An evolution of the established MASTER 6003 platform, the new press introduces an enhanced inking system that reduces ink required in circulation to print by 60% and,consequently, the solvent consumption by up to 40%. It also incorporates automated functions designed to improve productivity, efficiency and sustainability.
As gravure packaging printers face pressure to reduce material consumption and protect margins while run lengths shorten, efficient ink delivery and fast setup times become increasingly important to performance. The new MASTER 6003 press addresses this with an evolved inking system that minimises the volume of ink in circulation, combined with automated functions that reduce and facilitate operator intervention.
The LeanPrint® inking system is designed to reduce the amount of ink required in circulation during production. Optimising the path from ink tank to pan as well as pipework design, the new system reduces ink circulation volume by 60%, compared with the existing configuration. As a result, less ink is exposed to the atmosphere, contributing to a reduction in solvent consumption of up to 40%. This means lower consumption, reduced waste and a cleaner, safer production environment.
The new pan movement facilitates a rapid and smooth precision positioning of the pan,relative to the cylinder. This allows consistent, controlled ink transfer even at high speeds,without manual adjustment.
The new press also brings greater visibility of resource consumption through its integrated ink measurement and energy consumption features. Using pressure measurement devices, the press provides real-time insight into the amount of ink used on the job, ink in circulationin the press, remaining ink prepared for the job, and an estimation of ink needed to complete production.
This function aims to give operators greater confidence in managing ink supply during production. Information is displayed on a dedicated page on the HMI.
The energy consumption feature provides real-time visibility of electrical power and compressed-air use, also helping identify potential inefficiencies at an early stage.
Integrated ink measurement and energy monitoring also supports growing demand for traceability and documentation of resource use in the production process, to meet stricter regulatory and customer reporting requirements.
The automated cylinder engraving pre-washing system at each unit removes the need for manual cleaning, thoroughly removing dried ink in the smallest engraved cells, to ensure clean, consistent ink transfer. Cleaning cycles are activated on all necessary stations and completed within one minute, accelerating makeready and reducing the risk of bottlenecks between jobs. By reducing manual intervention, the system reduces operator workload and contributes to a more operator-friendly working environment.
The redesigned auxiliary trolley also simplifies ink-tank handling during job changes, with a compact, barrier-free configuration allowing the tank to be removed from either direction. It includes a reference system to allow precise positioning of the cylinder according to therepeat of the job, removing the need for additional manual operations during cylinder blocking. A floor-level support position also eases loading, while floor-level positioning helps reduce physical effort when moving the tanks.
When combined, these developments address the economics of gravure printing at several points in the production process. Reducing ink in circulation and solvent consumption helps reduce material use and operating costs, while real-time measurement gives converters greater visibility of resource consumption and traceability. Additionally, automated cleaning and ink handling can release additional production capacity, of significant value.
“Converters are seeking ways to improve efficiency and control costs, but without adding complexity to their workflow,” says Davide Rossello, Process R&D Manager Gravure at BOBST. “With the NEW MASTER 6003, we have focused on evolving a proven gravure technology with solutions that reduce consumption, automate routine processes and provide greater visibility of production. The press delivers on a simple objective – to improve the economics of the gravure process, without asking the customers to change the way they work.”
