We have conceived, designed, and manufactured the Modular 921™, a flexo printer from our “Flexo stack” family, developed as an in-line solution specifically dedicated to the extrusion, converting, paper, non-woven, and textile industrial sectors. We structured this flexographic printing machine to work continuously and in-line with the moving substrate on unwinding flexible materials such as paper and cardboard, offering a specific application for front and back register printing on paper envelopes.

To ensure accurate print results, we equipped the system with two Miniflex® 541 printing units configured for 1+1 color processing. The system features advanced axis control for group synchronization and two photocells that accurately monitor the position of the two films at the sealing stage. From a production specification standpoint, our flexographic printer handles a fixed print width of 1100 mm and guarantees a variable print repeat, from a minimum of 260 mm up to a maximum of 500 mm. Furthermore, we mounted two calenders with dancer rollers on the support structure to ensure perfect material tensioning throughout the operation. To keep the production process efficient and cost-effective, we adopted a closed-chamber inking system based on an Ultralox™ ceramic anilox roller, paired with an ink recirculation system from the tank using a pneumatic pump. This engineering choice makes washing and color changeover operations fast and easy to perform and is optimized for the primary use of water-based inks. To support the process, we included two hot air drying boxes equipped with electrical resistors, specifically designed to speed up the ink drying process. Thanks to this solid construction configuration, our printer reaches an operating speed of 50 meters per minute on the production line.

Precision control of the entire system is entrusted to a gearless motorization system with synchronized brushless motors, featuring a dedicated motor for the print roller and another for the anilox roller. We developed a roller distance regulation system using electric cylinders so that the operator can easily perform all adjustments directly from the electrical panel or the control panel. To make operations increasingly rapid, we integrated the capability to perform in-line sleeve changeovers, facilitating the procedures to quickly vary the print repeat depending on the envelopes being produced. With the Modular 921™, we deliver a rational technology, designed to reliably respond to industrial needs.