NEW CREATIVE POSSIBILITIES IN SCREEN PRINTING

The new Screeny screen-printing unit delivers more than just modern printing technology. It unlocks new creative possibilities. Screen-printed labels and packaging truly stand out at point of sale, with their striking visual, tactile and sensory effects.

Screen printing ‘speaks’ directly to the senses, creating striking visual, tactile and even olfactory experiences. No other printing process offers such a wide range of effects that not only capture attention, but also significantly enhance brand perception. This creative potential is a key driver behind the continued growth of screen printing, even in emerging areas of application.

Retrofitting an existing narrow-web press with a screen-printing unit has, so far, been anything but straightforward. Historically, the market offers only a limited number of standardised solutions. Meanwhile users are increasingly seeking alternatives that meet today’s state-of-the-art standards.

“Gallus Screeny screen-printing unit positions itself as an innovative solution”

This is where the new Gallus Screeny screen-printing unit comes in. It was specifically developed for retrofitting and integration into existing narrow-web production lines. It can be integrated with any press type or manufacturer. The new unit features an attractive design and a carefully curated range of equipment options. The compact unit can be amalgamated on a rail system above the printing units. This can be achieved with no major modifications or extended downtimes. Alternatively, installation on a separate frame between printing units is also possible.

“It can be integrated with any press type or manufacturer”

As a stand-alone unit, the Screeny only requires a supply of power and compressed air. No speed signal is necessary. It begins printing as soon as the web runs through. Alternatively, it is equipped with the necessary connections to be linked to a machine’s start-stop signal.

The unit supports screen formats from 85T up to a maximum of 208T. It is available for print widths of 340mm, 440mm and 580mm, as well as a web width up to 600mm. The screen is driven on the drive and operator sides, features screen-break monitoring and a large ink-collection tray. 

The unit is operated via a 10” colour touch panel, which shows the operator all the main functions on one level. This colour display allows the operator to monitor and control all operating functions at a glance.

For ease of use, the touchscreen includes a tool tip that indicates the function of the currently selected button. This saves the operator from having to search through the user manual during training or when questions arise.

The coloured frame around the touch panel serves more than just a design purpose. It shows the operating status in a simple way, no matter where they are at the machine. An orange frame means the unit is ready for operation. When the machine system starts and the printing unit is running, the frame turns green. A red frame indicates a fault and the operator must intervene.

“The Screeny only requires a supply of power and compressed air”

Far from being just a ‘nice to have’, the automatic format and gap adjustment between the screen cylinder and the impression cylinder is a highly practical innovation. This adjustment is performed by two servo motors that automatically set the gap to 0.2mm. This replaces what was previously a manual process. The adjustment works for all printing cylinder diameters and is controlled by a specially developed software solution.

The Screeny screen-printing unit is the only one on the market to offer this feature – effectively eliminating operating errors caused by incorrect settings.

In addition to the standard longitudinal and lateral adjustments, the screen-printing unit also features a diagonal register adjustment. This proves to be a particularly useful function on systems where printing units can be flexibly positioned on a rail system. Minor deviations in parallel alignment – caused by the web path – can be compensated for via the diagonal adjustment by up to 0.5mm.

The doctor blade system is compatible with blades from all major manufacturers, regardless of their construction. Whether it is a classic rubber blade, a carbon-reinforced variant or a strip steel blade with bonded rubber, any type can be used. The pneumatically adjustable blade height of ±5mm makes operating the unit especially easy.

The compact design of the standard RCS screen rings used is noteworthy. These rings have no gears and, thanks to their compact size, allow for space-saving integration directly onto the rear wall of a machine system. This means that the web path is not affected.

In a screen-printing unit, errors when gluing the welded screen tube to the screen rings quickly lead to the destruction of the screen. The Screeny screen-printing unit has a sophisticated solution to this problem.

When the screen is inserted, the two drive sides of the unit are mechanically decoupled for a short time. The screen rings – equipped with a precisely fitting lug on both sides – slide automatically into the designated locating pins of the drive coupling when closing. Even if the lugs are not exactly aligned during insertion, they are reliably locked in place. This is achieved by the clutch closing automatically for operation. This results in the mechanical connection being precisely re-established.

Among the practical options available for the Screeny screen-printing unit is a GEW UV-curing system with an integrated chill roller. The unit is prepared for both conventional UV and UV-LED systems and features an efficient water-cooling system. For coating applications, an additional one-meter extension path can be integrated. Furthermore, the unit can be equipped with an integrated ink pump. When combined with an automatic ink-level control system, this ensures consistently high print quality and convenient operation.

With flexible integration capabilities, robust technology and proven print quality, the Gallus Screeny screen-printing unit positions itself as an innovative solution for rotary screen printing. It is suitable for cross-brand integration in diverse press environments, for retrofitted finishing steps or as an efficient inline module.

Another strong advantage of the Gallus Screeny is its full compatibility with the established RCS technology and existing Screeny peripheral equipment. Converters – already working with Gallus systems – can continue using their existing stencil rings, cutting tables, welding devices and mounting tools without any limitations. This results in time saving, cost reduction and the prevention of unnecessary system disruptions.