Industrial machines that improve productivity in digital printing finishing

Productivity in the digital printing finishing department is one of the issues that causes the most concern among professionals. This is mainly because product finishing is often a bottleneck in any print shop. In many cases, finishing processes are labor-intensive and involve little automation, which makes them a serious productivity problem in large print shops.

In response to this challenge, printing shops have called for greater innovation and automation in finishing processes to reduce costs and turnaround times.

One area of innovation has been the development of industrial eyelet-setting machines, which, for example, reduce the time required to set eyelets on printed rolls measuring 50 to 100 meters by 75%.

Similarly, the seaming machine you purchase should be appropriate for your production volume. The number of seams made per minute can range from 4 or 5 when using a manual machine to approximately 50 with an automatic machine. The increase in speed is immense, which reduces processing times to a minimum. With this in mind, we must also consider the physical strain on the operator working with a non-automated machine.

Types of Industrial Machines for Digital Printing Finishing

In large-format digital printing, there are various tools and machines used in the finishing department. Among the main ones are laminators, coating machines, cutters, welding machines, and creasing machines. Below, we’ll look at the main features of each one.

Laminators

Laminators are sturdy machines designed for digital environments. Today, the market offers very powerful automatic laminators with process automation features.

Laminators allow plastic to be fused with paper or other materials, and this process is designed to protect the sheet of paper. Although they serve the same purpose as a plastic laminator, laminators typically perform the process at room temperature, and the plastic film is very thin.

Coating

Like laminating, coating is a process in which a coating—in this case, a varnish—is applied to the surface of a support, commonly referred to as a substrate. The purpose of the coating may be decorative, protective, or both.

Cutters and cutting machines

Among cutting tools, the most notable are utility knives, XY-type industrial cutters, cutting plotters, and automatic cutters. These tools come in various designs tailored to specific applications.

Cutters are typically used to trim excess material, thereby achieving finishes with the desired shape. When selecting this type of tool, it is important to consider the required production volume and the type of finish.

Welding Machines

The most commonly used heat sealers in the printing industry are typically impulse or hot-air models. The latter operate using a stream of hot air to seal the vinyl used in advertising banners, truck tarps, tents, and coverings, among other applications. There are manual welders for small-scale production and automatic welders for jobs involving large production runs. When working with a manual hot-air welder, a roller is required as a pressure tool.

In digital printing, hot-air welders are used to reinforce areas along the entire perimeter, which provides the material with greater strength for attaching fasteners, such as eyelets. These welders allow for adjustment of pressure, air volume, and speed to adapt the welding process to the type of material.

Pot-making machines

Hemming machines are widely used in large-format digital printing and in textile production, such as in the manufacture of curtains. There are three types of hemming machines: manual machines, semiautomatic machines, and automatic machines.

Eyelet setting machines are used to set eyelets, and the type of machine will depend on the production volume of the printing shop.

Manual pot-making machines

They’re compact and easy to carry, so you can work anywhere—whether at a table or on the floor.

Semi-automatic pot-making machines

These are very convenient pneumatic machines that allow you to perform tasks with minimal effort. This type of machine can punch holes and set the eyelet at the same time, simply by pressing a button or stepping on a pedal.

Automatic machines

They are the most advanced on the market and are perfect for large production runs. They are fast and can handle a variety of materials, such as plastics, textiles, corrugated cardboard, and thin materials.

Finally, there are fully automated systems that improve productivity and reduce costs. They are the perfect solution for high-volume production. These automated systems allow for precise welding, measuring, and placement of eyelets in just a few steps.

Learn more about automated systems here.

Every graphic designer and employee in other departments of a printing shop should keep in mind that the finishing of large-format pieces serves a dual purpose. On the one hand, it adds a visual element that helps highlight the print (such as the level of gloss); on the other hand, it provides strength and durability that help preserve the image quality.

To improve productivity in the finishing process, automatic eyelet machines reduce labor requirements, cut down on processing time, and deliver higher quality. For example, by increasing the speed of finishing large-format prints, more time is freed up to handle the workload. This makes it possible to increase profits within the same time frame.

Check out the industrial machines we manufacture at PLASTGrommet and streamline the finishing department at your digital printing shop.