Koenig & Bauer Technologies for the Entire Label Production Process Chain

Koenig & Bauer has always been present in the growth market of label production with sheetfed offset technology. Recently, we have been offering technical solutions for the entire label production process chain – printing, die-cutting and blanking. The following overview will give you an impression of the latest state of the art, as was also presented at drupa.

Technology & Innovation
Read time: approx. 5 minutes
Rapida 106 X in a typical configuration for label production: seven printing units, RS 106 X reel-to-sheet feeder, cold foil module, inline coater with AniloxLoader and extended delivery

From printing to blanking

Let’s begin with Koenig & Bauer’s classic domain of printing. As a high-end sheetfed offset press for the 3b format class, the Rapida 106 X sets the standards in terms of automation with production speeds of up to 22,000 sheets/h. That level of output yields a printed area equivalent to 2.4 football pitches every hour!

Koenig & Bauer has installed a Rapida 106 X configured specifically for label production in the Customer Experience Centre at its Radebeul location – with an RS 106 X reel-to-sheet feeder, seven printing units, an inline coater, extended delivery and a cold foil module. By combining flexibility, quality, performance and a diversity of finishing options, it is the ideal sheetfed offset printing press for label production.

RS 106 X reel-to-sheet feeder in production with IML film

High substrate flexibility

The Rapida 106 X handles the full range of substrates found in the labels segment: label papers in sheets and from the reel, mainly between 70 and 90 g/m2, coated and uncoated, and of course inmould films as well, for example as reel stock with a thickness of 50 to 90 µm and in white or transparent variants.

The conversion from sheet feeding to reel-based production, or vice versa, is completed within two to three minutes and with a bare minimum of manual intervention thanks to the RS 106 X reel-to-sheet feeder. The feeder and sheeter are designed to ensure full accessibility and thus guarantee maximum substrate flexibility.

The cold foil module FoilTronic optimises foil consumption – with MFU and indexing

Broad variety of economical inline finishing options

Economical, high-quality inline finishing has always been a strength of the Rapida sheetfed offset press range. Two innovations at the coaters are pivotal for the automation of job changeovers:

  1. All functions of the fully automatic coating plate changer CPC+ can be controlled from the press console. There is essentially no longer a difference between printing and coating plate changing: all manual intervention is eliminated, no tools are required, and the changing times are also identical.
  2. The AniloxLoader system has also allowed anilox roller changes to become highly automated. Three different anilox rollers are stored in the magazine on the coater and can be selected at the press of a button. It goes without saying that the anilox rollers in the magazine can be swapped at any time. That provides for practically unlimited flexibility when it comes to coating application.

The cold foil module FoilTronic further extends the finishing options to include 3D effects, counterfeiting protection and other special effects used to visually refine labels and folding cartons. And as if that were not enough: process automation – for example, automatic threading of the foil web – has slashed makeready time further still and also ensures that optimum use is made of the expensive cold foil, allowing savings during the production process. 

Non-stop IML production

Another innovation for IML production is the automated hurdle delivery. This provides for smear-free and non-stop production with small batches of the conventionally printed IML labels gathered into separate piles. The individual hurdles are created fully automatically by the Rapida in the process, allowing the operator to insert the supports and board with no stress whatsoever. Higher production outputs are possible and the smear-free, unblocked pile can be passed on for further processing without problems.

Ultimate print quality

Koenig & Bauer offers various equipment packages for print quality control, each of which is tailored precisely to the needs of the respective application. The standard system is QualiTronic ColorControl for inline colour density control based on measurements in a colour bar. A brand new alternative is QualiTronic Image+, a control system which does away with colour bars. Measurements are performed directly in solid colour elements that are part of the image, or else placed in the print-free spaces between the individual blanks. It is no longer necessary to set aside space on the sheet for a colour bar. Further expansion levels in inline quality control are: 

  • QualiTronic PrintCheck: sheet inspection
  • QualiTronic PDFCheck: additional comparison of the printed sheet with the pre-press PDF
  • QualiTronic PDF HighRes: especially high-resolution inline inspection at 290 dpi, thereby also enabling content monitoring
The rotary die-cutter CutPRO X 106 sets new standards in terms of die-cutting output, job changeover times and die-cutting quality in label production

Unrivalled performance – also in die-cutting

With the rotary die-cutter CutPRO X 106, Koenig & Bauer has had a perfect means of production for label finishing in its portfolio for some years now. The die-cutter runs at speeds of up to 16,000 sheets/h and is therefore on a par with conventional printing presses. It handles both ultra-thin inmould films and label papers of all kinds.

A film-handling package with high-performance antistatic systems forms the basis for stable processes and precise pile formation when using particularly sensitive materials. The “Click & Cut” register pin system positions the process formes on the cylinder without additional manual intervention. Makeready times can thereby be reduced to less than five minutes. The perfect pile quality also permits immediate further processing of the die-cut sheets.

On both the inmould and paper label markets, it is often the case that small pieces of waste must be removed from within the blanks. To cater for this, Koenig & Bauer has developed a special hole punching and extraction feature for the CutPRO X 106. In a separate die-cutting unit, waste elements ranging from ones with a diameter of 5 mm up to small windows can be cut out within or between the blanks and be removed immediately – all in an inline process.

The hurdle delivery improves pile formation when printing on IML films and similar substrates

Master Blanker BLK for high-speed blanking

The Master Blanker system separates the individual blanks making up a sheet. In this case, too, fast job changeovers and ultimate production speeds are placed in the foreground. This process involves separating blanks from the remaining waste by way of pins or a blanking tool.

The combination of rotary die-cutter and blanker can handle the same throughput as several flat-bed die-cutters. The system delivers precise blank stacks for direct further processing or shipment to the customer.

Label production has never been faster. Not only in sheetfed offset printing, but also in label die-cutting and blanking, Koenig & Bauer is defining new standards in terms of performance and quality. With future-oriented technologies – for the success of our users and their customers.