2-Color Stack-Type Full Servo Printing Press (TF-FS02-1000 1200)

Product Overview

The TF-FS02-1000 1200 is a high-performance 2-color stack-type full servo flexographic press integrated with Siemens technology, designed to meet the strict demands of modern packaging and printing industries. With a maximum material width of 1200mm and an impressive ±0.05mm registration accuracy, this press delivers high-quality printing results across an extensive range of substrates, including plastic films, various papers, aluminum foils, composite films, and non-woven fabrics. It combines advanced stack-type flexographic technology with full servo control, ensuring stable operation, precise color registration, and efficient production, making it an ideal solution for diverse multi-variety production environments.

Technical Principles & Core Structure

Based on advanced stack-type flexographic technology, the TF-FS02-1000 1200 features 2 independent printing units stacked sequentially, which enables high-precision multi-color registration. Each printing unit is equipped with international-brand servo motors that independently drive the plate and impression cylinders, ensuring precise control over every printing process. The closed-chamber doctor blade system plays a key role in ink transfer: it ensures uniform ink transfer from precision ceramic anilox rollers to the photopolymer plates, laying the foundation for accurate and consistent printing on various substrates.

The entire system is centrally managed by a Siemens PLC, which integrates high-precision photoelectric encoders for closed-loop tension and registration control. This integration ensures that every parameter of the printing process is accurately monitored and adjusted in real time, maintaining stable tension throughout the unwind to rewind process and eliminating registration deviations caused by material stretching or slackening, especially during high-speed production. The machine also features a dual-stage electric heating drying system, which includes both main oven and inter-color drying configurations. The high-temperature, high-velocity airflow generated by this system ensures thorough ink drying even at high production speeds, effectively preventing ink offsetting or buildup and ensuring the quality of printed products.

Key Performance Parameters

1. Design Speed: 260 m/min (actual production speed ranges from 30–220 m/min, depending on substrate type and design complexity)
2. Maximum Material Width: 1200 mm
3. Print Repeat Length: 360–1000 mm
4. Anilox Roller Specifications: Supports 100–1200 lines per inch with micron-level precision
5. Registration Accuracy: ±0.05mm
6. Compatible Substrates: Plastic films (PE, OPP, BOPP, CPP, PET, breathable films), various papers (kraft, coated, offset, thin cardstock), adhesive labels, aluminum foils, composite films, non-woven fabrics

Core Competitive Advantages

1. International Tier-1 Core Components: The machine adopts a complete SIEMENS full-servo system, including PLC, servo motors, HMI, and frequency inverters. It also incorporates global premium components such as Japan’s NSK bearings, Germany’s Leuze sensors, and Ingersoll Rand ink pumps. These high-quality components ensure long-term operational stability and consistent printing precision, laying a solid foundation for reliable production.

2. Industry-Leading ±0.05mm Registration Accuracy: Both horizontal and vertical registration are driven by independent motors and precision ball screws. Combined with real-time closed-loop feedback from photoelectric rotary encoders, this press can meet the rigorous registration requirements of high-end sectors such as food and pharmaceutical packaging, where even the slightest deviation can affect product quality and compliance.

3. Fully Automatic Intelligent Impression Control: Each printing unit is equipped with a synchronized four-servo motor closed-loop linkage system, which enables automatic pressure detection and correction. Operational parameters are permanently stored in the system, allowing for one-click recall during production. This system supports both individual and synchronized unit engagement/disengagement, greatly simplifying operation and improving production efficiency.

4. Closed-Chamber Doctor Blade System (2 Units): The precision CNC-machined alloy chamber is finished with an anti-stick coating, ensuring excellent sealing performance to eliminate ink leakage. The tool-free doctor blade design allows for one-step replacement, reducing downtime during maintenance and significantly improving the workshop environment by preventing ink contamination.

