In the flexible packaging sector, the move away from mechanical gear trains has reshaped what operators expect from a modern press. A Gearless flexographic press delivers smoother rotation, lower vibration, and tighter registration on demanding substrates. When configured as a Gearless flexo printing press, the system uses independent AC servo motors to drive each plate cylinder and anilox roll without any gear backlash. This architecture, also known as a Full servo flexo press, allows infinitely variable repeat lengths and faster job changeover. The latest generation of this equipment meets the definition of a Full servo flexographic printing machine, with automated pre-register, closed-loop tension, and recipe-based job storage. For converters handling BOPP, PET, PE, paper, and laminates between 12 and 250 micron, the CI gearless flexo printing machine provides measurable gains in print quality and waste reduction.
| Technical Parameter | Specification |
|---|---|
| Printing width | 850 mm / 1050 mm / 1250 mm / 1450 mm |
| Color stations | 8 or 10 (12 optional) |
| Max mechanical speed | 400 m/min |
| Repeat length range | 370 – 800 mm (optional 300 – 900 mm) |
| Registration accuracy | ±0.05 mm |
| Substrate range | BOPP, PET, PE, PVC, paper, aluminum foil, laminates (12 – 250 micron) |
| Drying system | Hot air / UV / LED with automatic temperature control |
| Unwind/rewind diameter | Max 1000 mm (optional 1200 mm) |
| Drive system | Independent AC servo motors per plate cylinder and anilox roll |
| Frame construction | Heavy-duty cast iron side frames, linear guide-mounted print stations |
The CI Gearless Flexo Printing Machine is engineered around a cantilever-free, modular frame that reduces deflection during high-speed production. Each print station slides on precision linear guides, making sleeve changes faster and repeatable within microns. The central impression drum has a double-wall design with a nickel-chromium surface, delivering uniform nip pressure across the full web width. Because there are no mechanical gears, the machine operates with lower noise and less mechanical wear, which is valuable for clean-room packaging environments. All servo drives are synchronized through a high-speed fiber-optic bus, and the control software automatically compensates for web elongation on extensible materials. Operators monitor registration, ink viscosity, and drying temperatures in real time from a single touchscreen. A typical six-color job changeover takes under 20 minutes, including wash-up, sleeve exchange, and automatic pre-register. An optional inline camera system verifies every impression at full speed, reducing off-spec output and enabling 100% quality control. The press supports integration of corona treatment, web cleaning, and lamination modules before or after the CI drum. Tension zones use load cells and dancer rollers to maintain wrinkle-free handling of thin gauge films starting at 12 micron. Quick-release anilox sleeves allow rapid switching between different line screens and cell volumes without removing the print station. The gearless servo architecture supports multi-process printing such as varnishing, cold foil, and reverse-side printing in a single pass. Because each motor follows a master virtual axis, registration remains stable during acceleration and deceleration, making the platform especially effective for short runs and frequent order changes. The electrical cabinet is climate-controlled, and all major components are accessible from the walkway side for routine maintenance. The CI Gearless Flexo Printing Machine can be configured with 8, 10, or 12 color stations, and dryer hoods are positioned to match the CI drum radius. The standard package includes automatic lubrication, static elimination, and a remote support module that allows factory engineers to access the PLC for preventive maintenance.
