In high-speed flexible packaging and label converting, a full servo flexographic printing machine delivers measurable gains in registration stability, repeat length flexibility, and waste reduction. Unlike older mechanical line-shaft systems, a Gearless flexographic press eliminates the main drive shaft, but it may still rely on partial mechanical coupling between decks. Converters comparing a Gearless flexo printing press often notice that registration drift and gear backlash remain issues at high speed. Our Full servo flexo press resolves this by assigning an independent AC servo motor to the plate cylinder, anilox roll, and impression roller on every print station. The Direct drive flexo press architecture further supports tool-less sleeve changes and electronically controlled repeat length, cutting setup time from hours to minutes on short-run jobs.
The FS-Series Full Servo Flexographic Printing Machine is engineered for mid-web and wide-web applications, including flexible packaging, shrink sleeves, labels, and laminated films. The frame is built from stress-relieved cast iron and precision-machined side plates, which resist deflection at speeds up to 300 m/min. Each color station uses independent servo axes for the plate cylinder, ceramic anilox roll, and impression roller. This direct-drive configuration removes gear trains entirely, allowing infinite repeat length adjustment from 300 mm to 900 mm without changing gears or sleeves.
| Parameter | FS-850 | FS-1050 | FS-1250 |
|---|---|---|---|
| Max web width | 850 mm | 1050 mm | 1250 mm |
| Print width | 820 mm | 1020 mm | 1220 mm |
| Repeat length | 300–700 mm | 300–800 mm | 300–900 mm |
| Max speed | 300 m/min | 300 m/min | 300 m/min |
| Anilox drive | Independent servo | Independent servo | Independent servo |
| Impression roller | Servo-controlled | Servo-controlled | Servo-controlled |
| Unwind/rewind | 1200 mm | 1200 mm | 1500 mm optional |
| Dryer type | Hot air / UV | Hot air / UV | Hot air / UV / LED |
On the control side, the machine uses a 15-inch HMI with recipe storage for up to 500 jobs. Automatic pre-register positions the plate cylinder before start-up, and a vision-based register control from BST or E+L corrects longitudinal and lateral drift in real time. The servo drives communicate over an Ethernet motion bus, which simplifies wiring and delivers faster response than analog systems. Optional features include a zero-speed butt splicer, web cleaning unit, corona treater, and a rotary die-cutting station for inline label finishing.
The press handles a wide range of substrates, including PET, BOPP, PE, CPP, PVC, paper, aluminum foil, and pressure-sensitive label stock. In a typical 8-color flexible packaging run, the closed-loop register system keeps waste below 1.5% during acceleration and steady-state printing. Servo-driven anilox and impression rolls also allow kiss impression settings that reduce dot gain and extend plate life. Because each axis is electronically synchronized, repeat order changes are completed in under five minutes on average, which makes the machine suitable for both long production runs and rapid short-run turnaround in label shops.
