Folding carton and liquid packaging production is faced with tremendous market momentum when it comes to design trends, printing processes, finishing methods, and functional aspects. With its highly flexible inline machine concept, Gallus Stanz- und Druckmaschinen GmbH provides folding carton manufacturers with superior solutions that prepare them optimally for present and future market needs. The Gallus portfolio comprises several different series, each one tailored to specific requirements within the carton industry. All of these models share a talent for economical and efficient inline production in a single pass from the carton roll to the cut and separated blanks.
The powerful Gallus INTRO series is predestined for mass production of standard folding cartons and liquid packaging with a low level of surface finishing. The machines are suitable for flexo printing with water or solvent based as well as UV curable inks. With a maximum printing width of between 560 mm and 1650 mm and speeds of up to 500 m/min, Gallus INTRO machines cover a wide range of formats and production requirements spanning several width classes. Specialized solutions, for example for lottery tickets, can also be realized with the help of the INTRO series. By contrast, the Gallus CCS 510 is targeted at the high end of the folding carton market, where short-to-medium run lengths with a variety of valuable finishing characteristics are the norm. This machine system for inline production is designed for printing widths of 510 mm or less. The proven platform concept with flexible exchange modules allows the press to be configured quickly according to the requirements of each particular job and minimizes set-up times.
Gallus ICS 670: maximum flexibility for exclusive folding cartons
Folding cartons uniting all facets of high-quality finishing and a mixture of jobs both with and without finishing are the domain of the Gallus ICS 670. With a maximum printing width of 670 mm (max. web width 690 mm) and the option of a mono or non-stop unwinder, this machine system is consistently modular and can be configured to match customer requirements. Depending on the type of production, methods used, and format lengths, the Gallus ICS 670 runs at a maximum speed of 220 m/min (flat-bed die-cutting) or 350 m/min (roll-to-roll). Thanks to the EVA (Easy Value Add) platform concept, it is also possible to combine different printing processes and finishing methods if the job so demands. The process can be changed over in only a few minutes without any tools simply by swapping the modules. A module cart and pallet system are provided for this purpose and facilitate a further reduction in set-up times.
Gallus positions flexo as the mainstream printing process on the ICS 670 for the majority of applications – cigarette packaging is an exception – whereas gravure and screen printing are considered to be optional finishing methods. The Gallus module for brilliant, high-definition HiDef flexo printing is largely responsible for the remarkable quality of folding cartons printed in this way, which is every bit as good as that achieved with offset or gravure processes. The HiDef flexo module features temperature-controlled anilox rollers with a precisely defined pick-up volume and automatic printing pressure adjustment to guarantee absolute consistency from proofing to full production speed regardless of the progress of the job. The automatic Gallus register control system prevents registration errors very effectively. Digital "flat top dot" photopolymer plates with a minimum linescreen of 175 lpi, mounted on sleeves and teamed up with bridge sleeves, are used for flexo printing. With multicolor production, one HiDef flexo printing module is required for each EVA platform.