5. Anti-Clogging Anilox Roller Design: Equipped with an independent drive mechanism, the anilox roller rotates automatically when the machine stops or disengages. This innovative design fundamentally eliminates the industry-common issue of ink drying and clogging the mesh, reducing maintenance costs and ensuring consistent ink transfer performance.

6. Sleeve Quick-Change Structure: The press features a rapid plate sleeve replacement mechanism with a simple flip-and-load design. Compared to traditional models, this structure reduces changeover time by over 80%, making it ideal for enterprises with short-to-medium run lengths and frequent job changes.

7. Full-Process Closed-Loop Tension Control: The system provides automatic tension detection and compensation from the unwind to the rewind unit. This prevents registration deviations caused by material stretching or slackening at high speeds, ensuring stable production from startup to shutdown and minimizing material waste.

8. Powerful Two-Stage Electric Drying System: With both main oven and inter-color drying configurations, the high-temperature, high-velocity airflow ensures thorough ink drying during high-speed production. This eliminates issues such as ink offsetting or buildup, ensuring that printed products meet high-quality standards even at maximum production speeds.

9. Intelligent Centralized Control System: A large-scale touchscreen serves as the central control interface, managing all operational parameters in one place. The system supports job recipe storage and historical data tracking, which streamlines production changeovers and simplifies operation, reducing the need for skilled operators and improving overall production efficiency.

10. Deep Flexible Customization: Standard web widths of 1000–1200mm can be expanded to larger specifications, such as 1400mm or 1600mm, according to specific production needs. Additionally, the number of color units is not limited to 2, allowing for the addition of more units based on specific process requirements, providing truly bespoke solutions for every client.

Product Core Value

1. High Precision & Consistent Quality: With ±0.05mm registration accuracy and advanced servo control, the press ensures consistent, high-quality printing results, meeting the strict standards of high-end packaging sectors such as food and pharmaceuticals.

2. Enhanced Production Efficiency: The sleeve quick-change structure reduces changeover time by over 80%, while the intelligent centralized control system streamlines production operations. These features enable enterprises to handle frequent job changes efficiently, improving overall production throughput.

3. Versatile Substrate Compatibility: The press supports a wide range of substrates, from plastic films and papers to foils and non-woven fabrics, making it suitable for diverse production needs and reducing the need for multiple specialized printing machines.

4. Long-Term Operational Stability: Equipped with international tier-1 core components, the machine maintains stable performance over long periods of operation, reducing downtime and maintenance costs, and ensuring a high return on investment.

5. Customizable Solutions: Deep flexible customization options allow enterprises to tailor the press to their specific production requirements, whether it's expanding web width or adding more color units, ensuring that the machine can adapt to evolving business needs.

Target Customer Groups

1. Medium-to-large flexible packaging enterprises: These enterprises specialize in roll-to-roll printing on diverse materials, including plastic films, paper, and non-woven fabrics, and require a versatile and high-performance printing solution to meet their production needs.

2. High-precision sectors: Manufacturers serving high-demand segments such as food, daily chemicals, pharmaceuticals, and label printing, where strict registration accuracy and superior printing quality are paramount to product safety and brand image.

3. Paper product manufacturers: Enterprises focused on printing for paper cups, paper bowls, paper bags, and kraft paper packaging, who need a reliable press that can handle different types of paper substrates with consistent quality.

4. Multi-variety label producers: Manufacturers specializing in pressure-sensitive adhesive labels, shrink-sleeve labels, and other complex label formats, who require fast changeover times and precise color registration to produce high-quality labels efficiently.

5. Factories undergoing equipment upgrades: Facilities planning to replace outdated mechanical-shaft presses or aging servo-driven machinery, seeking to improve production efficiency, printing quality, and operational stability.

6. Flexible production enterprises: Businesses characterized by short-to-medium run lengths, frequent job changes, high-frequency material switching, and mixed-mode production, who benefit from the press's quick changeover capabilities and versatile substrate compatibility.

