Making Multilayer Labels Easy with the Servo 3000

Sept. 11, 2010 - PRLog -- The Servo 3000 Digital Infeed +Re-register™ system made by Rotary Technologies commonly reduces waste and speeds up flexographic printing on all jobs. Add the Servo 3000 to a Flexo press and printing multilayer labels becomes faster and easier with less wasted material.

Multilayer labels are commonly used when a product comes in a small package but requires more information than can be printed on a standard label. Pharmaceutical and medical products are examples of the requirement of too much information for a small space. Additional examples are manufacturers who choose to add promotional material to the label or when the label must contain information in more than one language. Multilayer labels peel back to a hinge exposing more layers for content. When all layers have been printed the label can be resealed.

Using traditional flexographic printing processes there are a number of problems and limitations compared to using a Flexo press fitted with the Servo 3000. This can be a difficult job although it does not have to be. In a traditional process the press operator needs to register the colors of two webs simultaneously and then register both webs together. There is a high level of waste both in set up and while running even though press speeds are typically very slow. Whatever the number of print stations on a standard press, it will need to split the stations among the sets of panels. This will cut in half the number of available colors per label. Furthermore, the number of labels produced across the web is limited to one half maximum web width.

The Servo 3000 automates this tough job. Because Servo 3000 can re-register the web the first layer can be pre-printed. Using the Servo 3000 the pre-printed layer is automatically laminated in register to the base layer. Thus the operator only needs to register one web at a time while the Servo 3000 performs the complex task. Using the Servo 3000 for printing multi-layer labels reliably results in less setup waste, less waste while printing, faster press speeds, and full web width production.

Printing multi-layer labels with the Servo 3000

First print the top layer. Because of the capabilities of the Servo 3000 this layer can be printed on the same press used for the rest of the work or on a different press. If the same press is used the only thing to slow press speed is drying as there is no die cutting or matrix stripping required in this step.

Prepare the base layer. Put the top layer roll on a lamination tower and run through the Servo 3000 to register the web. Then attach the two layers. This is typically done with a clear laminate or by printing adhesive on the base layer. Either a mid-feed nip or a die station can be used where the two webs come together.

Next use the Servo 3000 to adjust the top layer so that it is in register with the base layer. The Servo 3000 will automatically hold the position. Die cut and strip as normal.

Differences between Using the Servo 3000 and a Traditional Process

A traditional process for printing multi-layer labels commonly requires the addition of other equipment to accommodate the second web. Such equipment is only used for making multi-layer labels. The Servo 3000 can be used on every job as it improves press register and reduces material waste.

For more in formation regarding the use of the Servo 3000 Digital Infeed +Re-register™ system for printing multi-layer labels, or on all jobs to in order to reduce waste and improve registration, contact Rotary Technologies.

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Rotary Technologies produces the Servo 3000 Infeed and Re-register System. This servo and re-register system is an easily attached upgrade for rotary presses that reduces material waste and allows a press to run a wider range of substrates than normally.