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Slitting & Rewinding Doubling the cutting speed on press


Abbey Labels has worked with MPS Systems to integrate a high-speed die- cutting module on its newest flexo press to increase efficiencies. The innovation, which is a world first, is part of an ambitious expansion programme and will more than double the cutting speed on press


pharmaceutical industries from its base in Suffolk. Part of the company’s success comes from its drive to continually push developments and engage with the latest technological advances. The most recent initiative has seen Abbey Labels work closely with Dutch press manufacturer MPS Systems to develop a die-cutting solution. It has combined its own expertise with AB Graphic’s patented Fast Track Die and the latest flexo press technology from MPS. It has taken a few years to bring the project to fruition, Chairman Tom Allum think it was worth the wait, commenting, “I firmly believe that this press with this particular option is a real game-changer not only for us, but for the flexo industry.”


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BETTER FIT FOR FLEXO Along with managing director Barry Pettit, Allum first came across the original Fast Track Die module at drupa in 2016, and quickly recognised the great potential that this new high-speed die-cutting unit from AB Graphic International could offer. Tom explains, “The Fast Track Die was demonstrated as an inline solution for a digital press when we first saw it in action in Germany. My immediate reaction was that it would be a better fit on a flexo press, which prints at much higher speeds and so could take full advantage of this super-fast die- cutting capability.” Abbey Labels had already fostered a successful partnership with MPS when investing in its two most recent flexo presses, so it was a natural choice to approach the Dutch manufacturer with the idea. Fast forward three years and a new MPS EFS 340 flexo press with a Fast Track Die


K printing company Abbey Labels supplies labels to the food, beverage, cosmetics, industrial, security and


departments of both ABG and MPS were able to overcome these.” Tom says, “Without MPS Systems and MPS UK working with ABG, we wouldn’t have got to where we are with this exciting new opportunity.”


module has been installed at the company’s facility to bring savings in downtime and thereby costs.


INNOVATION THROUGH COOPERATION With a top speed of 150m/min and a repeat of up to 508mm, the new semi-rotary die- cutting module enables the speed of cutting to be more than doubled compared to conventional single-anvil semi-rotary systems. Traditionally die-cutting can become a bottleneck as it slows down the speed of the press depending on the size of the die repeat, but with two anvils in operation on the Fast Track, this is no longer the case.


Not only does the Fast Track system offer


faster cutting speed, it is also much quicker to change the die as the magnetic cylinder stays in place at all times. Barry says, “The benefits in time savings should be immense. We’re a short to medium run printer and we’re constantly changing size, so if you’re saving 20 minutes every time you do that, we’re looking at a huge improvement.” Equally important, the new die-cutting unit does not need special cutters, but can use existing ones, so Abbey Labels can run the same flexible dies across its equipment rather than having to invest in new tooling. The fast changeover fits well with the MPS EFS, which comes with many automation features, meaning that less operator intervention is needed. It offers multi-substrate capability and a print speed of up to 200m/min, printing on 15 to 450- micron media. Nick says, “The whole project was a very exciting concept. Apart from being a world first, it was also going to be a very challenging technical integration that would offer web transport, tension and register questions that we not encountered previously. Thankfully the engineering


18 March 2020


PART OF A BIGGER PICTURE The new press is part of a major investment programme undertaken by Abbey Labels over the past 18 months. This is being carried out in three phases and will see the company invest some £1.1 million overall, a significant amount for a business of its size. The first phase was the arrival of an AB Graphic Digicon 3 finishing line, installed to increase the embellishment offering to clients. The second phase involved expanding the flexo print department, where the MPS EFS 340 eight-colour press with Fast Track and traditional semi-rotary die-cutting now stands, having been installed in February 2020. The third phase, now under way, is extending the facility and reorganising to optimise the workflow throughout the whole operation. In addition to the 2018 acquisition of the 4,000 sqft unit next door, an extra 3,500 sqft space is being built onto the existing building. This will become the new warehouse for materials and other consumables, while the existing warehouse will become the finishing department. “In order to realise our ambitious plans,


we needed more space, and we were fortunate enough to be able to take on the neighbouring unit,” explains Tom. Abbey Labels may not be part of a global


group, nor the biggest label printing company in the UK, but they are forward- looking and astute when it comes to making the right move.


abbeylabels.co.uk


convertermag.com


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