FW CNC GL

FLEXO PRINTING LAMINATING SLITTING ENVIRONMENT & LOGISTICS

CI FLEXO PRINTING

OPEN YOUR MIND

www.comexigroup.com2 3

COMEXI GROUP, ALWAYS AT YOUR SIDE

Comexi and its holding company COMEXI GROUP were set up as a business venture guided by a spirit of excellence.

Our nature as a family business moulds our values and gives our Group a founding legacy in order to sustainably forge ahead over the long term. Our strategy is to be a leader supplier of machinery and services to the flexible packaging converting industry, with a high degree of specialization in each of our product lines (printing, lamination, cutting and rewinding and logistical and environmental solutions). These lines complement one another in order to offer total solutions and exploit synergies to the fullest.

The continuous search for excellence is our path to customer satisfaction.

Our philosophy embraces constant adaptation to the demands of our customers. In 1989 we developed the first 8-color CNC flexo press, because you needed it. That same press provided a new level of printing quality and created new business opportunities for flexographic converters.

In 2000, we launched the world’s first 10-color gearless machine, which represented a quantum leap for the industry. Once again we listened to you, learned from you, and created what you needed.

In 2004, FI and FW model presses were presented at Drupa and K shows which represented a significant progress in the performance of Comexi presses. These models have been evolving to this day in order to adapt to our customers’ needs.

In 2006, Comexi Group again shocked the market with the debut of EB (electron beam) Flexo printing. Because you needed a differential

Flexibility in flexo is the ability to quickly adapt to market demands and obtain the right economic results.process, high printing quality and minimum environmental impact, we created EB Flexo for you.

In 2009, we launched the FPLUS product range. This new development addresses the needs of converters working with a wide range of print repeats and requiring high performance at a very competitive price.

During Open House 2010, the F4 FLEXOEfficiency® concept was presented. This newly developed technology includes, on the one hand, the tendency of the flexo market to short jobs; and on the other hand, the business expansion by facilitating the entry to the label market. The elimination of photo initiators through eCOMEXI® solutions (www.ecomexi.com) which utilizes EB Flexo technology in high performance flexographic printing is another possibility offered by this product range.

Our customers are well-supported through our extensive sales network that includes branch offices in five countries, a manufacturing facility in Brazil and sales representatives in more than 65 countries.

For more than 50 years we have been at your side, participating in the growth of your business. Your future growth is in your hands.

DEVELOPING NEW MARKETS

The FPLUS press is capable of printing print repeats of up to 1,100 mm which makes it possible to combine traditional food markets that have a much lesser degree of print repeats with others that are rapidly growing.

FLEXIBILITY

The new concept of clamps and frames minimizes vibrations even at very high printing speeds and offers quick job changes. From the control screen, moving printing decks is done automatically as well as the register and pressure set up procedures (CINGULAR DOT2), thus reducing waste generated during the work set up process.

These features make FPLUS the perfect machine for medium and long runs in the large format market.

FLEXIBILITY IN FLEXO

SUSTAINABILITY

eCOMEXI® solutions (www.ecomexi.com), especially EB flexo printing with electron beam inks, have been the most important technological advances over the past few years. Zero emissions. No environmental impact. A step towards sustainability.

COMEXI GROUP, ready for the future

- These days, many industries view printing as a “commodity”, a view which requires the development of new markets in order to escape the price wars.

- There is a trend towards reducing run lengths.

- Customers demand easier operation of flexo presses, an ongoing process of improvement and the perpetual challenge in our line of business. MARKET

- Customers ask that we establish sustainable processes to reduce the carbon footprint impact.

- Customers desire harmonization of the flexographic printing processes, making them more predictable.

What do our clients have to say about the printing industry? We asked, we listened, and this is what we heard:

www.comexigroup.com4 5

CI FLEXO PRINTINGFW CNC GL

www.comexigroup.com6 7

The FW printing body was the first one created with the MONOBLOCK® concept. The development of all previous frames for Comexi presses have been based on this concept. The cast frame is a closed, reinforced structure that is capable of delivering top accuracy and printing quality even at the maximum speed of 400 mpm.

The FW uses configurations with 8 or 10 printing decks mounted in a radial pattern around a central drum. Each printing deck has a longitudinal anchor. The four central printing decks are placed horizontally whereas the 4 printing decks on the lower and upper ends are inclined 20 degrees from the horizontal, thus creating a compact positioning and easy access.

Each printing deck transmits its longitudinal movement through a preloaded ball screw system guided by positioning preloaded double linear guides (above and below) that distribute forces and lower the lever bar in the presence of vibrations caused by plate impact.

The MONOBLOCK® frame concept is a technological innovation that integrates printing decks into the resistant frame for a complete integration of components. This minimizes vibrations which in turn benefits printing QUALITY.

