Greg Hrinya, Associate Editor10.14.16
A technology that was foreign to the narrow web label printing industry not long ago continues to see a rise in relevancy. Laser diecutting has emerged as a viable finishing option for many converters, especially with the prevalence of short run digital printing.
Laser diecutting features two major components: a scanhead and a laser source. The scanhead, or galvanometer, features a set of mirrors that use the cut information to trace around the desired cut shape. The mirrors are positioned accordingly to redirect the light around the cutting surface. According to Mike Bacon, vice president of sales and marketing at Spartanics, using a single scanhead will provide higher-quality cuts. Some converters might use two scanheads, however, to accommodate software limitations or to keep pace with faster speeds.
“When we work with Durst, and we’re running an inline laser system, we have some machines that are out there that are a single scanhead, 13" wide, and the last two we’ve sold with them we’ve doubled-up,” explains Bacon. “They’re still 13" wide, but as the material is going left to right, we stack those in the material direction so that we basically do double the work so we can increase our speeds. That way, we can run inline with a Durst machine or Domino or whomever it may be.”
When utilizing laser diecutting, the goal is to run as fast as the digital printer is capable of running. “Back when Xeikon and HP were coming out, they were only running at 800 to 100 fpm, so it wasn’t that big of a deal,” adds Bacon. “With these new UV inkjet presses that are out running 50 m/m or 100 fpm, the laser diecutting will start to slow down what they can produce on the printer.”
Delta ModTech, a finishing specialist that has been integrating lasers into its converting systems for over 15 years, cites several advantages to laser diecutting. The flexibility of the laser allows for tough cuts and tight tolerances. “The laser’s claim to fame is that it can cut through intricate, tricky patterns in which it would be difficult for a traditional rotary diecutter,” explains Jason Newville, design engineer at Delta ModTech. “It’s also prototype-friendly for quick turnarounds. Laser cutting doesn’t require hard tooling, so it’s ideal if you want to create a quick prototype. You can then invest in a more durable rotary die down the road.”
Additionally, there are long-term cost benefits. “A rotary die may be less expensive to purchase, but it will eventually become dull and need to be sharpened and replaced. A laser will last significantly longer,” adds Newville.
The laser source essentially dictates how fast laser diecutting will run. Most systems will be 400, 500, or 600 watts on 13" wide webs. By moving to a narrower web, some applications will require less power. “We have an INX press that we run a laser inline with, and their UV inkjet machine is only 8.5" wide, so most times a 200 watt laser will suffice because the limiting factor is the digital printer that’s only running at about 60 fpm. So we don’t need more power to run more,” says Bacon.
According to Spartanics, 400-500 watt laser systems – single source lasers – comprise 90% of the units the company sells into the label market. These systems will comfortably run at 120 fpm, similar to semi-rotary diecutting speeds.
The laser source cuts on an angle, with Bacon describing the process like a flashlight in a dark room. The light begins at the circumference of the flashlight and goes out on an angle. “That’s essentially what a laser is doing,” he says. “We’re mounting that scanhead above where the material is running through, and in order to get to 13" wide, we have a specific height that we set that laser scanhead. Then we’re able to cut, and that angle will burn away the material.”
Cartes, a developer of labeling solutions since 1970, offers exclusive laser technology for diecutting and converting. The company provides single and dual laser sources, and its laser machines are capable of using a semi-sealed CO2 laser source. This generation of laser beam involves stimulating a lasing material with electrical discharges or lamps within a closed container. CO2 lasers are commonly “pumped” by passing a current through the gas mix using radio frequency energy (RF-excited). As the lasing material is stimulated, the beam is reflected internally by means of a partial mirror.
Bacon estimates that laser diecutting accounts for 7% of the finishing market, but says that the market is growing. While digital technology still makes up a small part of the label industry compared to flexo, some converters are looking to find their niche in digital short runs. Featuring quick turnarounds and customizability, printers are investing in a digital printer and a laser unit. “There are companies that just start out brand new into the label market with digital printing and laser cutting,” says Bacon. “That makes them truly a digital printing and finishing company.”
