F3 Series Flexo printing machine

F3 series flexo printing machine

Application object: Application: printing of packaging, paper bag, paper box, milk carton etc.

Paper used: coated paper, paperboard, non-woven fabric, light-weight coated paper, Kraft paper and paper-plastic composite material, PET, BOPP,BOPA etc.

Main characteristics: The F3 series medium web flexo printing’maximum running speed is 240m/min. It adopts sleeve technology on plate cylinder with features like fast job change and low production cost. New designed mechanical structure can efficiently reduce machine vibration to realize high printing quality. Additional advantages over traditional presses include short web paths, without adjusting pressure after changeover, pre -register function and minimal ink usage requirements resulting in waste savings up to 50% and fast changeover times for increased productivity.

BRIFE INTRODUCTION

Specifications: DHF3 1000

Max. unwinding diameter: 1524mm

Max. rewinding diameter: 1524mm

Max. paper width: 1020mm

Max. printing width: 1000mm

Printing repeat length: 350-810mm

Plate thickness + tape thickness: 1.7mm+0.38mm

Substrate: Paper:60-350gsm / Thickness:0.1mm-0.4mm

Max. designed speed: 200m/min

Max. printing speed: 200m/min (The speed will be impacted by but not limited to following factors:Character of Substrate、Character of ink and additives、Printing Quality Request、Flexo plate and tape

Drying system: Hot air / Electric heating

Ink: Water based ink/Solvent ink

Layout: Operator faces to the machine, unwinder in left hand direction./

Left or right according to the workshop layout

Machine color: DongHang standard

Power supply and compressed air
Power: 380V 3PH 50HZ
Compressed air:0.6MPa
Compressed air Consumption :2 m3/min

Environment requirements for workshop
Relative humidity: 30 -80% (at 20°C).
Temperature: 15°C – 35°C
Altitude: Less than 2000 m
Ground pad to fix and the thickness of the floor should be no less than 20cm

SMART OPERATION
Job save/recall, save necessary data of job setup, make job repeat more easily,no need set and adjust again,improve time efficiency and reduce paper waste
If you do not follow the procedure, the machine will alarm automatically
On-line monitoring of the whole machine status, real-time monitoring
Lack of air pressure, auto alarm
Each printing section was specified with control panel
Camera based register-Camera based registration system
Pre-register
Remote control system-Long distance diagnosis
Maintenance reminding,automatic remind maintenance(Weekly/Monthly/Yearly)

Unwinding structure features

Unwinding unit 2 sets
Max unwinding diameter 1524 mm
Shaftless unwinding, the chuck has self-locking function when rotate
Equipped with 3 inch, 6 inch, 12 inch cylindrical step chuck, with chuck rotation self-locking device
Electric control arms around, move up and down, single arm around mobile convenient lifting paper rolls
Automatic paper connection speed is ≤ 150 meters/minute

Splicing system

Unwinding structure features

Equipped with automatic tension control system, including pneumatic brake, tension sensor and controller, electronically controlled switching valve
The current roll diameter can be displayed in real time, and the alarm roll diameter value can be set. Once current roll diameter achieve setting diameter, system will give alarm.
with fault analysis and record function

Paper storage device

Web guide system(Italy ST)

Installed before printing station
Inspection: the edge precision ±0.02mm
Electronic web guide traction device. If there is any excursion in paper feeding, the system will have a constant and accurate adjustment.
Single side sensor for manual and automatic control and adjustment

Web cleaning unit（British technology high pressure vortex）

Double static rod design, first remove static electricity, then vacuum dust, then remove static electricity, used for cleaning printing materials
Through high-pressure fan to form a vacuum, with dust brush, through the separation of flow guide slot, high-pressure eddy current is formed on the paper surface, which can remove the dust of printing material more effectively

Infeed tension control system

Infeed tension impression roller is servo motor control for high register accuracy
One set servo motor,
One set servo driver,
One high-precision planetary gearbox,
Use the double rubber roller to clutch and feed paper and to ensure the tension .

Structure and features(patented technology)

Unit type with 6 printing station
Machine wallboard is used of HT250 cast iron
With N- type 4 guide rail design which can eliminate the shock vibration caused by the printing plate discontinuity. With heavy-duty high-precision ball screw, the printing pressure adjustment precision of plate roller bottom roller can reach 0.002 mm (patent technology can not be copied)

