FL5 + FDC 600 - carton production line

FL5 CARTON PRODUCTION LINE

CARTON PRODUCTION SIMPLIFIED

MOBILE VERSION STARTS HERE

FL5 + FDC 600 - carton production line

FL5 CARTON PRODUCTION LINE

A single pass production solution for sustainable paper based cartons.

The ground breaking fully automated single-pass carton production line enables you to produce a highly embellished carton in just one step.

You can print, reverse print, foil either hot or cold, laminate, add holographic effects, cast and cure and coat.  The FDC-600 can run in line with the FL5, combining low tooling costs with cut, crease, emboss, braille, waste stripping and diverging delivery, all in a single pass.

The FL5 carton production line is ideal for short-run work from 1,000 – 100,000 units and reconfigurable for a wide range of sizes and forms.

Advanced tension control, robust construction and technologies dedicated to handling paper board means that the FL5 can handle substrates up to 700 microns (24pt) thick and 600mm | 23.6” wide.

The FL5 carton production line running in line with the Edale FDC-600, web-fed flatbed die cutter, make a highly efficient solution specifically designed for short-run folding carton production.

Book a demonstration and see how the future of embellished cartons can be produced quickly and efficiently on Edale’s unique single pass carton production line.

MOBILE VERSION FINISHES HERE

A single pass production solution for sustainable paper based cartons.

The ground breaking fully automated single-pass carton production line enables you to produce a highly embellished carton in just one step.

You can print, reverse print, foil either hot or cold, laminate, add holographic effects, cast and cure and coat.  The FDC-600 can run in line with the FL5, combining low tooling costs with cut, crease, emboss, braille, waste stripping and diverging delivery, all in a single pass.

The FL5 carton production line is ideal for short-run work from 1,000 – 100,000 units and reconfigurable for a wide range of sizes and forms.

Advanced tension control, robust construction and technologies dedicated to handling paper board means that the FL5 can handle substrates up to 700 microns (24pt) thick and 600mm | 23.6” wide.

The FL5 carton production line running in line with the Edale FDC-600, web-fed flatbed die cutter, make a highly efficient solution specifically designed for short-run folding carton production.

Book a demonstration and see how the future of embellished cartons can be produced quickly and efficiently on Edale’s unique single pass carton production line.

  • Reduced set up and running waste
  • Just one operator needed
  • Short runs and multiple variations with ease

From raw material to finished carton in 1 minute!

The Ultimate Single-pass printing machine short-run folding carton line

SOLVING TYPICAL LITHO PRODUCTION ISSUESOUR SOLUTION
Reduce your powerFewer machines and processes and the latest LED curing system can reduce your power consumption by >75%.
Reduce your set up wasteA highly automated, single set up produces a finished carton in one operation with minimal waste.
Reduce your running wasteA single production process eliminates risk of scrappage between multiple production stages.
Reduce staff Once in production the line can be run by one operator.
Reduce space needed for your manufacturing & storageTypical sq. feet for offset vs flexo - Example to go here.
Reduce your time to marketTraditionally it can take between 8 to 16 weeks for carton production. You could reduce this time by at least 50% - New York Label & Box – Example to go here.
Reduce your WIP and stockEliminates need to store WIP between printing and die cutting, vastly freeing up shop floor space. Produce short runs to order rather than overprinting and stocking.
Handle increase in SKU’sEfficiently produce multiple variations in smaller run sizes and deliver when needed, hence less waste.
Reduce issues with ongoing Support & Maintenance1 Supplier - Edale provide a single point of support throughout the whole process

We took the 7 key challenges of modern carton production and we solved them

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Challenge the Tradition

Single-Pass vs Multi-pass

The Ultimate Single-Pass Carton Production Line

For printed, embellished, sustainable, paper based die cut cartons.

Silver Foil

has been laminated on the FL5 Prime full width to give the effect of more costly Met PET cartons.

Embossing

is added inline on the FDC to give a 3D tactile effect.

Unique Uniprint

Colours are printed using Edales unique Uniprint print head to ensure the best possible quality.

Carton Cutout loupe1

AiiR System

(Autonomous Inking Impression and Registration) on the FL5 gives unparalleled automation and repeatability of quality and print accuracy.

Cast & Cure

has been added to give a finish that adds brand protection and allows the carton to really stand out from other production methods.

Cut, Creased & Stripped

The carton was finally cut, creased and stripped before being discharged onto a conveyor by the FDC 600.

Combine, print, cut, crease, brail embossing and waste removal in a single machine with the FL5 carton line, ideal for Embellished sustainable, paper based die cut cartons.

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Cartons Production Examples

News &
Case Studies

We believe that the most powerful story comes from our customers, and we will be sharing these with you. To keep up to date with news and stories – follow us on LinkedIn.

Press Release

New York Label & Box Works Lead the Way as first US Company to invest in Edale’s FL5 Technology

New York Label & Box have invested in an FL5, 510mm, 20-inch, 8 colour, single-pass flexographic carton and label press, the ultimate single-pass press and most versatile on the market.

They have been given high praise from the FTA judges for their winning entry, for Narrow Web, process, paperboard, which was a vibrant soap carton.

Learn More

Press Release

Reelvision Invest in their third Edale single-pass Flexographic Carton Line

Edale is proud to announce that Reelvision, manufacturers of Pharmaceutical, Healthcare, Personal Care and FMCG cartons have invested in an FL5, single-pass printing and converting carton line, comprising of 8 colours, 540mm width and an FDC 600 web-fed flatbed die-cutter to join their existing Edale machinery.