Whether a job ranges from 10 labels to 5,000 labels, some converters will want to bypass the 24-72-hour wait for a die, instead choosing to finish on-demand for quicker turnaround times. This is a boon for the short run market, although AB Graphic International explains that it can be beneficial for all types of printing. “One particular segment taking advantage of the laser is sticker producers, particularly in the US,” says Floriana Montella, laser business development manager at AB Graphic. “This technology is perfect for short runs. Negating the need for a die, all cut parameters are downloaded straight onto the machine using our unique ‘Compiler’ software, enabling producers to turn jobs around right away. No more waiting for prepress or die delivery. Laser cutting is also suitable for longer runs, since it can cut shapes and sizes of labels that are unable to be cut using a conventional die, including through cutting. We showcased this at last year’s Labelexpo Brussels with our 900mm long rocket label and CD cover.”
Laser diecutting offers other benefits as well. Tooling costs are virtually eliminated, as many companies will invest anywhere from $70,000 to $100,000 for dies. Lasers save time too. “Typically, a semi-rotary machine will take anywhere from seven to 12 minutes to change over,” says Bacon. “At maximum on a laser, it would take five minutes. There are some cuts – if you have a lot of intricate cuts within the laser itself – where you’ll want to do a test cut. If it’s a material you’ve never run before or there are a lot of interior cuts or sharp angles, you’ll want to run through a few tests in order to make sure your depth of cut is good.”
According to Luca Goldoni, sales department, Cartes, laser diecutting has the potential to grow in popularity. “Laser diecutting technology represents a tool that is applied in so many different fields that it can be considered a universal application,” she explains. “Obviously, short run digital printing has created higher demand for digital converting. We believe that any technology has its pros and cons, but as it was with digital presses, people were reluctant to get into that world of technology. They then felt forced in some way to make that next step, and we feel something similar will happen with laser technology.”
A finishing revolution
The enhancements in laser diecutting have been anything but evolutionary. This finishing process has grown by leaps and bounds over the last several years.
“Laser technology has come a long way, and new advancements are taking place every day,” says Newville. “We’ve listed the new lasers on the market, and more appear daily.”
Xeikon, a digital print solutions provider, recently launched the Xeikon Laser Diecut Unit (LDU). Xeikon developed the technology to meet the growing demand for shorter runs and faster turnaround times. The LDU is designed to work in tandem with the company’s press portfolio, featuring a web width of up to 330mm and handling materials from conventional or other digital presses, including PP, Silver PP and PET.
“The laser diecut unit is the perfect entry-level solution completely integrated into the Xeikon workflow,” explains Jeroen van Bauwel, Xeikon’s director of product management. “It matches seamlessly with the speed of the Xeikon 3030 digital press, making it the ideal solution for short run, quick turnaround jobs.”
The LDU’s inline configuration with the Xeikon 3030 is developed to match the 31.5 fpm speed of the press. The Xeikon LDU also applies varnish, slits and rewinds labels. The laser station can kiss cut and perforate too. “We’ve had a lot of interest, specifically in the complete solution,” says van Bauwel. “Most of the potential is with commercial printers taking their first steps in label printing without legacy. Also, web-to-print shops benefit since they require extremely quick turnarounds.”
The process has become far more efficient, as well. “When we started in this business, the cut quality was terrible and the speeds were terrible,” says Bacon. “That’s where it started, and that’s why nobody gave it a shot.”
Bacon says that several developments significantly enhanced the technology. The laser source improved from a 10.6 to 10.2, which allows for the cutting of a wider array of substrates. The spot size – or the circumference of the laser beam – can also be adjusted. The circumference should range from 190-210 microns, where it was over 300 microns a few years ago.
“It doesn’t sound like much, but it’s like taking a piece of bread and using a butter knife to cut it or a sharp knife to cut it,” explains Bacon. “It takes longer to cut through when the laser source is comparable to a butter knife, and the quality of the cut is not going to be as good. The race was finding the optimum micron spot size.”
In just three to four years, the materials have changed dramatically too. “At that time, it was a problem because none of the material guys cared because nobody was buying lasers,” explains Bacon.
The growth of digital printing has accelerated the process. At the recent Labelexpo Americas, Spartanics showcased machines in the INX and Konica Minolta booths, both of which highlighted very short run technology. Spartanics, the North American distributor of SMAG Graphique, showcased the SMAG Digital Galaxie, the Spartanics SRL-350, and the NW210-E inkjet printer with a 200-watt laser.
