For converters seeking a complete custom press or a UV print engine to mount on an existing inline flexo press, Prototype & Production Systems Incorporated (PPSI) has them covered in the hybrid solutions market. Typically characterized as a combination of both analog and digital technologies in a single inline manufacturing operation, hybrid presses have grown in popularity given the surge in short-run orders.

PPSI has found success with its new DICEweb 6-color UV print engine that can attach to an inline flexo press or any roll-to-roll converting equipment. According to Willard (Chuck) Raymond, president of PPSI, the retrofit integration process is quite simple. “The print unit mounts above the press, and the web is threaded through the arched-roller print station,” explains Raymond. “An encoder keeps track of the web position and speed, and an optical ‘print-go’ sensor–usually mounted on the die-station–tells the system when to print digital data. The web is not driven by the DICEweb system, so the operator does not need to take any special steps to manage the web.”

Raymond adds that the DICEweb system can transform “an old, well-depreciated pre-servo, flexo press into a highly-capable short-run or variable data color printer.” DICE web utilizes UV-curable inks that can accommodate almost any substrate. In addition, mounting after a flexo print station allows for the application of low-cost primers, leading to the necessary improvements of to the surface energy of the substrate if needed.

“Good control of the web is critical to quality in digital printing; the arched roller design of the DICEweb ensures minimal web weave and flutter under the printheads,” says Raymond. “The DICE technology includes not only recirculating ink supplies that keep gas bubbles and particles away from the nozzles, but also an automatic head-maintenance system that periodically vacuums the heads – minimizing the need for the operator to manually wipe the heads.”

Since DICEweb integrates with an existing investment, this hybrid solution presents an economical way of going digital. The ability to repair printheads at a low cost has also decreased the overall cost of ownership associated with DICEweb.

PPSI has targeted its products toward customers who want to go digital without supplementing their existing print technology with another standalone press. “Our customers fall into two main categories: they are either label printers who want to get into digital without making a million dollar investment, and have a flexo press that runs well but is uneconomical to set up for short runs; or they are CPG companies that use roll-to-roll production equipment for their products and need to apply variable data or do late stage customization,” says Raymond. “In both cases, the benefits of combining digital and analog technologies are greater than the sum of the parts, because the entire manufacturing process is done in a single inline operation.”

While the practicality of retrofit technology is sometimes questioned, PPSI has received positive feedback from its customers. In addition, the company also displayed a complete custom press, designed for a customer’s specification, under the name “DICEpress” at Labelexpo Americas. The custom press was a 12.5” wide, 4-color inkjet printer with a festoon and lamination station, and custom software to integrate with the customer’s variable image/variable data workflow.

“People love the idea of breathing new life into their well-depreciated assets,” says Raymond. “They also like saving process steps by being able to use their existing investments in inline diecutting, etc. Our main bottleneck is our ability to produce samples for customers who send us their materials and images.

“The strength of the hybrid concept can be seen in the number of major manufacturers that showed hybrid offerings at the last Labelexpo,” he adds. “Soon hybrid will come to be seen as the logical way to go.”

PPSI’s technology has improved significantly since its first iterations. The company introduced its first DICE add-on print engine in 2010, but Raymond notes that its speed was a hindrance. “People loved the concept, but at only 80 fpm, it was too slow,” he says. “The new DICEweb system has doubled the speed and gained a loyal following. One DICEweb customer has ordered his third machine and retired most of his flexo presses.”

PPSI, which originated as a custom automation company, using technologies like robotics and machine vision to improve manufacturing productivity, has since become a specialist in inkjet integration. It is exploring new ways to transform the industry, as well. “We see the next opportunity after label converters being in flexible packaging and folding carton production, possibly with Electron Beam inks to overcome the food safety concerns associated with UV-curables,” explains Raymond. “We demonstrated a ‘proof of concept’ system with ebeam Technologies at Labelexpo, which attracted a lot of attention.”