Working of the module
The Foil Loading Station will be installed cross against the press, next to delivery. The upper frame with crossbars is connected with an adapter joined with the last coating module and the delivery.
Cast & Cure
In the coating tower, before the UFC unit, UV varnish is applied to the sheet. A full foil reel with hologram effects is unwinded and transported to the upper frame. The foil is then fed trough a foil storage, over a crossbar, to the DFD (Direct Foil Drive) module. From here the foil goes through the blanket and Impression cylinder, where after the UV Varnish is cured by a UV lamp, which shines through the hologram film (This system to be delivered by the pres manufacturer) After that the foil goes back over a crossbar to the foil loading station and is wound up.
When the reel is empty, the Vinfoil module sends a stop signal to the printing press. When the last sheet is ready, the foil transport is stopped and the changeover can begin. 2 vacuum bars installed in the splicer keep the foil in position and cut it off. 2 other vacuum bars take over the foil which is in the machine. Than the change-over takes place. After that the 2 vacuum bars place the foil towards the other vacuum bars. The foil is sealed and the production can start. The estimated production break: 2 à 3 minutes (the operator must be present).
The cast & cure foil will be unwind and winding up at the same time
Automatic foil reel changing
During the change-over the paper feeding of the mother press will be interrupted for a maximum of 2 minutes
For the changing of a new foil reel (maximum diameter of 450mm) there is an electrical roll manipulator. This makes the changing of the reeleasier
The very sensitive hologram layer of the cold 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 UV Film Casting
Through the whole process the foil is transported with the new generation of vacuum rollers
Highlights of all Infigo modules:
Fully automatic foil changeover
During the automatic foil gluing cycles, the paper feeding of the mother press is stopped for maximum 2 minutes
Because of the unique DFD (Direct Foil Drive) unit, a speed of up to 18.000 sheets/hour is achievable with the best cold 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 cold 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 cold 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 (compactor is optional)
Thanks to the fully automatic foil changeover, also partially used foil reels can easily be used, because there is no time lost during foil changeover
No waste foil rolls are removed. Cut waste foil is removed to the public waste disposal
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 – pneumatically 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 cold foil never gets damaged
Touch screen for adjusting and controlling the whole process
Foil break detection system
Electrical roll manipulator for easy loading and unloading the foil cores
Cross Section (CS):
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):
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