Delta ModTech, also present at multiple Labelexpo booths, currently offers Edge Laser Technology. “We offer our Edge, a modular laser system mounted on our Crusader machine,” says Newville. “We also have our Edge Flex, a standalone system that can run roll-to-roll, sheet fed or inline with another converting machine. Additionally, we provide completely custom laser diecutting systems that are designed for specific process and production demands.”
AB Graphic, which offers laser cutting modules for the Digicon Series 3, has customizable solutions for its customers, and it has even developed technology to limit the “yellow edge” on PP materials. Many of the company’s solutions have evolved quickly in the last several years. “A couple of years ago, the bar code scanner for immediate workflow changeover was just an idea,” says Montella. “However, in the last two years we have completely revolutionized the way label and sticker producers can work. In addition, we’ve created a solution to significantly reduce the need for operator intervention, as well as reducing the waste of material. Thanks to the automatic changeover, all this is now a reality. We could also definitively solve the issue of the ‘yellow edge’ on PP, thanks to a new calibration of power and laser wavelength. All these goals were almost unthinkable two years ago, but they have been realized thanks to constant research by our laser engineering department.”
The value of software
Software plays a valuable role in laser diecutting, and in many cases, it can be what separates the technology providers. When a prepress operator or art designer is setting up the job to go to print, there is a vector layer that identifies the diecut line.
“When we take the raw information from the artwork file, Adobe Illustrator allows you to set up that die line in the file itself,” explains Bacon. “We’re sending information to the scanhead, to the set of mirrors, that will allow us to start or stop cutting sooner or later, depending on what the registration is.”
A laser is setup in much the same way as a digitally printed job. There is a cut file that goes to the press, and some customers will even set up a job in one location, with the finishing taking place at another plant entirely.
“When we work with Durst and INX, we actually go through their RIP software in order to take the information that we need,” says Bacon. “We also work with Esko and Onyx, so it actually starts at that level, whereas an offline machine will start at the Adobe Illustrator level.”
At AB Graphic, the laser development department has completely designed the software and will routinely invest in upgrades. “We have a unique software package, not only because it can be modified or upgraded by our engineers to meet each customer’s specific needs, but also for its functionality, which allows a completely automatic workflow changeover,” explains Montella. “The software pre-processes a job in advance, so when the printed web enters the laser cutter, the job bar code has already been read and the laser is prepared for that individual job, minimizing setup time. The software controls every single step of every job printed in the same roll and automatically adjusts the register and the settings at every changeover. In this way, the operator just needs to check that the work is performed correctly.”
Challenges with lasers
While there are benefits to laser diecutting, the process does offer a few hurdles. The first involves the substrates. The suppliers must provide materials that are capable of being laser cut.
Spartanics says there are some materials that it will not cut with its machines, including PVC materials. When the laser burns vinyl chloride, it emits certain gases. Some vinyl materials will also turn yellow upon cutting.
Polypropylene used to pose a problem, as the frequency of the laser would go through the top material and cut the liner first. “About a year ago, we were able to talk to the laser manufacturers and ask them how to cut PP better, and that’s where we shifted,” says Bacon. “Now we can cut that with a 400 watt laser – it’s a 10.2 laser frequency versus a 10.6 – and it opens up another avenue for materials.
“Materials have always been kind of a challenge, but I think that’s starting to go away,” adds Bacon. “There are now some vinyl substitutes that FLEXcon is working on for outdoor applications that we’re able to laser cut, so that’s all shifting and changing.”
Cartes believes that the job of the laser diecutter manufacturer is to develop technology that supersedes substrate limitations. “Substrates play an important role, but it is more important to find solutions to the substrates’ limitations,” says Goldoni. “This is why Cartes is constantly investing and developing new solutions.”
Another factor that could inhibit some converters from adopting laser diecutting involves price. A basic semi-rotary or full-rotary unit will run anywhere from $175,000 to $200,000. A 400-watt laser, installed in place of the semi-rotary diecutting unit, will cost $400,000.”
“The pricing certainly still makes a difference to people, especially when they’ve just spent $800,000 on a printer,” says Bacon. “The nice thing that we’re seeing as a benefit, from where we started to where we’re going, is we can sell someone a semi-rotary diecutting machine and put a laser in at any point.”