The new design of the braces located between frames enormously simplifies access to printing decks, especially those located high up.

Every printing deck’s contact/separation movement is controlled via servomotors through a new preloaded ball screw system specially designed to withstand the most adverse industrial conditions. This eliminates all hydraulic fixing and blocking mechanisms.

The highest precision electronics are incorporated in the unit with encoders used on each motor. Additionally, the structure’s strength has been enhanced with preloaded linear guides.

These design enhancements improve the pressure control on the plate and result in the highest quality print possible.

PRINTING BODY: PRINTING DECKS

MONOBLOCK®

PRINTING DECK

PRINTING BODY: A HEART OF STRENGTH

View of printing deck

Printing Body and MONOBLOCK® frame

www.comexigroup.com8 9

CENTRAL DRUM: THE STRATEGIC ELEMENT

No other flexo press manufacturer so strictly controls the manufacturing process of this highly important component. Comexi dedicates part of its industrial process to the manufacture and quality control of the central drum, as part of our policy to internally manufacture the key components of our flexographic presses.

During this industrial process, the drum is stabilized, balanced and adjusted to the tightest tolerances in the market. These adjustments are conducted at working temperature maintained via an internal temperature stabilization circuit. Stabilization is conducted at 30ºC/86ºF via an automatic system integrated into the press. Additionally, an anti-corrosive Hastalloy coating is applied to the central drum to protect it against oxidation.

DDDrive®

Not all “gearless” systems are created equal. The VIRTUALMaster®

technology – used by Comexi throughout our entire product range – unites all motors electronically and controls them via a common virtual signal that ensures register even during the machine’s acceleration and braking stages.

In a typical system, the motor position adjustment requires a reference signal obtained from an encoder located on a reference shaft (True Master). This type of system has two important disadvantages. First, any reading error from the reference signal is transmitted to the rest of the shafts that are synchronized to it. Second, the true signals include a set of delays in the readings and retransmission of the

VIRTUALMaster®: THE ORCHESTRA CONDUCTOR

Aceleración de la máquina Precisión

- Perfectly aligns the material’s surface speeds, the plate and the anilox, improving print quality.

- Performs direct, automatic and rapid positioning of longitudinal register between printing decks, decreasing the waste generated in adjustment.

signals, which imply deviations between the master shaft and the synchronized shafts. The consequence of these two disadvantages is variation in machine speed. These two disadvantages are solved with the patented VIRTUALMaster® system, which generates a virtual signal, created digitally by the Motion Control Processor (MCP). The virtual signal is transmitted to all the shafts simultaneously, thereby eliminating the concept of a “master” shaft. In this way, the signal is generated without errors and consequently without affecting the rest of the synchronized shafts.

- Regulates and memorizes longitudinal register positions for future runs, , which saves time in adjustments prior to print runs.

- Can slightly vary the plate and anilox speeds in relation to material speed, in order to specifically and exactly adapt the tolerances of print repeats.

ADVANTAGES

VIRTUALMaster®

VIRTUALMaster® ALSO PROVIDES THE FOLLOWING ADVANTAGES:

Actuation is another key area in which Comexi relies on the most sophisticated technology. In a joint effort with Siemens, we have integrated the DDDrive® Gearless, CNC and servomotors into the only technology platform in the market based on the SIMOTION control system. This “direct-drive” system is the most advanced in the market, reaching the highest levels of precision and eliminating all types of mechanical transfer (e.g., belts or gears).

The DDDrive® controls the motor via a high-resolution hollow shaft encoder, directly coupled to the drum axle. The encoder is designed for easy access, which makes maintenance easy.

The press can be configured with an optional automatic drum cleaning system.

DDDrive® directly coupled to the drum

www.comexigroup.com10 11

CHANGING SLEEVES: Xtrac®

Changing plate sleeves and anilox is fast thanks to Xtract® technology. An ejector arm unblocks the sleeve from the working position and

The plate and anilox shafts are held in place on one end by conical roller bearings and on the other end by double needle bearings with an inside diameter of 85 mm/3.35 in. The positioning of bearings allows for a cantilever suspension which is necessary at the time changes are undergone. It also provides a much higher degree of rigidity as compared to traditional needle bearing devices.

Comexi also utilizes DDDrive® technology for shaft actuation via alternating current motors with no mechanical transfer, controlled

DDDrive®

Plate sleeve changeover

Anilox changeover

makes extraction by the operator much easier and quicker.

View of Xtrac® for an easy job changeover

by absolute encoders also directly coupled to the shafts. These technological advancements improve register and therefore the quality of printing.

