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Heidelberg’s ‘Zero Defect Packaging’solution

Heidelberger and its Swiss subsidiary Gallus will present solutions for defect-free, industrialized folding carton and label production, under the motto ‘Smart Print Shop – Zero Defect Packaging’.The joint participation of the two companies will focus on the challenges of defect-free packaging production from the point of view of brand companies.

Heidelberg is responding to the demand for serial or even customized packaging and labels with the Primefire 106, the first digital printing system in B1 format for industrialized printing applications, presented at drupa as well as the Gallus Labelfire 340 for digital label production. The integrated Prinect Packaging workflow developed by Heidelberg plays a central role here, by laying the foundations for industrialized production. It enables automation of the workflows – from order acceptance, through structural design, prepress, and press through to postpress – and facilitates intelligent communication between the areas in order to prevent defects.

The Primefire 106 features Perfect Stack technology for automatically removing incorrectly printed sheets from the process and immediately and correctly reprinting them. Integrated barcodes and QR codes or even serial numbers can also be added to all sheets for complete traceability.

The Gallus Labelfire label printing system also provides the option of individually identifying entire packages or even the individual label. Inspection systems can be used to register locations in packages with missing labels as well as incorrectly printed or damaged labels so they can be corrected in downstream systems by removing or reprinting them.

Gallus will also be presenting its new process, ‘Metallic Doming’. It can be used to produce raised textures with metallic luster on plastic substrates using rotary screen printing. The result is a haptic sensation that could previously only be produced using hot-foil embossing on paper substrates. Effects of this type are now also possible on tube laminates as well as PP and PE substrates.

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