Due to the angles at which lasers cut, a full-bleed label on top of a dark bottle could have the ink cut off on the top to where the white label substrate underneath is exposed. Bacon notes that this could be particularly problematic with wine labels. “If 90% of their work is wine labels, then we probably won’t sell them a laser machine,” he says. “That’s always something we talk to our customers about.”
Bacon adds: “If you’re running 500,000 labels all day every day, then laser technology is probably not for you. You can run that faster through a full rotary die and sometimes through a semi-rotary die.”
Label Traxx MIS has announced integration with AB Graphic’s Digilase digital laser cutter. The project is the result of collaboration with Label Traxx customer Innovative Labeling Solutions (ILS) of Hamilton, OH, USA, Esko and AB Graphic International. The aim of the assignment was to speed up job changeover and increase throughput through ILS’ digital finishing department.
The integration enables the Digilase to pre-process the job in advance so that when a barcode printed on the web is scanned, the digital finisher knows which job it is running, is ready to cut the correct die line and the slitting knives are positioned automatically.
“Our digital label business has been growing fast,” explains ILS owner Jay Dollries. “We already have Label Traxx integrated with Esko’s Automation Engine, which has significantly streamlined the flow from order processing to prepress and printing. However, the volume of job changes has meant that a clear bottleneck was looming in finishing. We are extremely pleased with the outcome of this project.”
Using Label Traxx’s new API module, an API (application programming interface) was created that feeds the Digilase data in realtime as production is processed. Esko’s Automation Engine creates the step and repeat of the job using data supplied by Label Traxx. There is a trigger in the file plan that runs the API. Label Traxx then creates and transfers the job data the Digilase requires via XML and generates an SVG (scalable vector graphic) file to give the laser a path to cut. The Digilase takes the vector file and plots each burst of the laser. This pre-processing means that when the printed web enters the Digilase, the job bar code is read and the laser is already prepared. Setup time on the finishing machine is minimized.
“This was a great project to work on with ILS, Esko and ABG,” says Label Traxx president Ken Meinhardt. “Together we have solved a real issue for our mutual customer ILS, and we have successfully miminized setup time on the Digilase finishing machine. This will enable them to finish a higher volume of digital label jobs every day.”
Label Traxx’s API module is now available in Version 8 of its software.
Laser diecutting features two major components: a scanhead and a laser source. The scanhead, or galvanometer, features a set of mirrors that use the cut information to trace around the desired cut shape. The mirrors are positioned accordingly to redirect the light around the cutting surface. According to Mike Bacon, vice president of sales and marketing at Spartanics, using a single scanhead will provide higher-quality cuts. Some converters might use two scanheads, however, to accommodate software limitations or to keep pace with faster speeds.
“When we work with Durst, and we’re running an inline laser system, we have some machines that are out there that are a single scanhead, 13" wide, and the last two we’ve sold with them we’ve doubled-up,” explains Bacon. “They’re still 13" wide, but as the material is going left to right, we stack those in the material direction so that we basically do double the work so we can increase our speeds. That way, we can run inline with a Durst machine or Domino or whomever it may be.”
When utilizing laser diecutting, the goal is to run as fast as the digital printer is capable of running. “Back when Xeikon and HP were coming out, they were only running at 800 to 100 fpm, so it wasn’t that big of a deal,” adds Bacon. “With these new UV inkjet presses that are out running 50 m/m or 100 fpm, the laser diecutting will start to slow down what they can produce on the printer.”
Delta ModTech, a finishing specialist that has been integrating lasers into its converting systems for over 15 years, cites several advantages to laser diecutting. The flexibility of the laser allows for tough cuts and tight tolerances. “The laser’s claim to fame is that it can cut through intricate, tricky patterns in which it would be difficult for a traditional rotary diecutter,” explains Jason Newville, design engineer at Delta ModTech. “It’s also prototype-friendly for quick turnarounds. Laser cutting doesn’t require hard tooling, so it’s ideal if you want to create a quick prototype. You can then invest in a more durable rotary die down the road.”
Additionally, there are long-term cost benefits. “A rotary die may be less expensive to purchase, but it will eventually become dull and need to be sharpened and replaced. A laser will last significantly longer,” adds Newville.
