Heidelberg Innovation for Label Production

KENNESAW, Ga.—Heidelberger Druckmaschinen AG (Heidelberg) has extended its product portfolio to include an innovative solution for label production. The new Speedmaster XL 105-DD was launched to an international audience on October 20 and 21 at the Print Media Center (PMC) Label Days in Wiesloch-Walldorf. “DD” stands for diecutting. More than 150 international guests used this opportunity to discover the benefits of the new press through various practical demonstrations and expert lectures. The Speedmaster XL 105-DD is ideal for use in label production, preferably for processing foil materials.

Positioning for the Speedmaster XL 105-DD

Heidelberg already offers two solutions for diecutting—Varimatrix and Dymatrix. Both solutions are designed for packaging production and are based on the principle of flatbed diecutting, whereas the Speedmaster XL 105-DD uses the principle of rotary diecutting and has been specifically designed to meet customer requirements for processing in-mold labels. These labels today are usually processed on flatbed diecutters or “push-through” diecutters (in which the punching stamp pushes the material stack through the cutting die to give the stack its intended shape), but both are hampered by limitations, because flatbed diecutters can only process single sheets and push-through diecutters are only suitable for labels measuring up to 400 mm.

The Speedmaster XL 105-DD press also offers advantages in terms of tool costs, because its delivers savings of more than 50 percent compared to flatbed diecutters. Makeready times of the XL 105-DD are impressive; it only takes around 15 minutes to prepare the Speedmaster XL 105-DD. Thanks to the high accuracy of the cylinders and cutting dies, separate adjustment is not required. With a flatbed diecutter, on the other hand, initial makeready for the IML takes up to five hours. The production speeds of the new machine are also much faster than the methods commonly used today. While flatbed diecutters reach production speeds of between 4,000 and 6,000 sheets per hour, the Speedmaster XL 105-DD reaches speeds of up to 10,000 sheets per hour.

Technical concept of the Speedmaster XL 105-DD

The new press is based on tried-and-tested XL 105 technology. It is equipped with two printing units, a Preset Plus Feeder, and a foil package for the feeder, diecutting unit, and delivery to ensure that critical plastics can be processed with ease. The impression cylinder in the diecutting unit is fitted with hard-wearing cylinder jackets. The diecutting cylinder is fitted with a clamping system that is identical to that of the coating blanket cylinder. The process of changing the diecutting plate is semi-automated—the clamping process is performed manually, while the press positioning and pressing roller functions are automated.