Narrow web flexo

Semi Automatic Mounting Machine Upside-Down (SAMM USD)

The semi automatic flexo plate mounter Upside Down is one of the latest additions to the AV Flexologic portfolio of innovative mounting machines for cylinders and sleeves. The SAMM USD is a great option for anyone looking for easy, fast and accurate mounting machine. Mounting with this machine requires nearly no operator skills, since the machine automatically positions the plate.

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Business case

Manual MountingSemi-Automatic MountingAdvantages
Manual Mounting
3 traditional mounting machinesVS
Semi-Automatic Mounting
1 SAMM replaces 3 manual mounting machines, since it can mount for all 5 presses
Advantages
No need for remounting, always the same accuracy
Manual Mounting
3 operators in the mounting department per shiftVS
Semi-Automatic Mounting
1 operator in the mounting department per shift
Advantages
€70,000 annual savings (based on average yearly expenses for an EU-employee)
Manual Mounting
9 hours of mounting related press downtime per weekVS
Semi-Automatic Mounting
0 hours of mounting related press downtime per week
Advantages
€94,000 annual savings (based on average downtime costs per hour of a narrow 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.

HD Ethernet Cameras

A high speed connection combined with sharp images, zoom up to 170x and a touchscreen monitor enables the operator to mount the plate with highest precision.

Laser pointers

Laser pointers are mounted next to the cameras to indicate where the field of view of the cameras is.

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The mounting marks can be easily positioned in a fraction time, instead of having to search for the mounting marks in the camera image each time.

Automatic positioning

The table of the SAMM moves the plate into the right position with a precision of 5 microns.

Camera encoders

The operator moves the cameras to the desired mounting positions by merely rotating the encoder wheels.

Customized air mandrel or clamping system

The sleeve-dedicated machines are equipped with an air mandrel and the cylinder dedicated machines are supplied with a pneumatic clamping system.

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For a sleeve and cylinder combination machine AV Flexologic's engineering team designs a special clamping system.

Windows based mounting software

Windows software on the machine incorporates the latest in AV Flexologic mounting software. The software is very user friendly and fast to operate with.

Cushioned table with vacuum

This table is acts like a support when positioning the plate and as a cushion to stick the plate onto the sleeve,eliminating air-bubbles between the flexo plate and tape. The vacuum holds the plate in place while the table positions it down to the micron.

Workflow of the flexo plate mounter machine

Workflow of the flexo plate mounter machine

The operator first loads the sleeve onto the mandrel or the cylinder into the pneumatically operated quick-lock clamping system. The machine then provides the option to load a previously created job, a just created job, or to move the cameras to the mounting position using encoders, creating a job in the process without manual entry. The operator then places the plate on a mounting table that is constructed in a fixed working height. The table consists of a large back and front part, enabling smaller and larger plates to be positioned before mounting them on the sleeve.
With its laser pointers, HD Cameras and an HD monitor, the flexo plate mounter Upside Down can quickly and accurately position the plate. This is where the mounting machine takes over from the operator, in order to ensure precision up to 5 micron. Once the plate is in position, the cylinder moves vertically down to fixate the plate, giving the highest possible fixation accuracy. The back-and-forth movement of the table allows for quick and easy mounting of the plate on the cylinder. The table functions as a pressure roller to eliminate air bubbles.

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Workflow of the flexo plate mounter machine

Direct Drive

The flexo plate mounter Upside Down is also available at the Semi-Automatic Mounting Machine Upside Down Direct Drive, the SAMM USD DD.

This option is equipped with a motor driven air mandrel. For instance, the table moves to position the plate and the mandrel goes down automatically. Then, the table and the mandrel are driven by the motor to attach the plate. This results in a safer machine with less effort needed from the operator.

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Eliminate setup time with repeating jobs, multicolor jobs and staggered mounting.

Interchangeable Cylinder Locking System to allow for hybrid functionality across a large variety of sleeve and cylinder types.

Video

Store positions in the computer to be recalled at any time.

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References

Americk

Americk Primopost is used to adopting the highest quality in flexographic print processes. They believe you should: “Add value through print quality”. Primopost continuously invests in optimizing the print quality and price of their operations. In 2012 they have installed the AV Flexologic MOM DD1500 and Demounter which help reaching this goal substantially. The MOM DD ensures a much improved mounting process that limits the downtime of the workflow. The Demounter contributes to the same goal, by quickly and safely demounting their plates Primopost saves time and ensures high quality plates in storage.

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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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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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Boran Packaging

Boran Plastic Packaging has recently purchased a Semi Automatic Mounting Machine (SAMM) 1300 and is happy to report its experiences. The company tells AV Flexologic: “The operational effectiveness has improved significantly compared to the old way of mounting. We are especially impressed by the image recognition software that automatically detect the microdots. The quality of the process of mounting plates has never been better and we now have perfect registration and great repeatability of the mounting.”

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