F2-ML

The Comexi F2 ML printer is the ideal solution for the demanding polyethylene market. An excellent machine from the point of view of profitability, designed to get the best quality at high speeds with large repeats.

An impeccable flexographic printing press that stands out for its high degree of versatility maintaining the ergonomics and usability features of the F2 range.

Main benefits for you

ERGONOMICS, faster job changes with platform

More SKU’s diversity and reduced job lengths are punishing the OEE (Overall Equipment Efficiency) of the machines, so we need to look for fast changeover machines with the highest ergonomics.

The F2ML is a bigger machine, either in 8 or 10 colors, and due to its maximum repeat up to 1.160mm, the sleeves are bigger and heavier.

These machines with the biggest repeats, are supplied with a big platform to facilitate the job change in the upper decks.  In this big platform (it is along the full face of the machine) we can allocate the trolleys with all the sleeves required to make the job change to minimize the movements and translations, so you can change at the same time inner & outer decks without going up/down

Two operators can work at the same time over the platform to make the fastest possible job change, and platforms keep all safety requirements in any country (extra fences showed for USA requirements)

The plate cylinder and anilox sleeve changeover takes a couple of minutes. The covers are opened manually, in a quick, simple way.

Ergonomics has also been applied to the Doctor blade, with the GeniusDoctoring solutions for the PIPELESS and magnetic doctor chamber.

GeniusDoctoring solution of the PIPELESS doctor blade in two parts that allow to make a full change of the doctor blade chamber (no more cleaning and changing blades onto the machine with machine stopped) in less than 1 minute without disassembling any pipe, and with a chamber weighting just 12Kg!

And once you have changed the entire doctor blade and you have the machine printing again, then you can clean and change the seals and blades without the need of any tool thanks to our patented magnetic fixation of blades


GeniusJob, job changeover during production

More SKU’s diversity doesn’t necessarily mean that jobs are totally different one from the other. Several times only 2 or 3 plates may change while the others remain the same, so given the case of having a 10-color machine it would be possible to change the free stations (if there are) in order to prepare for the next plates, minimizing the time dedicated to the change-over.  When you combine the GeniusJob with the GeniusFlow options to prepare and conditionate the inks for the next job (even if the anilox is not yet changed)  the stop time is minimized even more.

 

Printing quality

The highest printing quality requires a robust & stable machine with the latest developments in materials and software tools. With GeniusTech we have a full range of mechatronic approaches for the main flexo challenges related to printing quality:

• Minimum and stable dot gain
• No bouncing effects
• Perfect intercolor registration.

GeniusRun is the mechatronic combination of the high robust frames with the Monoblock concept, mandrels with an extensive use of Carbon fiber, bearing supports with preloaded linear guides and ball screws, and all together with an intelligent software that “understands” printing and adapts the response of the motors to the printing conditions.

All mandrels are made in carbon fiber, with the highest possible diameter to help minimize bending, and with hydraulic fixation of the intermediate sleeves (also made in UHM carbon fiber) to maximize the rigidity of all the elements that are primarily absorbing vibrations.

GeniusDrive is our patented technology of the Virtual Master, together with its exclusive and also patented Direct Encoder (Encoder directly fitted on the shaft instead of at the rear of the motor) that allows us to offer the highest longitudinal register tolerance in the market, with a value as good as ±25µ

GeniusDoctoring allows for the minimum pressure between the blades and the anilox that will give you minimum and more stable dot gain.

• A solid and robust bar with a flat surface where the doctor blade stands
• 3D-verified doctor blades with the highest precision

Forward-backward movement over linear guides with Low friction pistons to keep the doctor blade in place but with the minimum pressure, therefore allowing the doctor blade to move together with the Anilox as they were a single piece

High quality Pressure and Register Set Up

Automatic Set up systems to have the best quality job adjustment

More SKU’s diversity, reduced job lengths and lack of skilled operators lead to the need to make machines with a high level of automation that permit to make the job changeovers faster and adjust the next job with the highest possible quality and without the need of an expert printer.

In this scenario, we have a full range of GeniusTech solutions to improve the quality of the job set up while reducing the time and waste, and more important, without being dependent on the skill of the operators.

All our pressure and register set up systems are automatic, based in the real impression (not based in theoretical calculations but based on real printing) and enhanced with the use of data through Industry 4.0 solutions to have the best quality (minimum overpressure) and minimum waste.

GeniusPrint is our best in class system due to its high adjusting precision, both for pressure, where we can assure a maximum overpressure between 20µ to 70µ, and for register (based in the PDF and so in the whole printing) with a deviation <50µ

• Totally automatic system (operator only has to push a button) without dedicated marks.
• Printing and register adjustment based on the 100% of the print.
• Register adjustment through the comparison against the digital file (PDF) used to create the plates.
• Average waste around 150m depending on repeat, number of colors and machine model

As the GeniusPrint is using the 100% inspection camera from AVT, when having it we have also the 100% inspection and quality assurance of the printing results.
 

