Indian self-adhesive label converter Zircon Technologies has invested in an SPGPrints rotaLEN direct laser engraver to provide a digital, efficient prepress workflow for imaging high volumes of rotary screens at its Dehradun (Uttarakhand state) factory. The sale was agreed upon at Labelexpo India on the Stovec stand, where the full range of SPGPrints’ solutions for labels was being presented.

The rotaLEN engraver offers fast, clean, high-definition (HD) screen imaging with minimal manual intervention. These characteristics make it suitable to complement Zircon’s Omet Varyflex V2 press that incorporates three rotary screen units for value-adding label enhancements and its newly ordered 10-color Omet XFlex with two rotary screen units. The rotaLEN will have the capacity to supply screens for both presses.

The rotaLEN engraver features CO2 lasers that burn the emulsion on the mesh in a dry, single-step and fully digital process requiring no chemicals, film, or exposure/drying processes.
The laser precision and control of the accompanying RIP software enables excellent levels of resolution, sharpness, tonal gradation and contrast. Zircon will be able to offer screen-printed small text, meeting the demand for providing more information on a label without compromising clarity.

rotaLEN engraving cycles are as short as 30 minutes per screen, ensuring a smooth-running workflow is maintained when high volumes and tight lead times are required. Additionally, with minimal manual input, risk of error is minimal and jobs can be recalled from the database and repeated to identical specifications.

In the unlikely event of screen damage during a print run, Zircon can perform an immediate remake and continue production without excessive downtime.

The rotaLEN engraver at Zircon will engrave SPGPrints’ RotaMesh seamless nickel screens, chosen by the customer because of their durability, re-usability and ability to be re-imaged several times.

“The rotary screen process is becoming a vital means of adding value to retail packaging in India, especially for the no-label look and tactile effects,” says Sanjeev Sondhi, director of Zircon Technologies. “The investment in the SPGPrints rotaLEN gives us a streamlined workflow that enables us to engrave high volumes of rotary screens for multiple printing units in our factory. This makes us well-placed to offer exciting designs that differentiate our clients’ retail brands on a larger scale.”

“Zircon seeks equipment with the highest standards of performance at every step so they can deliver the stringent quality demands, often within short lead times,” explains Hank Guitjens, commercial manager, Label Printing at SPGPrints. “The rotaLEN direct laser engraver in combination with RotaMesh screens provides the precision and flexibility to do this.”

Zircon sees the rotary screen process as the key to offering high-value solutions for brand owners in sectors such as home care, food and drink, automotive and industrial, personal care and security printing. The demand for product differentiation and high-perceived value products has accelerated rapidly in the Indian market. Spot varnishes, metallic effects, fine line designs and textured finishes can all be applied by rotary screen printing, and the detail possible with screens imaged with the rotaLEN will deliver high-quality finishes over very long runs.

The combination of the Omet flexo presses, with the company’s rotary screen stations, will be able to exploit the full creative potential of the processes while meeting the high expectations of brands, retailers and consumers.