The COVID-19 pandemic has increased demand at food retailers, which has undoubtedly disrupted the supply chain.

ProPrint Group, which is based in Wellingborough, UK, has been able to respond quickly to the situation thanks in part to the timely installation of Martin Automatic technology on its latest Edale FL3 narrow web press.  The FL3, which joins eight other Edale lines at the company, is a 430mm 10-color flexo press devoted entirely to the production of linerless labels and is currently working a double-day shift pattern.

With increased demand on the newest Edale, the use of automation seemed like a natural process to follow, and after a visit to Labelexpo Europe in 2019 and a factory tour at Desmedt Labels, near Brussels, which is one of Martin Automatic’s best European showcase installations, ProPrint decided to place an order.

Bob Green, operations manager for ProPrint Group, says, “We were seriously impressed with the Martin installations at Desmedt, which have effectively automated all of the company’s narrow web presses. The owner, Henri Köhler, was very open and helpful with production figures and we could see with our own eyes how smoothly the whole production process flowed.” 

The result of this visit was an order for a Martin Automatic MBS non-stop butt splicer, and a non-stop LRD rewinder. The MBS and LRD are two of Martin’s bestselling models from an extensive range that spans narrow to ultra-wide webs and substrates from self-adhesive and linerless labels and delicate films to sandpaper and roofing felt. Martin Automatic’s technology is simple to operate, easy to maintain and reliable, matching the requirements of today’s production environments where just-in-time delivery leaves little margin for error.

The MBS automatically shears and tapes the running web to the new reel while the press continues running at full production speed, which at ProPrint is typically around 140 m/m. It makes an ideal butt splice, that is with no overlap, and “irons” the tape across the web to ensure good bonding. Other features include web tension control and automatic web alignment with an ultrasonic sensor. The LRD rewinds and unloads the finished rolls also at full production speed without the operator needing to be present. Unlike a conventional turret rewinder, the LRD has a short transition between winding positions that reduces the risk of web movement and changes in web tension.

Green adds,“In the short time since the machinery was installed we have found it easy to use, reliable and very efficient. I estimate that the Martin equipment is saving us around 30% of the time it took to change a roll manually and has also cut make ready waste significantly by between 50-100 meters per change. Overall, I’d say the Martins have boosted output by at least 20%, and that’s being conservative.”

The investment package, which also included a Lundberg waste extraction system, is part of a larger program to widen the Group’s range of printed packaging. Currently operating from modern facilities across two sites – one for cartons, the other for labels, ProPrint offers digital and offset printing capability in addition to its narrow web flexo. Design and prepress are both handled in-house, and the company has invested heavily in streamlining all of its management and production processes to support and develop its staff.