Ink system（patented technology）

Inking system by enclosed chambered doctor blade system. The chamber is provided of inlet and outlet ports for the ink circulation. Side sealing system to close laterally the chamber
The closed chamber doctor blade adopts a chamber design, and the knife holder can be easily separated from the main body, and the replacement of the blade is faster and lighter. (Proprietary support mechanism to ensure that the blade does not vibrate at high speed)
There is a special pressure relief device in the chamber , which will not cause the blade to deform due to overpressure in the chamber
The contact pressure between the scraper and the anilox roller is guaranteed by air pressure, and the pressure is adjusted by air pressure, and the wear of the blade can also ensure that the pressure remains unchanged. (Precision pressure regulation system can improve the service life of the blade and reduce the cost of use)
Each color group contains an air pressure ink supply system, stainless steel ink barrel, equipped with double pumps, ink supply and cleaning scraper holder, ink pipe and mesh roller are more convenient and fast, can be combined with automatic cleaning system
A stainless-steel ink tray, located under each printing unit, collects ink surplus during working and cleaning operations. The trays are mounted on quick release supports to facilitate replacement.
Coating on the inner surface of the ink chamber doctor blade system is easy for cleaning
Automatic ink supply device with magnetic filter function shall effectively extend the life of the anilox roller
Automatic cleaning system.

Anilox roller and plate cylinder auto positioning system

The plate cylinder and anilox roller automatically adjust the position according to the repeat length. The position adjustment is performed by a high-precision ball screw and four servo motors, and the plate roller and the anilox roller are respectively controlled by two servo motors.
The plate cylinders and anilox rollers of all selected printing stations are positioned at the same time
Positioning is completed automatically, which is easy and convenient

Printing station

Each printing station is driven by servo motor, the main motor is German servo motor and drive system
Each printing station has 6 servo motors

Anilox roller

Laser engraved ceramic anilox roller
There are ink splash guards on both sides.
The anilox roll will rotate to prevent the ink on its surface from drying and blocking holes on it when the machine stopped
The anilox roller and support device are installed on the linear guide rail, and the printing pressure is adjusted by the servo motor driven the high-precision ball screw with an accuracy of 0.002mm
6 High-precision anilox rollers (LPI decided by customer)
High-speed pressure adaptive system

Plate cylinder

Aluminum alloy-made plate cylinder
On the machine operation and non-operation side, the plate cylinder and the support structure are stably supported by four upper and lower linear guide
The plate cylinder and support device are installed on the linear guide rail, and the printing pressure is adjusted by the servo motor driven the high-precision ball screw with an accuracy of 0.002mm
Servo motor controls lateral movement of plate cylinders
Printing cylinder 6 pieces
High-speed pressure adaptive system

Printing adjustment and setting

Automatic registration in the paper-feeding direction and accurate registration with servo motor in the horizontal direction.
Register adjustment in the paper feeding direction can be adjusted at the printing unit and the main control console.
The paper feed direction registration is adjusted by plate cylinder servo motor phase compensation, 360° adjustment. This operation is completed when the machine is registered
Horizontal registration adjustment is realized at the printing unit and the main control console.
Horizontal registration is realized by moving plate cylinder, and the maximum adjustment distance is +10mm.
Printing pressure adjustment is precisely controlled by the ball screw and the servo motor with an accuracy of 0.002mm.
When the machine is stopped, the anilox roller pressure is immediately released, and the supply of ink to the plate cylinder is stopped. The plate cylinder continues to run for a specified period of time and then depressurizes to ensure complete transfer of residual ink on the plate.
The pressure is controlled by four servo motors of the printing station. The system ensures precise positioning of the printing station.
Simultaneous pressure on and off can be achieved.
Having pressure memory storage function, once adjusted, the pressure is directly in place for the same product
Dynamic adjustment for pressure, especially at high speed, automatically compensate the pressure and reduce waste due to pressure problem

Max unwind diameter 1524mm
Clamp type without shaft, auto lock of clamp head
3’ convert to 6’
Auto tension control system, air brake system
Hydraulic roll shaft lift: used to load and unload the paper roll without the forklift.
Auto stop when paper broken
Paper splicing device

Specified in front of the printing section
Equipped with pneumatic paper-holding device to splice the paper
Inspection: the edge
Adopts the photoelectric sensor for web guide transmission
Electronic web guide traction device. If there is any excursion in paper feeding, the system will have a constant and accurate adjustment.
Adopts closed-loop control system to accurately detect the deviation and correct it.

