Edale has announced the installation of its biggest order to date – a 430mm wide 14 color Card Line machine to an undisclosed company based in Africa for the production of pre-paid telecom recharge cards.

The unnamed high security printer realized that its existing sheetfed machines were no longer commercially viable with continued business growth.

The two companies spent a year researching products, visiting existing Edale customers and developing and testing equipment to ensure that they had a specification tailored to their exact requirements. In December 2014, they took ownership of a 14C hybrid flexo/digital/screen Card Line with a wide range of additional options. The Card Line boasts 14 UV flexo heads, Domino K600i for variable printing and verification of variable data (PIN numbers), scratch off verification with G series void marking, alongside a screen unit for application of the scratch off inks and two die units; with the machine measuring 30m long.

“We were delighted to receive this order,” says Bernhard Grob, export sales director of Edale. “Our focus is on the design and engineering of products that are more efficient than current methods or equivalent technologies. This press certainly showcases some fantastic next generation technology, and with the quantities this company is producing, they will soon see return on their initial investment.”

Productivity and flexibility are achieved by combining “traditional” multi-stage manufacturing processes into a single modular machine solution while having the capability to produce all conceivable formats of single and multi-pin cards. This single pass machine has been designed to produce up to 1.5 million pins per hour.  Combining processes streamlines production, eliminates work in progress and increases the security and traceability of the cards.

“This press allows us to better serve our customers by utilizing new capabilities and services that go beyond what we could previously offer,” says an anonymous CEO. “Our traditional sheetfed production was no longer commercially viable, and flexo will be a lot more cost efficient for us. By purchasing a proven technology with a guarantee of machine quality from a British manufacturer gives us great peace of mind.”

The newly installed flexo press offers several advantages over traditional presses, including minimal ink usage and reduced waste to support environmental considerations. The fast make-ready times enhance productivity rates while incorporating lean manufacturing principles. 

“The installation of this Card Line illustrates the high security of the Edale personalisation lines and the latest flexo technology available, eliminating outsourcing and providing our customers with a turnkey service, shortened cycle time and enhanced quality levels on specialized applications,” says James Boughton, Edale’s managing director. “Being modular in construction means the company has a lot of scope for adding more diverse application options should they wish to in the future.”

Two Edale engineers installed the 14 color Card Line as experienced scratch card instructors were brought in for an additional couple of weeks to train the in-house machine operators.

Edale has installed a Card Line machine to help a company meet increasing demands.