For flexible packaging converters that demand fast changeover, repeatable print quality, and low mechanical maintenance, the direct drive CI flexo printing press has become the preferred platform. In a direct drive configuration, each print station is powered by its own servo motor, eliminating the gear train completely. This architecture is functionally identical to a Gearless CI flexo press, and many operators also classify the machine as a Gearless central impression flexo press because every color station transfers ink against the same central impression drum. When plate and anilox sleeves are mounted on air-expanding mandrels instead of conventional shafts, the system is referred to as a Shaftless CI flexo press, which reduces tooling weight and allows fast sleeve changes without removing the mandrel. The most automated variations are described as a Full servo CI flexo press, with servo motors controlling not only print registration but also impression pressure, ink metering, pre-registration, and web tension. The removal of gear backlash eliminates barring and density variation, giving converters tighter process control on fine text, vignettes, and high-screen process color across long runs. Common applications include flexible packaging, shrink sleeves, wrap-around labels, and paperboard packaging such as liquid cartons and medical packaging.
The Direct drive CI flexo printing press is engineered for a wide range of substrates and production scales. The machine uses a ground and dynamically balanced central impression cylinder, with independent servo drives on every print deck. This design allows quick changes between repeat lengths and substrate thicknesses without sacrificing registration accuracy. The following table lists the standard technical parameters for an 8-color configuration.
| Parameter | Standard specification |
|---|---|
| Web width | 850 mm / 1,050 mm / 1,250 mm / 1,450 mm, custom up to 1,800 mm |
| Number of colors | 6 / 8 / 10 stations |
| Repeat length range | 300 mm – 850 mm depending on sleeve size |
| Maximum mechanical speed | 400 m/min |
| Maximum production speed | 350 m/min for film, 250 m/min for paperboard |
| Registration accuracy | ±0.03 mm at 200 m/min |
| Substrate thickness | 12 – 200 μm for films, 80 – 250 gsm for paper |
| Unwind and rewind | Turret flying splice, 1,000 mm roll diameter |
| Anilox rolls | Ceramic coated, 200 – 1,200 lpi, quick-change cartridge |
| Dryer system | Inter-color hot air and tunnel dryer, 80°C – 220°C |
| Printing repeat accuracy | Length deviation ≤ ±0.05 mm |
Key operational features of the Direct drive CI flexo printing press include:
For converters with frequent short runs or specialty applications, the press can be equipped with optional stations and automation modules. The table below shows commonly selected configurations.
| Optional configuration | Function |
|---|---|
| Automatic plate mounting device | Camera-assisted position verification and plate sleeve loading |
| Reverse printing unit | Enables backside printing for transparent films |
| Cold foil applicator | Applies metallic foil without heat for decorative packaging |
| Rotary screen unit | Adds tactile and high-build effects for premium labels |
| Automatic wash-up system | Cleans ink chamber and anilox in under 5 minutes per station |
| Varnishing station | Applies water-based or UV varnish for protection or gloss |