To guarantee the cleanness of substrates
First remove static, then clean the dust in vacuum and then remove static.
Vacuum is formed by high pressure fan, with the collaboration of dust removal brush, it is separated by the guide groove to effectively remove the printing material dust

CORONA SYSTEM

To increase ink adhesion to film side of the printing material

Use the pressure glue roller to clutch and feed paper and to ensure the tension
Tension roller is driven by servo motor, the tension is controlled by servo motor to ensure the precision registration

IN-FEED TENSION CONTROL

Printing section/Each printing section with two servo motors

Servo motors/ servo driven /
Flower type structure achieved the dual pressure independent adjustment and locking, avoid material waste caused by frequent pressure adjustment
The machine board is made of overall alloy and cast iron, which improves the stable performance and durability of the press machine
For every printing section: Impression cylinder is driven separately by one servo motor, plate cylinder and anilox roller share another servo motor through gear.Every plate roller with sleeve plate cylinder

INK SYSTEM

Single blade with reverse angle and ceramic coated anilox roller
Easy handle without tools

Unwinding structure features

Unwinding unit 2 sets
Max unwinding diameter 1524 mm
Shaftless unwinding, the chuck has self-locking function when rotate
Equipped with 3 inch, 6 inch, 12 inch cylindrical step chuck, with chuck rotation self-locking device
Electric control arms around, move up and down, single arm around mobile convenient lifting paper rolls
Automatic paper connection speed is ≤ 150 meters/minute

Splicing system

Unwinding structure features

Equipped with automatic tension control system, including pneumatic brake, tension sensor and controller, electronically controlled switching valve
The current roll diameter can be displayed in real time, and the alarm roll diameter value can be set. Once current roll diameter achieve setting diameter, system will give alarm.
with fault analysis and record function

Paper storage device

Web guide system(Italy ST)

Installed before printing station
Inspection: the edge precision ±0.02mm
Electronic web guide traction device. If there is any excursion in paper feeding, the system will have a constant and accurate adjustment.
Single side sensor for manual and automatic control and adjustment

Web cleaning unit（British technology high pressure vortex）

Double static rod design, first remove static electricity, then vacuum dust, then remove static electricity, used for cleaning printing materials
Through high-pressure fan to form a vacuum, with dust brush, through the separation of flow guide slot, high-pressure eddy current is formed on the paper surface, which can remove the dust of printing material more effectively

Infeed tension control system

Infeed tension impression roller is servo motor control for high register accuracy
One set servo motor,
One set servo driver,
One high-precision planetary gearbox,
Use the double rubber roller to clutch and feed paper and to ensure the tension .

Structure and features(patented technology)

Unit type with 6 printing station
Machine wallboard is used of HT250 cast iron
With N- type 4 guide rail design which can eliminate the shock vibration caused by the printing plate discontinuity. With heavy-duty high-precision ball screw, the printing pressure adjustment precision of plate roller bottom roller can reach 0.002 mm (patent technology can not be copied)

Ink system（patented technology）

Inking system by enclosed chambered doctor blade system. The chamber is provided of inlet and outlet ports for the ink circulation. Side sealing system to close laterally the chamber
The closed chamber doctor blade adopts a chamber design, and the knife holder can be easily separated from the main body, and the replacement of the blade is faster and lighter. (Proprietary support mechanism to ensure that the blade does not vibrate at high speed)
There is a special pressure relief device in the chamber , which will not cause the blade to deform due to overpressure in the chamber
The contact pressure between the scraper and the anilox roller is guaranteed by air pressure, and the pressure is adjusted by air pressure, and the wear of the blade can also ensure that the pressure remains unchanged. (Precision pressure regulation system can improve the service life of the blade and reduce the cost of use)
Each color group contains an air pressure ink supply system, stainless steel ink barrel, equipped with double pumps, ink supply and cleaning scraper holder, ink pipe and mesh roller are more convenient and fast, can be combined with automatic cleaning system
A stainless-steel ink tray, located under each printing unit, collects ink surplus during working and cleaning operations. The trays are mounted on quick release supports to facilitate replacement.
Coating on the inner surface of the ink chamber doctor blade system is easy for cleaning
Automatic ink supply device with magnetic filter function shall effectively extend the life of the anilox roller
Automatic cleaning system.

Anilox roller and plate cylinder auto positioning system

The plate cylinder and anilox roller automatically adjust the position according to the repeat length. The position adjustment is performed by a high-precision ball screw and four servo motors, and the plate roller and the anilox roller are respectively controlled by two servo motors.
The plate cylinders and anilox rollers of all selected printing stations are positioned at the same time
Positioning is completed automatically, which is easy and convenient

Printing station

Each printing station is driven by servo motor, the main motor is German servo motor and drive system
Each printing station has 6 servo motors

Anilox roller

Laser engraved ceramic anilox roller
There are ink splash guards on both sides.
The anilox roll will rotate to prevent the ink on its surface from drying and blocking holes on it when the machine stopped
The anilox roller and support device are installed on the linear guide rail, and the printing pressure is adjusted by the servo motor driven the high-precision ball screw with an accuracy of 0.002mm
6 High-precision anilox rollers (LPI decided by customer)
High-speed pressure adaptive system