The laser source essentially dictates how fast laser diecutting will run. Most systems will be 400, 500, or 600 watts on 13" wide webs. By moving to a narrower web, some applications will require less power. “We have an INX press that we run a laser inline with, and their UV inkjet machine is only 8.5" wide, so most times a 200 watt laser will suffice because the limiting factor is the digital printer that’s only running at about 60 fpm. So we don’t need more power to run more,” says Bacon.
According to Spartanics, 400-500 watt laser systems – single source lasers – comprise 90% of the units the company sells into the label market. These systems will comfortably run at 120 fpm, similar to semi-rotary diecutting speeds.
The laser source cuts on an angle, with Bacon describing the process like a flashlight in a dark room. The light begins at the circumference of the flashlight and goes out on an angle. “That’s essentially what a laser is doing,” he says. “We’re mounting that scanhead above where the material is running through, and in order to get to 13" wide, we have a specific height that we set that laser scanhead. Then we’re able to cut, and that angle will burn away the material.”
Cartes, a developer of labeling solutions since 1970, offers exclusive laser technology for diecutting and converting. The company provides single and dual laser sources, and its laser machines are capable of using a semi-sealed CO2 laser source. This generation of laser beam involves stimulating a lasing material with electrical discharges or lamps within a closed container. CO2 lasers are commonly “pumped” by passing a current through the gas mix using radio frequency energy (RF-excited). As the lasing material is stimulated, the beam is reflected internally by means of a partial mirror.
Bacon estimates that laser diecutting accounts for 7% of the finishing market, but says that the market is growing. While digital technology still makes up a small part of the label industry compared to flexo, some converters are looking to find their niche in digital short runs. Featuring quick turnarounds and customizability, printers are investing in a digital printer and a laser unit. “There are companies that just start out brand new into the label market with digital printing and laser cutting,” says Bacon. “That makes them truly a digital printing and finishing company.”
Whether a job ranges from 10 labels to 5,000 labels, some converters will want to bypass the 24-72-hour wait for a die, instead choosing to finish on-demand for quicker turnaround times. This is a boon for the short run market, although AB Graphic International explains that it can be beneficial for all types of printing. “One particular segment taking advantage of the laser is sticker producers, particularly in the US,” says Floriana Montella, laser business development manager at AB Graphic. “This technology is perfect for short runs. Negating the need for a die, all cut parameters are downloaded straight onto the machine using our unique ‘Compiler’ software, enabling producers to turn jobs around right away. No more waiting for prepress or die delivery. Laser cutting is also suitable for longer runs, since it can cut shapes and sizes of labels that are unable to be cut using a conventional die, including through cutting. We showcased this at last year’s Labelexpo Brussels with our 900mm long rocket label and CD cover.”
Laser diecutting offers other benefits as well. Tooling costs are virtually eliminated, as many companies will invest anywhere from $70,000 to $100,000 for dies. Lasers save time too. “Typically, a semi-rotary machine will take anywhere from seven to 12 minutes to change over,” says Bacon. “At maximum on a laser, it would take five minutes. There are some cuts – if you have a lot of intricate cuts within the laser itself – where you’ll want to do a test cut. If it’s a material you’ve never run before or there are a lot of interior cuts or sharp angles, you’ll want to run through a few tests in order to make sure your depth of cut is good.”
According to Luca Goldoni, sales department, Cartes, laser diecutting has the potential to grow in popularity. “Laser diecutting technology represents a tool that is applied in so many different fields that it can be considered a universal application,” she explains. “Obviously, short run digital printing has created higher demand for digital converting. We believe that any technology has its pros and cons, but as it was with digital presses, people were reluctant to get into that world of technology. They then felt forced in some way to make that next step, and we feel something similar will happen with laser technology.”
A finishing revolution
The enhancements in laser diecutting have been anything but evolutionary. This finishing process has grown by leaps and bounds over the last several years.
“Laser technology has come a long way, and new advancements are taking place every day,” says Newville. “We’ve listed the new lasers on the market, and more appear daily.”
Xeikon, a digital print solutions provider, recently launched the Xeikon Laser Diecut Unit (LDU). Xeikon developed the technology to meet the growing demand for shorter runs and faster turnaround times. The LDU is designed to work in tandem with the company’s press portfolio, featuring a web width of up to 330mm and handling materials from conventional or other digital presses, including PP, Silver PP and PET.
