Corrugated Flat Plate Mounting Machine on Myllars

Flatmount

Mount faster, verify smarter, and standardize your corrugated workflow - built for trade shops supplying mounted mylars to corrugaters.

Up to 30% faster than a round mounter
Automatic HD Cameras alignment for accurate positioning
Optional image recognition + VPP to reduce or eliminate wet proofing
Fast job creation and repeatability for high throughput
Quick and easy mounting
Easy job creation

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Used by corrugated trade shops worldwide

Built for speed, repeatability, and digital verification

ROI drivers

Save operator minutes per color
Reduce rework & remakes
Reduce/eliminate wet proofing with VPP (optional)

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Discover Flatmount

Introduction to the Flatmount

An overview of the Flatmount, a machine designed for mounting printing plates onto mylar sheets for the postprint corrugated industry. This video highlights its key features and operational benefits.

Flatmount In-Depth and Technology Overview

This section includes a detailed instructional video on operating the Flatmount, alongside a presentation on inkjet digital printing technology, providing context for its application.

Customer Testimonials

Hear from industry professionals at Pacificolor, ZDue Italy, and Rudico as they share their experiences and the results they have achieved using the Flatmount.

Features

Patented Overlay System

Once the first plate is on the right position, a snapshot can be taken and used semi-transparently for the next plates.

HD Ethernet Cameras

Ultra high definition cameras moving to the exact position of the mounting marks.

Camera Encoders and Keypad

The cameras can be controlled by encoders for quick adjustments. The operator can insert commands through the touchpad.

Digital Calibration of the Camera Beam

The camera images are used in a calibration procedure to create a lookup table to digitally ‘straighten’ any deviations in the camera beam, down to 10 μm over the entire width of the camera beam/sleeve

Windows 10

Windows 10 icon-based AV Flexologic mounting software for easy job creation and storage. The user interface is optimized to offer the best operator experience.

DOAL Lights

Latest technology DOAL lights for optimal target recognition.

Laser Pointers

Indicators of where the mounting marks are located for placing easily the plates.

Quality report

The mounting marks are checked and a PDF is automatically created with the measurements of the Image Recognition.

Options

Pressure Roller

The pressure roller has become a standard feature in AV Flexologic flexo plate mounting machines over recent years. The roller is used to apply the plates evenly over the carrier such as a sleeve, cylinder or Mylar. The use of the pressure roller eliminates the typical 'hand-rolling'. The feature saves time and avoids un-ergonomic working procedures.

Image Recognition

Specialized software developed by AV Flexologic can 'recognize' the mounting marks on the printing plates which are used as the references for the mounting process. The ability to measure the positions not only during mounting, but also after plates have been mounted provides endless possibilities to enhance a flexo printing production workflow.

Quality Report

The image recognition system measures the exact positions of the mounting marks and thus how accurately the printing plate is fixed on the sleeve. After mounting, the system will automatically check the precision of the mounting process and a PDF is automatically created.

Inkjet - Digital Printing Technology

The revolutionary Inkjet technology is used to apply individual print job information directly onto the plate shim/mylar at the point of mounting, rather than having to manually label each one on-site. This saves time and removes the need for labeling consumables, which are prone to damage, for print operators. The new automated shim printing solution avoids human error, improves standardization of shim information for ease of plate identification, and eliminates duplication of information.

Clamping System and Vacuum Table

The clamping system for the mylar and the vacuum table are used to fixate the mylar perfectly to the table.

VPP - Virtual Proof Print

The ground-breaking technology of the VPP offers a digital printing proof by scanning each plate after mounting. The extra camera provides a digital visualization of the image of the plate with a 5K resolution. After all the plates are mounted and scanned, there is a clear image of the final result that can be compared to the PDF file. The VPP scan can be exported as a PDF file and be used as proof of the mounting accuracy.

Success Stories

ZDUE Italy Invests in AV Flexologic's New Technology

ZDUE confidently chose AV Flexologic's Flatmount and has implemented multiple units in their Italian plant. This upgrade has resulted in improved mounting capacity, with the Flatmount being favored over round mounters. The video showcases the ease of mounting with Flatmount and illustrates how options like Image Recognition streamline their processes.

Rudico Group

We have invested in a new mounter because it can mount faster, and the quality is very good. As a result, our customers are very happy with the printing plates. With the Flatmount, you can mount 30% faster than on a round machine. It is also possible to obtain a Quality Report for the customer, so they can see for themselves that everything is correct.

Contact Originators

We have recently invested in two AV 3000 Flatmounts with Image Recognition Software, making this move set a new standard in the Corrugated sector.'

Kirk Group

We’ve just ordered our second Flatmount machine from AV Flexologic. These machines are easy to use and deliver mounting accuracy which is second to none. We know with the Flatmount that the job will be done right, first time every time, and our customer couldn’t be happier with the results.
Ben Dunlop - CFO of Kirk Group

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