Wide web flexo

Fully Automatic Mounting Machine (FAMM) 2.0

The FAMM 2.0 is the second generation Fully Automatic Flexo Plate Mounter. The FAMM 2.0 automatically mounts multiple plates after one another, and will mount a plate extremely accurately every 45 seconds without operator interaction. The only action left to the operator is to load a sleeve and lay the plates on the conveyor belt.

  • Fast
  • Accurate
  • Operator independent

Wide-Web Portfolio

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Testimonials

Amcor

Amcor has been working with AV Flexologic's for over 15 years. The machines are placed all over the world in their different plants.
“In 2011 I travelled to Cumbria to see the FAMM in action at the SGS plant that serviced Amcor in the region. I was instantly intrigued by the simplicity and incredibly efficient output of the FAMM. I then travelled to Holland and viewed 2 FAMMS in operation at Elopak, again incredible output."

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Mondi Group

"Thanks to the FAMM we have saved a lot of costs." This explained Joachim Block, technical director at Nordenia in Halle, Germany. Nordenia is now part of the Mondi Group. Block: "AV Flexologic is the main supplier of flexo plate mounting machines for the whole Nordenia group and our cooperation with AV Flexologic has always been optimal.” He continues: “We consider AV Flexologic to be the market leader in the flexo plate mounting machines field and therefore we have a lot of confidence in their products. In the year 2008 we were looking for a new mounting machine and after comparison with mounting machines from other suppliers, we have made the decision to do business with AV Flexologic again."

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Elopak

Elopak supplies over 800 markets, which illustrates their need for an AV Flexologic FAMM in their workflow. Reinard Dreesmann, plant manager Elopak says: “Since the installation, output and quality are as expected. We mount approximately 1000 sleeves per week and mounting is considered an important part of the printing job. In the past, mis-registration often caused press down time. Now our mounting results are consisted and precise.”, in an article by Flexo & Gravure from 2008.

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Segers & Balcaen

Segers & Balcaen is a family-owned flexible packaging and technical film producer based in Liedekerke, Belgium. The Company manages their product life cycle from extrusion to final packaging product. Since 2014, Segers & Balcaen is running their plate-mounting and stripping area on a Fully Automatic Mounting Machine (FAMM), in combination with the Demounter, for stripping plates

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References

Business case

A leading flexo printing plant with 6 printing presses recently purchased a FAMM. This company handles 22.000 – 24.000 sleeves annually. See the chart below.

Manual MountingFully Automatic MountingAdvantages
Manual Mounting
3 traditional manual mounting machinesVS
Fully Automatic Mounting
1 FAMM replaces 3 traditional mounters as the FAMM is three times more efficient
Advantages
Quick and spot on mounting. Your operator can attend other tasks while the machine mounts
Manual Mounting
3 operators in the mounting department per shiftVS
Fully Automatic Mounting
1 operator in the mounting department per shift
Advantages
$80,000 annual savings (based on average yearly expenses of a US employee)
Manual Mounting
15-20 hours of mounting related press downtime (per week)VS
Fully Automatic Mounting
0 hours of mounting related press downtime (per week)
Advantages
$ 375,000 annual savings (based on average downtime costs per hour for a wide web printing press)

Features

Image recognition software

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.

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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.

Automatic positioning

Driven by the AV Flexologic software, the robotic table positions the mounting plate with high accuracy, each and every time.

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After positioning the vertically moving cylinder automatically comes up.

HD Ethernet Cameras

Using the latest technology in high - speed Ethernet cameras, AV Flexologic ensures crisp and sharp ultra-high resolution images, enabling an efficient and accurate mounting process.

Conveyor belt

The operator simply places the to-be-mounted plates on the conveyor belt and the machine does the rest.

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The conveyor belt transports the plates to the pick-up position where a camera recognizes the mounting mark. Subsequently the FAMM's robotic arm picks up the plate and places it on the correct mounting position.

Pressure roller

The roller is used to apply the plates evenly over the carrier such as sleeve, cylinder or Mylar.

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The use of the pressure roller eliminates the typical "hand-rolling". The feature saves time and avoids un-ergonomic working procedures.

Multiple safety features

To ensure risk-free operation, the FAMM is equipped with light beams and multiple other sensors that do not allow movement near to where the machine mounts the flexo plate.

Quality report

After each plate is mounted, the machine has the ability to automatically check the tolerance of mounting plates using image recognition.

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A pdf quality report is generated on-the-fly with ability to check top and bottom.

Automatic easyreg detection (optional)

Using our patented image recognition system, a visual mark on the edge of a sleeve such as W&H Easyreg strip can be automatically "set to zero" on the mounting machine by simply pushing a button.

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The camera automatically homes in on the Easyreg mark and also automatically "sets zero" in X and Y direction with 0.001 mm accuracy.

Automatic Flexo Plate Mounter Workflow

Automatic Flexo Plate Mounter Workflow

The only responsibility of the operator is to select a job and put the printing plates on the conveyor belt. After this, the automatic flexo plate mounter takes over. The robotic manipulator picks up the flexo plate and places it in the correct mounting position with accuracy down to 5 microns. The mounting table’s vacuum system switches on to fix on the printing plate before final positioning. Every flexo printing plate is mounted automatically in less than one minute.

Being able to measure the position of mounting marks using ground-breaking Image Recognition technology down to 1μm (0.001mm or 0.4*10-4 Inch) during the plate mounting process, it provides a phenomenal print quality to printer’s end customers. During the time the machine is mounting, the operator has time available to perform other offline tasks, such as applying tape, preparing plates, finishing sleeves, etc.

After mounting the flexo plate onto the sleeve the FAMM conducts an automatic quality check. When the mounting marks are within tolerance the machine continues to mount the next plate on the sleeve. The machine can mount one or more plates per sleeve and can stagger the plates automatically.

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Automatic Flexo Plate Mounter Workflow

Points of Difference

The result of more than 10 years of R&D and experience in flexo plate mounting equipment:

  • A reduction of waste in the production process
  • Reduction of man hours
  • Reduction of waste material in press startup
  • Elimination of press downtime due to mounting mistakes
  • Removal of inconsistencies in the production process
  • No operator dependency
  • Improved traceability

The automatic flexo plate mounter is suitable for every flexible packaging printer and is developed for our customers who demand the highest standards in mounting speed, repeatability, consistency and accuracy.The Flexible production system of FAMM 2.0 enables users to respond to changes in market demand rapidly are vital for a flexo printer’s growth strategy. The FAMM 2.0 flexo mounter has won several awards, among them the FTA’s technical innovation award.

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