When Labelexpo Americas 2022 arrives in September, guests will have an opportunity to see just how much label and package printing technology has changed in the last four years – when the show last took place in 2018. Automation has become a hallmark for so many manufacturers, as they try to drive label converting efficiency and help printers navigate multiple current challenges.

Automation can help accomplish numerous tasks, from reducing waste to accounting for the workforce challenge presently facing the industry. The challenges have been exacerbated by the pandemic, supply chain constraints, “The Great Resignation,” and more.

Manufacturers are working diligently to ensure the latest equipment can meet the specific needs of their customers. Prati, for example, has optimized its DIGIFASTone product line to meet demand for the “present future.” The servicing has become automated, as well.

“These challenges have accelerated the trend to more automation and intelligent machines that can handle a broad range of applications and end-customer needs,” explains Chiara Prati, CEO and CSO, Prati Company. “Furthermore, Prati’s Remote Training Support and Remote Control System are a terrific boost to let our customers stay in touch with us and be guided step-by-step during the remote installation and training of their new machines by our experienced in-house technology team.”

Based on Futura Technology, DIGIFASTone features laser diecutting units and customized digital finishing groups, such as tactile effects and textures, decorations and textures up to 130 μm, Braille and more, to better assist this generation’s label converters with solutions that meet the requirements of Industry 4.0.  DIGIFASTone is completely modular and available in S-D or D-S configurations.

To accommodate just-in-time printing and finishing, Prati’s digital finishing utilizes DOD LED/UV printheads. With a speed of 50 m/m, converters are capable of selective UV coating even at high thicknesses. In addition, the complete version is already available with the application of foil for an entirely digital “cold gold” and “hot gold” effect. According to Prati, this printing technique allows a limited investment and reduces processing costs. 

“We are very close to the market and customers, and we adapt to their requirements with our custom-made solutions,” says Prati. “All our machines are configured to our customers’ specific needs, and rarely are two machines the same. Based on a modular concept, each module can operate in a totally independent manner. Whatever our customers need to have or upgrade to include a new processing function, a dedicated module is integrated without excessive costs.  The company motto is ‘Standardize the Customization’ and perfectly mirrors our pro-client working philosophy.”

This modular concept, which provides customers with upgrade capabilities, allows them to protect their initial investment and adapt to any market condition with Futura technology. This range is designed to simplify the work of the operators and increases their safety – while ultimately delivering for the brand.

DIGIFASTone generates a very small amount of waste material, reduces setup times and boasts a register accuracy of 0.15 mm, even reaching 100 m/m in the configuration with laser diecutting. DIGIFASTone is available with various accessories and can perform a range of functions. These include buffering for connection to a digital printing machine and rotary and semi-rotary diecutting in register on pre-printed material. Longitudinal cutting systems with manual and automatic blade positioning are feasible, as are single, double and turret rewinding.  Plus, a control module for 100% inspection of print quality is available.

The digital finishing unit, which is designed to generate high levels of productivity, can be built with a single printhead for ink thicknesses up to 250 microns at a speed of 25 m/m, or with a double printhead for thicknesses up to 280 microns at a speed of 50 m/m.

The DIGIFASTone Laser module is also able to process the entire workflow completely digitally, from the PDF file to the ship-ment, guaranteeing what Prati says is a unique workflow for a truly digital model: web-to-labeling, web-to-sticker, web-to-packaging.

“Among the advantages of using DIGIFASTone with the optional Laser is the ultra-fast delivery times and high productivity thanks to a job change through automatic Barcode/QR code reading,” the company says. “In addition, the laser can process detailed diecut shapes, without any contact with the substrates, working on strong adhesives without damaging the liner – and there are no limits in the length of the label. And, above all, laser diecutting ensures a completely digital workflow, from design to delivery, for an extremely efficient and truly digital business model.”