In order to make the changing and printing process more flexible, going from a print to a non-print position can be done individually for each printing deck or simultaneously for all printing decks and synchronized with the stop and go of the machine and with the automatic changes of the unwinder.

www.comexigroup.com12 13

DOCTOR BLADE: ACCURACY AND FAST CHANGEOVERS

The doctor blade is assembled in a closed swinging chamber mounted on linear guides. It moves across horizontally thanks to a pneumatic piston and it has manual fine adjustment against the anilox. The system has been specially designed to maintain the inking position with a minimum blade pressure against the anilox.

The new placement of the braces and the position and length of the hoses improves access to printing decks. In addition, linear guides make extracting tubs easier, and new aids have been designed for the operator to access printing deck #10 (in the 10-color version).

Changing the blade is fast and safe thanks to the patented MAGNETBlade® technology consisting of a tool-free magnetic changing system. Changing the shutters is also conducted without tools so that changes can be completed quickly on or outside the machine.

Doctor blade access

Detail of Doctor blade

DRYING: POWER AT ANY SPEED

The new drying system is based on 7 intercolour screens. It has a specific lip design that allows for an air speed of up to 50 m/s and an air flow of up to 6,500 m3/h without recirculation. Depending on whether the version is 8 or 10 color, the drying tunnel is composed of 14 lips (8c) or 16 lips (10c) installed on the 4.5 (8c)/5 (10c) meter long surface and assisted by 3 (8c)/4 (10c) fans and has an independent circuit for drying between colors. The tunnel’s

structure is 12 mm/0.47 in thick, thus improving the unit’s resistance, accessibility and efficiency and increasing the degree of thermal and acoustic insulation. Some of the novelties are right inside the unit. Its new twin flat belts are used to motorise the material transfer rolls, achieving a soft contact with the substrate and a silent operation, with low maintenance requirements and an accurate and long-lasting alignment.

MA

GN

ET

Bla

de

®

Detail of the drying system in 8 colours model

Detail of the drying system in 10 colours model

www.comexigroup.com14 15

The FW configuration is equipped with automatic change unwinders and rewinders which improve the efficiency of job changeovers.

They are composed of two motors for shaft actuation in order to improve high-speed rotation and minimize reel torsions. Additionally, the press is equipped with a high-sensitivity pneumatic compensator and electronic equipment for tension control, capable of controlling a wide range of materials.

UNWINDERS AND REWINDERS: HIGH-PERFORMANCE AUTOMATIC CHANGES

During the change and rotation process, a splicing device composed of a rubber roll and a pneumatic cutting knife guarantees a non-stop printing process at high speeds.

The turn direction is reversible, capable of unwinding or rewinding in both directions, thus allowing printing on both sides of the material.

SIMOTION AND THE CONTROL CONSOLE: THE BRAIN OF THE MACHINE

The FW press is designed so that most functions can be controlled from the control console. Similarly, the SIMOTION platform simplifies maintenance tasks thanks to its high degree of electronic integration.

Many operations can be conducted through the display, such as advancing/reversing the printing decks, placing all accessories in operation, tension selection, machine speed and temperatures, inserting change orders at a pre-established footage, operations, etc.

Additionally, production data can be obtained for later analysis, such as the quantity of quality footage, the quantity of lost footage, working time, downtime, printing time, average real speed, and more.By assigning the reasons for downtime by the operator, statistics can be gathered on the distinct causes of downtimes and the times for each one. All the data can be stored in the computer memory and/or on discs as necessary.

Duplex unwinder

Control console

Printing deck controlRegister screen

Control panel screen

Also job tickets can be created for the purpose of increasing the efficiency of job changeovers, enabling the operator to later recover these job tickets.

The control system is totally integrated in a graphical environment that simplifies operation and understanding.

Duplex rewinder

FW1508 EB series

www.comexigroup.com

0,0000

0,0020

0,0040

0,0060

0,0080

0,0100

0,0120

0,0140

-65%

60 %75 %

15080

4214

16 17

Pressures: dot spreading Final DOT

Also available is the iREG system developed exclusively for Comexi by AVT, which enables semi-manual register adjustment in less than 30 meters/99 ft.

Selfcleaning and inking system

Ink tanks

Excitink® technology is essential for controlling the inks (viscosity, temperature and, optionally, pH) so that the selfcleaning system remains efficient during job changeovers. The technology maintains a balance between supply ink and return ink that permits printing with an optimal pressure in the inking chamber.

The inking system comes in 3 versions: LITE, PREMIUM, and EXCEL, which fulfill diverse viscosity and temperature control needs. Each version comes with various levels of automation.

The structure is completely integrated into the machine’s cowling and the ink tanks are located on the exterior. These tanks use NATURALMixing® technology, which eliminates air consumption from pneumatic agitators (pneumatic agitation is an option).

