Launched at the recent Labelexpo Americas, the Mark Andy DSHD HighSpeed 1200 inkjet/flexo hybrid press raises the bar for high-speed, high-quality label production and sets a new benchmark in the industry for performance and efficiency, according to the St. Louis, MO-based press manufacturer. Demonstrated each day of the exhibition, this latest version of Mark Andy’s Digital Series HD line showcases speed and quality, making the switch from traditional flexo to hybrid production a whole new calculation.

Available in 13” and 17” web widths, the new HighSpeed 1200 model is capable of 480 fpm in up to eight digital colors at 1200 dpi, and with the digital engine installed anywhere in the servo-driven flexo platform of Mark Andy’s Performance Series, it offers flexibility of specification both before and after the digital print section, from-roll-to-roll up to full hybrid with decorating and converting inline.

Raising the production speed of an inkjet engine to 480 fpm is not straightforward.  It requires powerful software (Mark Andy ProWORX DFE) and liquid-cooled control boards integrated into the press chiller to manage the additional thermal load from the data processing power required.

Mark Andy states the press is now the fastest digital label press on the market and is available at a fraction of the cost of its nearest competitor. The DSHD HighSpeed 1200 running at 480 fpm moves the crossover point between flexo and digital production further up the run length scale by as much as 60%.  In addition, it can run white or invisible security ink at this high speed and single or full color VDP. 

What this also achieves is a change in ROI calculation. Typically, when compared with the latest flexo press, a Digital Series HD running at 240 fpm would give a 56 month return on two-shift 75% press utilization. 

“By doubling the speed, throughput can be increased by up to 46% and the payback be shortened to just 15 months, because profitability per job increases almost threefold,” says product manager, Ben Luly. “The numbers tell the story.  This is also reflected in the cost of ink, which sees the curve flatten with added speed, along with the crossover point, making throughput the key to increased profit.”

One of the key development issues was the decision by Mark Andy to use the two-head system as opposed to native 1200 dpi print heads that are often perceived as superior.  Mark Andy closely evaluated the commercial performance of native 1200 dpi heads in everyday production and found them wanting. 

Adds Luly, “Our stainless-steel heads are more robust and reliable with far fewer nozzle outages, making them the preferred choice for labels. We have a better color gamut, and twice as many grayscale levels as silicon heads, not to mention a higher running speed.  If you need consistent performance in manufacturing across many batches, there is only one choice. The heads used on the Digital Series HD offer a white consistency above 82% opacity, which the competition cannot match at half the production speed.  Mark Andy’s inter-color pinning design allows converters the ability to optimize performance across a wide range of substrates – other integrators do not have full color pinning, which impacts on their capability to print consistent quality.

“The other significant advantage is the fact that the Digital Series HD HighSpeed 1200 is a totally Mark Andy product – so, one supplier of software and hardware, one support team, and more than 80 years of narrow web experience and expertise that no other manufacturer can match,” Luly says. “As a truly integrated hybrid incorporating digital, flexo, and converting, the machine’s design concept makes it uniquely customizable to individual requirements, existing workflows, and business development. No wonder Mark Andy sees it as a game-changer and the greatest single advance in narrow web since the arrival of digital print.”