC – known as NDigitec – is a family-run business founded in 2005 in Dubai (UAE). As the industry leader in the MEA region in terms of production facilities, staff members, and square meter consumption, the prepress division of the company supplies a complete package of services – from file reparation to final processed flexo printing plate.

Employing a total of 125 staff across two branches in Dubai, a facility in Riyadh (Saudi Arabia), and an office in Yerevan (Armenia), NDigitec also offers digital printing solutions, e-commerce, creative media production, and fabrication of exhibition equipment. Some 500 customers in 25 countries avail themselves of the company’s many high-end competencies, which also include Online competencies: the DUBAIPRINT.COM web-to-print platform with solutions for the widest variety of print applications, and FLEXOEASY.COM, an unprecedented digital platform that makes flexographic plate-making easy and allows customers to access high-quality Prepress and Premedia services from anywhere in the world.

Plate innovation leader with big ambitions

NDigitec Prepress is known as an innovation trailblazer, always seeking out the latest plate-making technologies to stay ahead of developments and to deliver leading solutions to its global brand owner customers. Some 55% of the annual 50,000 sqm plate output is supplied to the flexible packaging industry, another 25% goes to the corrugated segment, while the remaining 20% is divided between folding cartons and labels.

“We were the first prepress company in the region to bring in LED exposure technology for making flexo plates with the Flint Group nyloflex NExT system back in 2016,” said Shahe Kavlakian, Executive Manager for Prepress at NDigitec and brother of the company’s CEO Vatche Kavlakian, who as a pioneer of integrated prepress and printing services, laid the roots for the business in the early 1990s.

“Now we are once again taking the lead as the first to install the XSYS ThermoFlexX Catena-E system; an investment we have made because we believe that this solution will best support us in responding to the many varied customer demands we are currently facing and to allow us to continue our global expansion.”

Improving quality and reducing waste

Providing high-performance LED exposure for precise image reproduction, the ThermoFlexX Catena-E 80 is an open system that can process plates in sizes up to 1270 x 2032mm (50 x 80”) and all thicknesses for any type of flexo printing. With a very high level of automation, the unit can also be combined with a ThermoFlexX imager and Catena washer, dryer, and light finisher units for a full end-to-end plate production

line, an option that NDigitec is closely evaluating as part of its future strategy. While the Catena-E 80 has been installed in Dubai, there are more immediate plans to upgrade the company’s exposure hardware across the other sites.

“The effect of the new Catena unit has been very noticeable,” said Shahe Kavlakian, who explained more about the team&’s criteria in evaluating the technology. “We are looking for standardization, durability, efficiency, and stability in plate production; these aspects are key to maintaining productivity and quality. Particularly in flexible packaging, consistent solid ink density with perfect highlights is a challenge, but with the Catena system and our own micro surface screening, we can deliver results that are much better than with other LED solutions.”

Among the other immediate benefits enjoyed in Dubai was a reduction in waste compared to the existing system. “The Catena-E is definitely helping to improve the sustainability of our plate-making operation because we can combine different jobs on the same plate. By our latest estimations, plate waste has gone down from around 26% to 16%, and we know that with the latest LEDs in the machine, energy consumption will also be less. So, from an environmental point of view, as well as in terms of costs, this is a great improvement.”

Quick and effective implementation

With any new technology, there is inevitably a learning curve, but the near plug’n’play nature of the Catena system meant that the unit was in full production at NDigitec within a week. Mr. Kavlakian praised the simplicity of the design and the user interface, and in particular, highlighted the ability to access the unit controls remotely.

“The Catena is very easy to operate with straightforward instructions and options, so training was pretty quick. It also comes with remote capabilities which means that calibration and regular maintenance checks can be done without having anyone coming on-site. This is of course a fantastic feature as we can avoid unwanted downtime because we don’t have to wait for an engineer to attend in person,” he said.

Supporting future growth

Looking to the future, NDigitec has major plans to take more of the global market share. To further this goal, it opened a new state-of-the-art 50,000 sqm factory in Dubai Production City in 2020. Another 3,000 sqm facility operates as an incubator for joint venture projects aimed at advancing innovation in flexo print production, complemented by more investment in best-in-class imaging, processing, and screening technologies.

“In addition to the immediate benefits we have already experienced, the ThermoFlexX Catena-E 80 exposure technology will give us a stable platform to build our future plate-making infrastructure, stay competitive, and support our ambitious growth strategy,” concluded Shahe Kavlakian.

www.xsysglobal.com

 

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