In the recent modernisation and expansion of one of Europe’s leading corrugated board plants, Weducon had the pleasure of integrating a single-sided sheet cleaning system just before the flexo press infeed.
The facility was expanded and equipped with a state-of-the-art corrugator (saving 154 tons of CO2 per year compared to the previous corrugator), and a conversion line. The large-scale operation, which took place while production continued, is aimed at:
- Increasing productivity and delivery reliability
- Optimisation of quality
- Minimising energy consumption
- Increasing occupational safety
- Reducing paper waste and using as much recycled substrate as possible
The new high-end conversion line comprises a prefeeder, flatbed die-cutter, and a Celmacch Chroma High Tech 2100. The Chroma High Tech is Celmacch’s top-line flexo press, excelling in print quality, efficiency and register accuracy.
Given the customer’s focus on quality requirements, Celmacch asked us: “Can we use Weducon’s cleaning system as a single-sided sheet cleaner before the press infeed?”.
Sheet cleaning before the flexo press infeed – why?
Why a sheet cleaning system just before the flexo press infeed? During manufacturing, corrugated board and paper release lots of dust and fibres that cling to the substrate due to static charge. Our web cleaning systems eliminate contamination at this stage to ensure clean, optimal production and a safe working environment.
But during subsequent operations, such as sheeting, stacking and transport, the substrate releases fibres and dust again. And as soon as these particles enter the printing press during sheet transport, they cause problems such as dirty ink, poor print quality, waste and production loss.
To prevent this type of contamination in flexo (and digital printing), we developed a single-sided sheet cleaning system* installed before the prefeeder, using the proven Weducon cleaning technology.
What are the advantages of a Weducon cleaning system in printing?
In the quest for optimum quality, energy savings and work safety, Weducon’s cleaning system offers significant advantages in digital, offset and flexo printing:
- complaint-free printing: fewer cleaning stops and less paper and ink waste
- perfect printability thanks to clean board; even with varying liner quality or frequently recycled substrate
- dust-free products that meet the quality requirements of health and safety authorities
- safe and healthy working thanks to less harmful micro-particles and reduced cleaning and maintenance
- cost reduction by preventing waste and premature equipment wear; without consumables, chemicals or expensive maintenance
No additional tasks and modifications to existing equipment
In any production facility, keeping the footprint as small as possible is crucial. Nowadays, every customer has occupational health and safety high on the agenda, so when designing the installation, we ensure maximum accessibility and avoid obstacles or hinder. In this case, this meant installation in a limited space. But by optimal preparation, the installation was ready within a standard maintenance stop — without any modifications to the flexo press.
A responsible footprint also includes minimal use of natural resources. Compared to conventional non-contact solutions with air balancing or air knives, Weducon’s cleaning system reduces electricity consumption by 20%. As the system is electronically controlled, no energy is wasted by controlling the flow through a barrier valve. And, of course, the cleaning method does not use expensive and difficult-to-recycle consumables or spare parts.
Printing results after integration of the sheet cleaning solution
For a representative survey of cleaning performance, we contacted the Head of Quality Assurance a few weeks after completion. He informed us that the new Weducon cleaner was running smoothly and that the cleaning results far exceeded previously implemented cleaning solutions. As a result, the sheets are much cleaner, which improves print quality and prevents unnecessary inserts.
Get in touch with us to discuss your production process and the savings you can achieve by implementing an efficient cleaning system.