The selfcleaning process is fast and easy, with a complete wash cycle taking as little as 4 minutes (*).

(*) in the 8-color PREMIUM version with options.

EXCITINK®: SELFCLEANING AND INKING SYSTEM

CINGULAR DOT2 SERIES: PRESSURE AND REGISTER ADJUSTMENT

The FPLUS press incorporates Comexi’s latest technology for a completely automatic pressure and register adjustment. CINGULAR DOT2 offers adjustment based on the true print of one 1.5 mm point in less than 90 meters/270 ft.

We understand the ever-changing and globalized marketplace. That’s why Comexi designs presses that adapt to these changes. Changes that generate greater efficiency in printing processes and, at the same time, reduce the environmental impact. Changes such as the new eCOMEXI concept.

The technological improvements incorporated into our presses have greatly reduced the power consumption, gas and compressed air. The new Siemens-Comexi technology and the continuous bus configurations reduce emissions from electricity consumption by 58%. In addition, concepts such as recirculation, improvements to thermal insulation and electronic fan control reduce the impact of gas consumption by an incredible 72%. Compressed air consumption has a large impact on emissions; however, the innovative NATURALMixing® technology and the installation of more efficient technology have achieved an 80% reduction in emissions.

Regarding solvent-based printing, Comexi has taken the initiative to find answers to the increasingly strict regulations on VOC emissions and the reduction of greenhouse gases. In the near future, solvent-based printing will face an increasing demand to tackle these issues.

The alternative is electron beam technology (EB). After 5 years dedicated to research and developing this process until it reached industrial performance, COMEXI has achieved radical changes in printing technology. It not only offers a printing system that is 100% solventless and VOC free, but also prints with the highest printing quality possible today without adding extra costs.

If you need to change in the face of increasingly strict regulations on your carbon footprint, we offer eCOMEXI (www.ecomexi.com) solutions that improve print quality while reducing greenhouse gas emissions, thus minimizing the overall environmental impact of your industrial process.

eCOMEXI: ENERGY EFFICIENCY AND ENVIRONMENTAL IMPACT, THE BEST RETURN ON INVESTMENT

Finally, we achieve an average global impact of a 65% reduction as well as the resulting improved economic performance and a better return on investment ratio.

We can also help you integrate on-line sections for application of coatings which add value to your finished product.

Kg

CO

2 / m

CO2 EMISSIONS

Total emissions

INK CONSUMPTION

SOLVENT EB FLEXO

Ink consumption SB vs EB Flexo ¡60% less!

CARBON FOOTPRINT

SOLVENT EB FLEXO

SB vs EB Flexo CO2 output ¡75% less!

www.comexigroup.com

15090

4890

17561

5860

18 19

FW 2110 LAY OUT

FW 1508 LAY OUT TECHNICAL SPECIFICATIONS

Note: the technical features are subject to change depending on the configuration selected. The photo on page 4 and the technical schematic correspond to the 10-color FW press with options. The final image might differ from the machine offered.

Type GEARLESS

Colours 8 / 10

Printing width (mm / inches) 870 / 34.2 - 1070 / 42.12 - 1270 / 50

Material width (mm / inches) 920 / 36.2 - 1120 / 44 - 1320 / 52

Minimum print repeat (mm / inches) 350 / 13.8

Maximum print repeat (mm / inches) 800 / 31.5

Maximum speed (m/min / ft/min) 400 / 1312

Dimensions (m / ft) (l x w x h) FW 1508 - 15.09 x 7.33 x 4.89 m / 49.2 x 23 x 13.12 ft (1270mm /50” 8c standard machine)

FW 2110 - 17.56 x 6.3 x 5.86 m / 57.6 x 20.6 x 19 ft (1270mm /50” 10c standard machine)

FW

Dip

òsit

lega

l: GI-x

xxx-

2010

FLEXO PRINTING FI, FW, FPLUS, F4 FLEXOEfficiency®

LAMINATING OPTIMA, POWER, DUAL, EVO, ONE

SLITTING EIKON, E-TURRET, DUO2. COMPACK2, BLADE, GUIDE

ENVIRONMENT & LOGISTICS SELFCLEANING, AUTOMATIC SLEEVE STORAGE, ECODISTIL, AUTOMATIC ROLL UNLOADER, WASHING UNIT

To learn more, visitwww.comexigroup.com

The information contained herein is subject to change without notice.

© 2010 Comexi Group Industries SAU. Polígon Industrial de Girona· Avinguda Mas Pins, 135· 17457 Riudellots de la Selva GIRONA (SPAIN)· Tel: +34 972 477 744· Fax: +34 972 477 384· comexi@comexigroup.com · www.comexigroup.com