Dominion Packaging – Taking flexo printing to new speeds

USA • To produce folding carton packaging for the tobacco, food and beverage markets, Dominion Packaging of Richmond, VA has chosen to develop new technology using a flexo press operation capable of replacing jobs that were previously printed on both gravure and offset presses.

The 55-inch, 10-color Tresu Innovator press equipped with rotec High Speed Sleeves and rotec Atlas Adapters provided by Flint Group (Source, Flint)

This advancement is based on the successful installation of a 10-unit, 55 inch (1400mm) FI 1400-10 TRESU Flexo Innovator press. The new Innovator is a flexographic in-line press equipped with rotec High Speed Sleeves and rotec Atlas Adapters from Flint Group. This particular combination of sleeves and adapters provides better control of plate bounce by absorbing press vibrations and providing added stability, thus permitting the press to run at faster speeds while still allowing for a solid kiss impression.

The polyurethane composition of the rotec sleeves provide the compression necessary to reduce bounce-induced skipping (a common occurrence on press as speed is increased) and offers a wider impression latitude, which enables the printing of half tone images and solids on the same print deck with a consistent print quality throughout the job. Additionally, since the sleeve has a durable compressible surface, plates can be mounted to the sleeve using an inexpensive 5 mm (0.20”) transfer tape, rather than the more expensive cushion tapes.

For greater stability at high print speeds, the rotec Atlas Adapter with a special carbon fiber structure and a hard surface presents further vibration dampening characteristics. Normally, according to Wes Johnson, regional sales manager, Flint Group Flexographic Products, “the maximum line speed of a typical folding carton press would normally be around 1200 fpm (366 m/min), but we were able to employ a combination of the rotec High Speed Sleeves and rotec Atlas Adapters to allow for the production of quality product at the maximum speed of the equipment.”

Dominion Packaging is perhaps the only folding carton producer using 150 LPI plates for this print segment, and “this press could possibly be one of the fastest folding carton presses the industry has seen to date,” speculated Johnson.

Flint Group is dedicated to serving the global printing and packaging industry by developing, manufacturing and marketing an extensive portfolio of printing consumables. Headquartered in Luxembourg, Flint Group employs some 7900 people.

Founded in 2004, Dominion Packaging is a mid-sized packaging manufacturer with two sites in the Richmond, VA area with over 350 full-time employees generating an estimated USD 150 million in annual revenue.

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