What is UV Film Casting (UFC)
The Cast and Cure process uses a holographic film in combination with a UV coating on any substrate to “cast” a holographic effect into the UV coating. While the holographic film, UV coating and substrate are in contact, the UV coating is “cured.” Then, as the film is removed from the substrate, the holographic effect is left on the surface of the material in the UV coating. Since there is no transfer of material taking place, as in Gloss foil, the film is re/usable.
How does it work?
The UV Film Casting technology makes use of a holographic film which, combined with UV varnish, “casts” a holographic effect into the UV varnish on the printed sheet.
When the holographic film, UV varnish and printed material are in contact between the blanket and impression cylinder of the last press tower, the UV varnish is formed by the holographic film and (directly after this casting process) the UV varnish is immediately “dried” by UV light.
After that, as the film is removed, the holographic effect is left in the UV coating on the surface of the material. During this process there is no transfer of material (like it is in Gloss/hot foil) so the film can be reused many times.
What is Gloss Foil (GF)
Gloss Foil transfer is a process in which aluminum, transported on a metalized polyester carrier, is applied on paper or cardboard in a conventional offset printing press without the use of heat. Adhesive is first printed on the paper sheet by means of the standard offset printing unit, while on the following printing unit the metalized coating of the polyester carrier is transferred only to the areas where the adhesive has been applied. The result is a silver or gold glossy layer on certain parts of the printed sheet
The cast & cure film will be unwind and wind at the same time
Because of the unique DFD (Direct Foil Drive) unit, a speed of up to 18.000 sheets/hour is achievable with the best foil result. (depending on printing press, paper/carton, UV varnish, and blankets)
Foil reel changing on ground level in less than 5 minutes
During the change-over the paper feeding of the mother press will be interrupted for a maximum of 5 minutes
For loading a new film reel there is an electrical roll manipulator
The very sensitive hologram layer of the film never comes into contact with any part of the Infigo unit; therefore the film never gets damaged. This guarantees the best quality of the UV Film Casting
Highlights Infigo SF110GF:
Fully automatic foil changeover
Because of the unique DFD (Direct Foil Drive) unit, a speed of up to 18.000 sheets/hour is achievable with the best Gloss Foil printing result. (depending on printing press, paper/carton, foil, adhesive and blankets)
The foil web can (optional) be cut before the turning bar, effecting production with a maximum of 5 separate smaller webs. By sliding this turning bar backwards and forwards, the cut web can be exactly positioned on the paper where it needs to be foiled. Fully automatic foil changeover can still be done
Changing the foil reel (maximum diameter of 450mm) takes place at ground level with an electrical roll manipulator – making a very easy and safe operation
The very sensitive metal layer of the Gloss Foil never comes into contact with any part of the Infigo unit; therefore the foil never gets damaged. This guarantees the best quality of the Gloss foil printing with less metal dust on the printing press
Foil waste is cut and transported away to the foil waste material separator. The air filtering unit, with automatic filter cleaning system and integrated fire protection system is standard The outside hydraulic press container can be rented locally or delivered as option. (see optional prices)
Description of all individual Infigo sections in Gloss foil mode:
Foil Loading Station (FLS) in Gloss foil mode:
Splicer with vacuum bar to prepare the new foil reel for the automatic glue cycles
During the automatic glue cycles the paper feeding on the mother press will be stopped for maximum 2 minutes
Foil storage – under pressure controlled – for leveling out the unbalance in the foil supply during the production with high speed and for a perfect web tension
Vacuum rollers, driven by Bosch Rexroth servo motors ensures that the sensitive metal layer of the Gloss foil never gets damaged
Electrical roll manipulator for easy loading and unloading the foil cores
Cross Section (CS) in Gloss foil mode:
This module will be delivered with 1 turning bar as standard
Optionally more turning bars (up to a total of 5) can be installed. Gloss Foil production can then be undertaken with a maximum of 5 separate webs, but only in combination with the cutting device. When the cross bar is moved, the sliced webs can be at any location on the printed sheet
Motorized foil pull-in systems from foil loading station to the cross section
Direct Foil Drive (DFD) in Gloss foil mode:
The foil web speed is controlled by 2 Bosch Rexroth servo motors – these motors are controlled by an encoder mounted on the printing press, thus guaranteeing a very precise synchronization of the foil web with the speed of the printing press
Electronically adjustable web tension
Web Splitting (WS) in Gloss foil mode:
In Gloss Foil mode the foil web can be split before the turning bar up to a maximum of 5 webs (optional). The width of each web is adjustable. The total width of the foil core is the total of all sliced webs. Maximum speed is still possible in Web Splitting mode
Fully automatic foil changeover still available
Foil Waste Cutter (FWC) in Gloss foil mode:
The used Gloss Foil is cut in little pieces after the printing process
The sliced foil is removed by air transport through a funnel and a piping system to the material separator
Foil Waste Removal (FWR) in Gloss foil mode:
The standard material separator drops the waste-foil into a outside hydraulic press container. This outside hydraulic press container can be rented locally or delivered as option. (see optional prices)
The air filtering unit, with integrated automatic filter cleaning system and fire protection system is standard
Description of all individual Infigo sections in UV Film casting mode:
Film Loading Station (FLS) in UV Film Casting mode:
Splicer with vacuum bar to prepare the new film reel for the glue cycles
Foil storage – under pressure controlled – for leveling out the unbalance in the film supply during the production with high speed and for a perfect web tension
Extra foil storage – under pressure controlled – so that the rewinding process is optimal without distorting of the expensive holographic film
Vacuum rollers, driven by Bosch Rexroth servo motors The very sensitive hologram layer of the film never comes into contact with any part of the Infigo unit
Electrical roll manipulator for easy loading and unloading the film cores
Cross Section (CS) in UV Film Casting mode:
This module will be only working with 1 turning bar
Motorized film pull-in systems from film loading station to the cross section
Direct Foil Drive (DFD) in UV Film Casting mode:
The film web speed is controlled by 2 Bosch Rexroth servo motors – these motors are controlled by an encoder mounted on the printing press, thus guaranteeing a very precise synchronization of the film web with the speed of the printing press
Electronically adjustable web tension
Foil Return section (FR) in UV Film Casting mode:
This module is mounted between the support frame on top of the printing machine and the cross section, to ensure the Holographic Film web returns back to the external splicer.
This module will be delivered with 1 turning bar
Also here the very sensitive hologram film never comes into contact with any part of the Infigo unit.
Second Direct Foil Drive (DFD) in Gloss Foil on another unit (optional):
The foil web speed is controlled by 2 Bosch Rexroth servo motors – these motors are controlled by an encoder mounted on the printing press, thus guaranteeing a very precise synchronization of the film web with the speed of the printing press
Electronically adjustable web tension
Motorized foil pull-in systems from foil loading station to the cross section
