Wide web flexo

Semi-Automatic Mounting Machine (SAMM 2.0)

The patented SAMM is AV Flexologic’s solution to common industry trends. The SAMM 2.0 is the next generation Semi automatic flexo plate mounting machine. Building on 10+ years of experience with automatic mounting machines using vision technology, the SAMM and FAMM are the most accurate and fastest mounting machines in the world.

With the change in the printing industry, where lead times are shorter and job runs more frequent, the workflow for operating the SAMM 2.0 was streamlined. By adding the Motorized Front Table, the flexo plate mounter gets even closer to a fully automatic mounter.

The SAMM 2.0 is very versatile and has many popular options available such as a nip-roll assisted tape applicator, TIR scanning device and cutting knives for plates or tape. The SAMM 2.0 is offered in the full wide-web flexo repeat range and printing widths.

automatic flexo plate mounter- FAMM 2.0 Booklet

 

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A flexo printer in Europe purchased a SAMM in 2014. This company is mounting between 15000 and 17000 sleeves per year and has 3 flexo printing presses. The chart below illustrates what the SAMM has done for this plant’s workflow.

Manual MountingSemi-Automatic MountingAdvantages
Manual Mounting
2 traditional manual mounting machinesVS
Semi-Automatic Mounting
1 SAMM replaces 2 traditional mounting machines since it mounts twice as fast
Advantages
Quick and spot on mounting, time and time again
Manual Mounting
2 operators in the mounting department per shiftVS
Semi-Automatic Mounting
1 operator in the mounting department per shift
Advantages
€60,000 annual labor savings
Manual Mounting
5 hours of mounting related press downtime (per week)VS
Semi-Automatic Mounting
0 hours of mounting related press downtime (per week)
Advantages
€90,000 annual savings

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

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.

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.

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.

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.

Windows 10 (new)

Striving for the latest up to date technology, the SAMM 2.0 is equipped with Windows 10, which is fully compatible with our AVMOM software.

Synchronised Motorised Front Table (new, optional)

Because of this feature the front table moves with the same speed and at the same height throughout the entire process of plate mounting.

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This results into an increased mounting accuracy.

Nip Roll Tape Applicator (optional)

The tape applicator assists the tape application and adds speed to the workflow by allowing a fast an accurate tape application and minimum waste of materials.

Workflow Semi Automatic Flexo Plate Mounting Machine

Workflow Semi Automatic Flexo Plate Mounting Machine

The operator needs only to select the job to be performed and to place roughly the flexo plate onto the mounting table. After the plate is recognized, the machine automatically positions and adjusts the plate with the register marks using the patented Image Recognition software, all with an accuracy of 5 microns. The register marks can either be crosshairs, dots or reversed negative dots.

After the positioning of the plate, the machine automatically mounts the flexo plate using the motorized front table. The SAMM 2.0 features a staggering 30-second mounting speed fully operator independent, attending to higher quality demands and reducing press downtime.

While the Semi Automatic flexo plate mounting machine 2.0 is mounting the flexo plate, the operator can focus on other tasks. Once the mounting process is complete, the machine automatically checks the tolerance of the mounting plates and generates a digital Quality Report.

 

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Workflow Semi Automatic Flexo Plate Mounting Machine

Building on more than 10 years of experience

Designed to supply high quality demands, our focus on bringing innovative technology into each of our products has given our customers maximum precision with low costs.

SAMM 2.0 key advantages:

  • Elimination of press downtime due to mounting mistakes
  • Almost no operator interference
  • Higher productivity
  • Faster and more frequent job runs
  • Lower costs in the long run
  • Quality reports allow tracing issues and quickly resolving them
  • Elimination of waste in the production process
  • ERP integration for added efficiency and planning

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References

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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Mission Labels

Mission Labels recently acquired an Aquasupreme, one of AV Flexologic’s waterwashable flexo plate making machines. Dave Humphrey: “We are very enthusiastic about the way the Aquasupreme doubles our capacity. It means that we are able to compete and take a much firmer stand in the market. It also means that we have saved a significant amount of costs with this investment.” He mentions: “My personal advice to anyone looking to invest in plate making facilities, is to opt for this water wash.”

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