The rise of servo drive technology has positioned the Gearless flexographic press as the core platform for high-end flexible packaging and label production. This gearless flexo printing press eliminates mechanical gear trains entirely, replacing them with independent servo motors on each print deck. As a result, operators can change print repeat lengths without swapping gears, reducing makeready time and material waste. When paired with closed-loop register control, a full servo flexo press keeps color-to-color registration within tight tolerances even at high speed. For converters that need maximum output and consistent color density on stretchable films, the full servo flexographic printing machine supports production speeds up to 400 m/min with precise tension management. Typical substrates include BOPP, PET, PE, PVC, paper, aluminum foil, and laminated structures. The press is compatible with water-based, solvent-based, and UV-curable inks, making it suitable for food packaging, shrink sleeves, wrap-around labels, and pharmaceutical cartons.
The Gearless CI flexo press features a central impression drum made of double-wall cast iron with internal water circulation for stable surface temperature. This construction prevents thermal expansion from affecting register accuracy during long runs. An automatic web guiding system, combined with load-cell tension control, keeps the substrate aligned across unwind, printing, and rewind sections. The technical parameters below highlight the machine’s capability:
Standard configurations are organized in the following table:
| Model | Max Web Width | Repeat Range | Max Speed | Register Accuracy | Drying Power | Unwind/Rewind Diameter |
|---|---|---|---|---|---|---|
| GCI-850 | 850 mm | 320–650 mm | 350 m/min | ±0.05 mm | 120 kW | 800 mm |
| GCI-1050 | 1050 mm | 380–750 mm | 380 m/min | ±0.05 mm | 160 kW | 800/1000 mm |
| GCI-1250 | 1250 mm | 450–850 mm | 400 m/min | ±0.05 mm | 200 kW | 1000 mm |
| GCI-1600 | 1600 mm | 500–1000 mm | 350 m/min | ±0.05 mm | 240 kW | 1200 mm |
The modular design allows end users to add or remove print stations based on production requirements. Optional features include automatic sleeve loading, video inspection systems, corona treatment, and remote diagnostics. Anilox rolls and plate sleeves can be changed without disassembling the print carriage, which keeps job changeover times under 20 minutes for a six-color configuration. The press also supports presetting functions for impression pressure and web tension, reducing operator dependency and improving repeatability from run to run.