“The laser diecut unit is the perfect entry-level solution completely integrated into the Xeikon workflow,” explains Jeroen van Bauwel, Xeikon’s director of product management. “It matches seamlessly with the speed of the Xeikon 3030 digital press, making it the ideal solution for short run, quick turnaround jobs.”
The LDU’s inline configuration with the Xeikon 3030 is developed to match the 31.5 fpm speed of the press. The Xeikon LDU also applies varnish, slits and rewinds labels. The laser station can kiss cut and perforate too. “We’ve had a lot of interest, specifically in the complete solution,” says van Bauwel. “Most of the potential is with commercial printers taking their first steps in label printing without legacy. Also, web-to-print shops benefit since they require extremely quick turnarounds.”
The process has become far more efficient, as well. “When we started in this business, the cut quality was terrible and the speeds were terrible,” says Bacon. “That’s where it started, and that’s why nobody gave it a shot.”
Bacon says that several developments significantly enhanced the technology. The laser source improved from a 10.6 to 10.2, which allows for the cutting of a wider array of substrates. The spot size – or the circumference of the laser beam – can also be adjusted. The circumference should range from 190-210 microns, where it was over 300 microns a few years ago.
“It doesn’t sound like much, but it’s like taking a piece of bread and using a butter knife to cut it or a sharp knife to cut it,” explains Bacon. “It takes longer to cut through when the laser source is comparable to a butter knife, and the quality of the cut is not going to be as good. The race was finding the optimum micron spot size.”
In just three to four years, the materials have changed dramatically too. “At that time, it was a problem because none of the material guys cared because nobody was buying lasers,” explains Bacon.
The growth of digital printing has accelerated the process. At the recent Labelexpo Americas, Spartanics showcased machines in the INX and Konica Minolta booths, both of which highlighted very short run technology. Spartanics, the North American distributor of SMAG Graphique, showcased the SMAG Digital Galaxie, the Spartanics SRL-350, and the NW210-E inkjet printer with a 200-watt laser.
Delta ModTech, also present at multiple Labelexpo booths, currently offers Edge Laser Technology. “We offer our Edge, a modular laser system mounted on our Crusader machine,” says Newville. “We also have our Edge Flex, a standalone system that can run roll-to-roll, sheet fed or inline with another converting machine. Additionally, we provide completely custom laser diecutting systems that are designed for specific process and production demands.”
AB Graphic, which offers laser cutting modules for the Digicon Series 3, has customizable solutions for its customers, and it has even developed technology to limit the “yellow edge” on PP materials. Many of the company’s solutions have evolved quickly in the last several years. “A couple of years ago, the bar code scanner for immediate workflow changeover was just an idea,” says Montella. “However, in the last two years we have completely revolutionized the way label and sticker producers can work. In addition, we’ve created a solution to significantly reduce the need for operator intervention, as well as reducing the waste of material. Thanks to the automatic changeover, all this is now a reality. We could also definitively solve the issue of the ‘yellow edge’ on PP, thanks to a new calibration of power and laser wavelength. All these goals were almost unthinkable two years ago, but they have been realized thanks to constant research by our laser engineering department.”
The value of software
Software plays a valuable role in laser diecutting, and in many cases, it can be what separates the technology providers. When a prepress operator or art designer is setting up the job to go to print, there is a vector layer that identifies the diecut line.
“When we take the raw information from the artwork file, Adobe Illustrator allows you to set up that die line in the file itself,” explains Bacon. “We’re sending information to the scanhead, to the set of mirrors, that will allow us to start or stop cutting sooner or later, depending on what the registration is.”
A laser is setup in much the same way as a digitally printed job. There is a cut file that goes to the press, and some customers will even set up a job in one location, with the finishing taking place at another plant entirely.
“When we work with Durst and INX, we actually go through their RIP software in order to take the information that we need,” says Bacon. “We also work with Esko and Onyx, so it actually starts at that level, whereas an offline machine will start at the Adobe Illustrator level.”