7. Specialized custom-order clients: Customers with requirements for ultra-wide format printing (1400mm+) for industrial packaging or complex multi-color processes for premium packaging applications, who can take advantage of the press's deep flexible customization options.

Application Scenarios

The TF-FS02-1000 1200 is suitable for a wide range of printing applications across various industries. In the flexible packaging sector, it can be used to print on plastic films for food packaging, daily chemical product packaging, and pharmaceutical packaging, ensuring precise color registration and high-quality printing that meets industry standards. For paper product manufacturers, it is ideal for printing on kraft paper, coated paper, and thin cardstock for paper cups, paper bags, and paper boxes.

In the label printing industry, the press excels at producing pressure-sensitive adhesive labels, shrink-sleeve labels, and other complex label formats, thanks to its precise registration and quick changeover capabilities. It is also suitable for printing on non-woven fabrics for applications such as shopping bags, medical supplies packaging, and industrial textiles. Additionally, its customizable features make it a perfect choice for enterprises requiring ultra-wide format printing for industrial packaging or multi-color processes for premium packaging.

Industry Pain Points Solved

1. Poor Registration Accuracy: Traditional printing presses often struggle to meet the high-precision registration requirements of high-end sectors like food and pharmaceutical packaging. The TF-FS02-1000 1200's ±0.05mm registration accuracy, driven by independent motors and closed-loop feedback, solves this problem, ensuring consistent and precise color alignment.

2. Long Changeover Times: Frequent job changes can lead to significant downtime with traditional printing machines. The press's sleeve quick-change structure reduces changeover time by over 80%, allowing enterprises to handle short-to-medium run lengths efficiently and improve overall production efficiency.

3. Ink Clogging & Leakage: Ink drying and clogging of anilox rollers, as well as ink leakage from doctor blade systems, are common industry issues that affect printing quality and workshop environment. The anti-clogging anilox roller design and closed-chamber doctor blade system of the TF-FS02-1000 1200 eliminate these problems, ensuring consistent ink transfer and a clean workshop.

4. Limited Substrate Compatibility: Many printing machines are only suitable for specific types of substrates, requiring enterprises to invest in multiple machines for different production needs. The TF-FS02-1000 1200's wide range of compatible substrates, from plastic films to non-woven fabrics, solves this issue, providing a versatile all-in-one printing solution.

5. Lack of Customization Options: Standard printing machines may not meet the unique requirements of some enterprises, such as ultra-wide format printing or multi-color processes. The press's deep flexible customization options allow clients to tailor the machine to their specific needs, providing bespoke solutions that support business growth.

Frequently Asked Questions (FAQ)

Q1: What is the actual production speed of the TF-FS02-1000 1200?
A: The design speed is 260 m/min, but the actual production speed ranges from 30–220 m/min, depending on the type of substrate being used and the complexity of the printing design.

Q2: Can the press be customized to handle wider web widths?
A: Yes, the standard web widths are 1000–1200mm, but it can be expanded to larger specifications such as 1400mm or 1600mm according to specific production requirements.

Q3: What types of substrates can the TF-FS02-1000 1200 print on?
A: It is compatible with a wide range of substrates, including plastic films (PE, OPP, BOPP, CPP, PET, breathable films), various papers (kraft, coated, offset, thin cardstock), adhesive labels, aluminum foils, composite films, and non-woven fabrics.

Q4: How does the press ensure precise color registration?
A: Both horizontal and vertical registration are driven by independent motors and precision ball screws, coupled with real-time closed-loop feedback from photoelectric rotary encoders, ensuring an industry-leading ±0.05mm registration accuracy.

Q5: Does the press have features to reduce ink waste and maintenance?
A: Yes, the anti-clogging anilox roller design prevents ink drying and clogging, while the closed-chamber doctor blade system eliminates ink leakage. These features reduce ink waste and maintenance costs, and improve the workshop environment.