Plate cylinder

Aluminum alloy-made plate cylinder
On the machine operation and non-operation side, the plate cylinder and the support structure are stably supported by four upper and lower linear guide
The plate cylinder and support device are installed on the linear guide rail, and the printing pressure is adjusted by the servo motor driven the high-precision ball screw with an accuracy of 0.002mm
Servo motor controls lateral movement of plate cylinders
Printing cylinder 6 pieces
High-speed pressure adaptive system

Printing adjustment and setting

Automatic registration in the paper-feeding direction and accurate registration with servo motor in the horizontal direction.
Register adjustment in the paper feeding direction can be adjusted at the printing unit and the main control console.
The paper feed direction registration is adjusted by plate cylinder servo motor phase compensation, 360° adjustment. This operation is completed when the machine is registered
Horizontal registration adjustment is realized at the printing unit and the main control console.
Horizontal registration is realized by moving plate cylinder, and the maximum adjustment distance is +10mm.
Printing pressure adjustment is precisely controlled by the ball screw and the servo motor with an accuracy of 0.002mm.
When the machine is stopped, the anilox roller pressure is immediately released, and the supply of ink to the plate cylinder is stopped. The plate cylinder continues to run for a specified period of time and then depressurizes to ensure complete transfer of residual ink on the plate.
The pressure is controlled by four servo motors of the printing station. The system ensures precise positioning of the printing station.
Simultaneous pressure on and off can be achieved.
Having pressure memory storage function, once adjusted, the pressure is directly in place for the same product
Dynamic adjustment for pressure, especially at high speed, automatically compensate the pressure and reduce waste due to pressure problem

Laser engraving ceramic anilox roller
8 pieces high precision anilox rollers
The anilox roll will rotate to prevent the ink on its surface from drying and blocking holes on it.
Sleeve plate cylinder
8 pieces sleeve plate cylinders (Repeat length is decided by customer but confirmed by DongHang).
Both sides of the cylinder was designed with shoulder metal structure
Air lock device can lock the cylinder directly without any tools

PRINTING AND SETTING

latest generation registration technology – Camera based dot model, the mark can be put anywhere
Auto register for paper running direction can be controlled on both printing section and touch screen
Operation direction’s registration can be realized by moving plate cylinder
Plate pressure & printing pressure area adjustment will be displayed on screen

Before running the machine, plate cylinder tries to find correct position by itself (position is calculated by machine computer). Lower down paper waste, achieve faster job setup.

VISUAL REGISTER

The automatic registration adopts the visual registration method independently developed by Donghang.
Starting from the second color group, each color group is equipped with one camera and one industrial control computer.
The registration of each color group with the base color can be corrected and adjusted in real time at the location of the color group, which can minimize the registration time and reduce paper waste.
It is equivalent to installing a small image inspection device for each color group. When performing manual corrections, one can immediately see the correction results without having to wait for the pattern to reach the final inspection point, which significantly saves paper.
The registration mark only requires a small dot of 1.5mm. It can be placed in the blank area of the pattern or within the shock-absorbing strip, without occupying any extra space. This significantly reduces the waste of paper edges.

Each of the printing units is equipped separately and adopts the high-power IR light tube
I.R short-wave heating and drying system and temperature is adjustable
Warm air and natural air-drying system including exhaust fan and blower with adjustable volume
Equipped with hot air fan to make sure the drying quality
Collect the waste gas and release it through the exhaust fan
IR power can be controlled separately and automatically according to the printing speed
Single printing section temperature control is available, better adapt to different printing materials and reduce the energy consumption of the whole machine

OUT-FEED TENSION CONTROL

Tension roller is driven by servo motor, the outfeed tension is controlled by servo motor to ensure the stable tension
Specified with pressure glue roller to clutch and feed and to guarantee the stable tension

IMAGE INSPECTION SYSTEM

Image inspecting camera can take pictures synchronously for the printing materials
Preset the inspecting position horizontally and vertically
It can magnify and observe the image with a fixed position to guarantee the printing quality.
High-definition resolution camera
High-definition color image monitor-17” LCD monitor
One high speed paparazzi flashing light
Product can be magnified, and the dot can be seen clearly

Surface driven winding type
Winding is controlled by motor, Independent motor drive, controlled by servo drive, constant tension control. Just set the tension value to control the paper tension. Automatic control, no manual intervention required.
Dance roller, air cylinder and sensor cooperate to control the tension
Rewinding unit diameter is 1524mm
Pneumatic air shaft 3″ & 6”
Hydraulic roll shaft lift: mainly used to load and unload the paper roll without the forklift.
When the paper is broken or cracked, the machine will stop automatically
Auto stop when paper broken
One set paper impress roller
Winding meter counting pre-set, when the meter reaches the set value, auto alarm

It has a screen including the bilateral symmetrical split-screen display
It is used for the plate mounting to realize the purpose of multi-color overprinting
One set image segmentation device

PLATE MOUNTING MACHINE