At AB Graphic, the laser development department has completely designed the software and will routinely invest in upgrades. “We have a unique software package, not only because it can be modified or upgraded by our engineers to meet each customer’s specific needs, but also for its functionality, which allows a completely automatic workflow changeover,” explains Montella. “The software pre-processes a job in advance, so when the printed web enters the laser cutter, the job bar code has already been read and the laser is prepared for that individual job, minimizing setup time. The software controls every single step of every job printed in the same roll and automatically adjusts the register and the settings at every changeover. In this way, the operator just needs to check that the work is performed correctly.”
Challenges with lasers
While there are benefits to laser diecutting, the process does offer a few hurdles. The first involves the substrates. The suppliers must provide materials that are capable of being laser cut.
Spartanics says there are some materials that it will not cut with its machines, including PVC materials. When the laser burns vinyl chloride, it emits certain gases. Some vinyl materials will also turn yellow upon cutting.
Polypropylene used to pose a problem, as the frequency of the laser would go through the top material and cut the liner first. “About a year ago, we were able to talk to the laser manufacturers and ask them how to cut PP better, and that’s where we shifted,” says Bacon. “Now we can cut that with a 400 watt laser – it’s a 10.2 laser frequency versus a 10.6 – and it opens up another avenue for materials.
“Materials have always been kind of a challenge, but I think that’s starting to go away,” adds Bacon. “There are now some vinyl substitutes that FLEXcon is working on for outdoor applications that we’re able to laser cut, so that’s all shifting and changing.”
Cartes believes that the job of the laser diecutter manufacturer is to develop technology that supersedes substrate limitations. “Substrates play an important role, but it is more important to find solutions to the substrates’ limitations,” says Goldoni. “This is why Cartes is constantly investing and developing new solutions.”
Another factor that could inhibit some converters from adopting laser diecutting involves price. A basic semi-rotary or full-rotary unit will run anywhere from $175,000 to $200,000. A 400-watt laser, installed in place of the semi-rotary diecutting unit, will cost $400,000.”
“The pricing certainly still makes a difference to people, especially when they’ve just spent $800,000 on a printer,” says Bacon. “The nice thing that we’re seeing as a benefit, from where we started to where we’re going, is we can sell someone a semi-rotary diecutting machine and put a laser in at any point.”
Due to the angles at which lasers cut, a full-bleed label on top of a dark bottle could have the ink cut off on the top to where the white label substrate underneath is exposed. Bacon notes that this could be particularly problematic with wine labels. “If 90% of their work is wine labels, then we probably won’t sell them a laser machine,” he says. “That’s always something we talk to our customers about.”
Bacon adds: “If you’re running 500,000 labels all day every day, then laser technology is probably not for you. You can run that faster through a full rotary die and sometimes through a semi-rotary die.”
Label Traxx MIS has announced integration with AB Graphic’s Digilase digital laser cutter. The project is the result of collaboration with Label Traxx customer Innovative Labeling Solutions (ILS) of Hamilton, OH, USA, Esko and AB Graphic International. The aim of the assignment was to speed up job changeover and increase throughput through ILS’ digital finishing department.
The integration enables the Digilase to pre-process the job in advance so that when a barcode printed on the web is scanned, the digital finisher knows which job it is running, is ready to cut the correct die line and the slitting knives are positioned automatically.
“Our digital label business has been growing fast,” explains ILS owner Jay Dollries. “We already have Label Traxx integrated with Esko’s Automation Engine, which has significantly streamlined the flow from order processing to prepress and printing. However, the volume of job changes has meant that a clear bottleneck was looming in finishing. We are extremely pleased with the outcome of this project.”
Using Label Traxx’s new API module, an API (application programming interface) was created that feeds the Digilase data in realtime as production is processed. Esko’s Automation Engine creates the step and repeat of the job using data supplied by Label Traxx. There is a trigger in the file plan that runs the API. Label Traxx then creates and transfers the job data the Digilase requires via XML and generates an SVG (scalable vector graphic) file to give the laser a path to cut. The Digilase takes the vector file and plots each burst of the laser. This pre-processing means that when the printed web enters the Digilase, the job bar code is read and the laser is already prepared. Setup time on the finishing machine is minimized.
“This was a great project to work on with ILS, Esko and ABG,” says Label Traxx president Ken Meinhardt. “Together we have solved a real issue for our mutual customer ILS, and we have successfully miminized setup time on the Digilase finishing machine. This will enable them to finish a higher volume of digital label jobs every day.”
Label Traxx’s API module is now available in Version 8 of its software.