GeniusDot is our automatic impression and register system for optimal combination of waste & quality.

• Pressure and register adjustment based on a 1.5mm dot that appear at the end as a black dot
• Average waste around 120m depending on repeat and machine model

As the GeniusDot is using the matrix camera from AVT, when having it we can easily upgrade (just software) to add the statistic inspection and quality assurance of the printing results

GeniusSet is our automatic impression system for minimal waste

• Pressure adjustment based on detecting the kiss point between substrate/plate/anilox by means of the torque of the motors
• Average waste around 70m depending on the repeat and machine model

As GeniusSet is only for pressure adjustment, it is perfectly complemented with the GeniusReg to make the register adjustment

GeniusReg is our register system where the operator locates manually a characteristic area of every color at the same place (drag&drop) on the video touch screen

• It does not need any specific mark, but specific marks (dots, microdots, register cross...) can also be used.
• Average waste around 30m as once the characteristic area has been selected and zoomed the process can be finished with the machine stopped.

As GeniusReg is only for register adjustment, it is perfectly complemented with the GeniusSet to make the pressure adjustment

Inking control

GeniusFlow, excellence with the most efficient inking system

GeniusFlow is the system that manages the ink supply to the print, and cleans the ink chamber, the anilox, ink tanks and connection hoses in the circuit. This is a compact inking and cleaning system focused in minimizing the solvent consumption while enhancing the cleaning results. It is composed by:

• Only one asymmetric pump (Pneumatic) or two electric pumps (electric)
• Reduced lengths of the pipes
• Pressurized pulse dampener
• Integrated Vibration viscosimeters (in-line)

The exclusive Asymmetric Pneumatic Pump allows for both pumping ink to and sucking ink from the doctor blade, and is controlled via PLC in order to be possible to adapt the flow rate to the specific working of the machine, so helping to save compressed air and increasing the life of the membranes.

GeniusFlow is built into the actual machine frame. Its ergonomic arrangement provides for easy operator access and facilitates the maintenance tasks for all elements.

There are different versions of the GeniusFlow, and multiple options to adapt to any specific need:

• Stainless Steel execution for Water based inks or EB inks
• Ink cooling or heating with or without external chiller integration
• Clean and dirty solvent tanks that can be connected to an external distillatory
• Ink viscosity and/or temperature adjustment without need to have neither the anilox nor the chamber installed.

GeniusFlow:

• Pneumatic Inking system that features both the inking for printing as well as the cleaning of the system itself, the ink hoses, doctor blades and anilox sleeves. 
• The system is based on having an asymmetric pneumatic ink pump for each deck that enables both the ink supply and the ink return to the ink bucket and a manual valve with two positions (fill/empty) that allows reversing the circulation in the circuit to remove the ink from the chambers back to the ink buckets.
• System is valid either for Solvent or Water Based Inks

GeniusFlow Prime
 

• Pneumatic Inking system that features both the inking for printing as well as the cleaning of the system itself, the ink hoses, doctor blades and anilox sleeves.
• The system is based on having an asymmetric pneumatic ink pump for each deck that enables both the ink supply and the ink return to the ink bucket and pneumatic valves that allow reversing the circulation in the circuit to remove the ink from the chambers back to the ink buckets.
• System is operated from 2 touch panels located in the CI covers, in the vicinity of the pumps and the decks, with visual control of both.
• From the touch panels it can be set and controlled any parameter of the inking system, not just pumping, but also viscosities, temperatures, maintenance control (life time of the membranes), …
• There are 3 pre-set cleaning programs to optimize the time and waste for cleaning depending on the color change needs.
• It can be connected to 2 tanks of 400l each (optional), one for clean solvent and one for dirty solvent.
• System as std is valid only for Solvent Based Inks, there is the option for Water Based inks as well

GeniusFlow Electric
 

• Inking system that features both the inking for printing as well as the cleaning of the system itself, the ink hoses, doctor blades and anilox sleeves.
• The system is based on having 2 electric ink pumps for each deck that enable both the ink supply and the ink return to the ink bucket and which are controlled by drivers.
• System is operated from 2 touch panels located in the CI covers, in the vicinity of the pumps and the decks, with visual control of both.
• From the touch panels it can be set and controlled any parameter of the inking system, not just pumping, but also viscosities, temperatures, maintenance control (life time of the pumps) ...
• There are 3 pre-set cleaning programs to optimize the time and waste for cleaning depending on the color change needs.
• It can be connected to 2 tanks of 400l each (optional), one for clean solvent and one for dirty solvent.
• System is only valid for Solvent Based Inks, there is no option for Water Based Inks