Directors Theo Raubenheimer and Rene Koen explain that it is the company’s fifth Mark Andy flexo press because they are proven, fast, robust workhorses and it is preferable to deal with one supplier. ‘We’ve built an excellent relationship with SArepco over the years and it is always handy when a technician is on call for a specific issue to be able to look at niggles on any of the other presses,’ Theo remarks.
Although the duo first saw the Evolution E5 running at Labelexpo Europe 2019 and the facility was close to capacity at the time, they didn’t want to commit to the investment until November 2020 because they weren’t sure what was going to happen as a result of the pandemic. ‘We were blessed with a brilliant year and decided to buy this dual servo-driven, eight-colour press featuring a Quick Change Die Cut (QCDC) module and Advanced Waste Winder System rather than run a night shift,’ Theo states.
The operator Piet Busak, who has been with the company for around 20 years, is enjoying the fact that with the QCDC system he can safely and quickly (in less than 50 seconds) slide each die in from the operator side with the cassette-based system – rather than from above as on the older equipment, which usually requires heavy lifting equipment or a hoist. ‘We have nicknamed the E5 the old man machine thanks to its ease of use,’ Theo comments. ‘Additionally, the QCDC system limits die damage caused by cumbersome loading and unloading processes. The hydraulic pressure automatically positions and sets the die pressure, while the die throw-off capability speeds up the setting of die registration and reduces time spent on setting up.’
Paul Bouwer, SArepco’s sales director, adds that the Advanced Style Waste Winder, which is complementary to the QCDC, has done away with the tall matrix tower to strip the matrix and instead runs it directly off the end stripping roller so that it doesn’t break. ‘The advantages of this lower positioning are that converters can run narrower material with smaller stripping edges because the matrix doesn’t break and it is easier for operators to manage,’ he explains.
The winder system also complements the shorter web, with the UV curing lamps located directly under the print stations and faster running speeds. ‘However, to prevent any UV varnish application issues in the final station – because Label Leaders runs the E5 at 228m/min instead of the industry “norm” of 120 to 150m/min – the web path has been extended at the end of the press down to the bottom of the machine,’ Paul reveals. ‘This allows the UV varnish to flow out and helps avoid the orange peel effect at high press speeds. It is vital for the varnish to be as smooth as possible so that the slip properties provide better scuff resistance and gloss to the labels.’
Adapting to a colourful future
In preparation for the arrival of the Evolution E5, Label Leaders had to move its Mark Andy Scout UV flexo press to behind one of the finishing machines in the front of the facility and knock down the factory manager’s office and rebuild it on the other side of the facility. The Scout was also downsized from eight to four print stations because it is mostly used to print barcodes and QR codes.
Once the floor had been cleaned up and painted, SArepco’s technician Jethro de Jager oversaw the unpacking, levelling and press assembly. Then technical director Jacques Koekemoer ran the test plates and some existing jobs so that the Label Leaders team could compare the quality, set-up and print times. ‘We were impressed with the results and found that the print on the E5 is very fine,’ Theo reports. ‘This means that we have to go lighter on the anilox rollers – we tend to go heavier on the older presses – and will use less ink.’
According to Paul, the E5 goes head to head with digital printing without the additional very high ink costs. ‘Its scalable technology enables converters to specify their current needs and then adapt to changes in the market by adding more of the upgrades, including print stations or peel and read label capabilities,’ he asserts.
Label Leaders is waiting for a specially made die adaptor to arrive so that it can push more jobs across to the E5. The maximum width of 330mm (compared to 250mm on the other Mark Andy presses) means that the operator can run more labels across in faster turnaround times because the E5 reaches registration and facilitates die changes more quickly. ‘These are essential time-saving assets in a business that sells time and not labels,’ Theo stresses.
He adds that the benefits of having 26 print stations in total are that the team can split the work better, take on jobs with more colours and offer customers quicker turnaround times. ‘The ability to deliver the correct amount of labels on time means that customers can, for example, order 50 000 units instead of 100 000 units and manage their cash flows better.’
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