Industry News

Omet focusing on multi-process presses, Lean printing

May 22, 2012

The Omet Group’s turnover in 2011 was the highest its ever been – $89 million, of which $64 million came from the company’s machines division, which is responsible for the production of narrow and mid-web printing presses and tissue converting machines. The other companies of the Group are Omet Systems in Motion, manufacturing ball bearings systems and O-PAC, active in the wipes industry.

Omet Srl,, headquartered in Lecco, Italy, is responsible for machine manufacturing, and has three subsidiaries worldwide: Omet Iberica in Barcelona – responsible for Latin America – Omet China based in Suzhou, and the recently founded Omet Americas Inc., based in Michigan, USA. For Omet, this translates to 24/7 customer service availability and local support in some of the most strategic areas of the world.

The company is not resting on its laurels but continuing to market through the ongoing innovation of its products, the refresh of its brand image and a deep internal reorganization that has the objective to go Lean on every aspect of the enterprise’s: production, processes, communication, and pre- and post-sales assistance.

The adoption of Lean principles has been a key focus of new Omet technology. Omet’s range includes inline presses with all-in-one-pass capability and a multi-process approach, meaning the inline combination of different technologies (UV and solvent-based flexo, offset, screen, digital, rotogravure, foiling, etc.) and converting equipment to build a “unique, scalable machine and a new vision for the modern converter,” Omet says.

Working on a multi-process inline press provides several advantages: the machine configuration is strictly dependent from the job to print. Whether it’s printing PS material, film, multi-layer or carton, the printer can switch on and off only the technologies needed. Flexo can be replaced with screen, and finishing units can be placed strategically on the rail – whether it’s cold foil, hot stamping, etc.

Also on the press, converters have the opportunity to use a rotogravure unit to laminate inline or manage hot glue melting or cold seals. The machine’s servo controls and performance control systems (Vision-1 or Vision-2, single or multi-camera register systems) allow the use of practically any substrate with few automatic adjustments to perform. The electronic equipment of the presses minimize human intervention, and eventual error.

Omet, while noting that only one press operator is needed, offers a Lean working environment: ergonomics in use, wide accessibility to both machine sides and components, easy maneuverability of moving parts – whether sliding or lifting – with a small number of operations to actually complete. All the activities on the press are monitored and managed from the main control pulpit or through local HMI interfaces positioned on the single groups. Set-up times are kept short and waste is decreased via the quick sleeve change system involving self-adjustment of the printing sleeves after each format variation, the short-web path outline, which restrains the wasted materials, or Monotwin Cut, all-in-one diecutting technology needing just one magnetic cylinder for the whole set of flexible dies.

To complete the range of possible configurations, Omet presses can be equipped with hot air dryers sized to the real needs of the machines. Furthermore, having in mind the needs of carton converters, the choice of possible deliveries is wide and in-line with today’s most stringent requirements.

Multi-process presses, especially those with narrow web configurations, from 370 to 430 mm (typical widths of XFlex X6 multi-process presses for labels), ideally meet short runs and just-in-time deliveries, jobs usually unadapt to larger machines requiring more than one pass and off-line processing. As the width increases (in Omet’s range up to 850 mm on Varyflex V2 platform presses), the level of profitability is preserved with runs going longer, leaving all other advantages unchanged.

Omet emphasizes that the purchase of such a press doesn’t require the hiring of new personnel but the proper training of the current one. No extra handling is needed since the production of the packages, folded carton boxes, or labels is completed in-line and ready for delivery, no building of stocks – even temporary (you can produce only what can be sold), is required.

“Printing on a multi-process, innovative press is a sharp change in the vision of traditional packaging converters but a real opportunity to make profitable a business whose margins are dropping, bringing with them the values inherent the process,” the company says.