Learn More

Press Release

Imprimerie Ideale opt for second FL5 from Edale

Based in Casablanca Morocco, Imprimerie Ideale have chosen Edale as their preferred machinery supplier for a second time, this follows on from their initial purchase of an 8 colour Edale FL5 with Flatbed die cutter.

Their latest machine is a 510mm wide, 8 colour FL5 equipped with a screen module as well as a rotary die station for inline die cutting, embossing and sheeting.

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ReelVision

Managing Director, Gareth Bakewell, Reelvision comments: “Our investment in the FL5 carton press will be a great addition to our existing Edale machinery.  We have worked with Edale on a number of specialist projects now, and our priority is to ensure that as we continue to grow, we stay ahead of the curve through our continued investment in the very latest new future-proofed technology to ensure we bring our customers the best possible packaging solutions.”

Product Technical Specifications

ProductFL5FL7
Web widths (inch) (mm)510mm | 20” 570mm | 22.4” 650mm | 25.5” 650mm | 25.5” 760mm | 29.9” 850mm | 33.4”
Repeat range (inch)8 – 24” 203.2 – 609.6mm14 – 36” 355 – 914mm
Material range (micron)12 – 700 microns 0.5 – 27pt<700 microns <27pt
Mechanical speed (m/min)200 m/min | 660 ft/min300 m/min | 990 ft/min
Sample pack update

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The best of everything as standard

Our focus is on quality engineering, and all our presses include the latest technology as standard.

Aiir

AiiR stands for Autonomous inking, impression and register.

AIIR is Edale’s own technology designed to automate the process, reducing the reliance on the operator to set and regulate.

  • Eliminates operator intervention whilst setting register.
  • Guarantees precision throughout the run.
  • Delivers consistency every time.
  • Simplifies printing ‘troublesome’ substrates.
  • Improves quality and reduces waste.
  • Space-saving design requires no additional module.

Autonomous Registration

Ensures register precision and consistent print quality.

  • Precision and quality to ensure the highest print quality and reduced waste.

Shaftless dual servo print technology

Ensures print precision and consistency.

Genuine full servo shaftless independent drive technology ensures print precision and consistency.

  • Gives the benefit of all print and converting modules as they are independently servo-driven.
  • Direct servo drives control each independent print and converting module.
  • This means that each module drive can be accurately tuned to its specific requirement in terms of function or overall tension control in the press.

Gearless Impression

Exceptional print quality and a wide substrate range.

No gear mesh so guarantees exceptional print quality and a wide substrate range.

  • Wide substrate range without the need for adjustment.
  • Eliminates typical print artefacts found in a geared system.
  • Ensures consistent print quality, whatever the substrate thickness.
  • Eliminates any deterioration in print quality that would be prevalent in a gear-driven system.

Jumbo Unwind

Jumbo unwind with optional with touch screen control.

1.5m (60″ ) Jumbo unwind with optional 2″, 6″ & 12″ mandrel and reel lift with touch screen control.

  • 1500mm | 60” Roll diameter means 100% longer run between changes compared to standard 1000m unwinds.
  • 12” mechanical mandrel reduces curl and prevents slippage.
  • Hydraulic roll lift.
  • Optional pre-tension and pre-conditioning tension guarantee register.
  • Optional contact and non-contact web cleaning.
  • Optional pre-heater.
  • Conditions material before printing.

Set & Forget Impression

Automatically set Anilox-to-Plate Impression.

Automatically set Anilox-to-Plate Impression ensures uniform ink coverage across the plate without over impressing.

  • Aids fast set-up, repeatability and consistency of print processes.
  • It maintains ideal pressure between jobs.

On-the-fly setup

Colour changes whilst you are still in production.

  • Saves time by setting up whilst still in production.
  • Achieve more job changes per shift.
  • Improve productivity of equipment and personnel.
  • Print components can all be changed independently.

Pre-register

Automatically positions the print cylinder.

Automatically positions the print cylinder in the correct position based on job recall.

  • Sets register in a single web length.
  • Reduces the operator workload.
  • Reduced material waste.
  • Increased productivity.

Short web path

Minimises waste and maximises efficiency.

  • Ensure minimal waste and maximum efficiency during print set up and on the run.
  • Reduces the time taken to set up a new job.
  • Reduced reaction time to register a correction.

UniPrint

Consistent high-quality print.

Consistent, high-quality print, whatever the repeat size.

  • Consistent high-quality print, whatever the print size.
  • Repeatable print reproduction.
  • Reduced impact of plate bounce.
  • Consistent setting of inking and impress.

Electronic linear and lateral register

Prepares the machine for EZ REG upgrade.

Electronic positioning of linear and lateral register prepares the machine for EZ REG upgrade.

  • Precise positioning, in addition, the EZ reg upgrade means there is no operator intervention required.

Modular Design

Build the machine to match your requirements.

  • Our engineers can configure any number of the modules to create a customised approach to suit your specific requirements.
  • Helps to upgrade and future proof your technology.

Job Storage / Job Recall HMI

Unlimited job storage.

Unlimited job storage, saves and recalls all job specific machine settings and job production data.

  • Unlimited job storage.
  • Saves and recalls all job-specific machine settings and job production data.
  • Stored locally on HMI improving screen response speed.
  • Can be backed up externally from the Edale press by USB.

QC Ink System

Colour changes in under 90 seconds.

  • Improves efficiency and ease of use for the operator.

Unrivalled customisable options to take your press to the next level

Our presses are tailormade to suit your needs with options available to future proof and evolve your press to suit your customers' needs.

AiiR

AiiR + EZ Reg or AVT Reg systems use camera technology to autonomously set both liner and lateral print register and monitors it throughout the run.

  • Ensures registration is set in the quickest time with minimal material waste.
  • Eliminates operation intervention whilst setting register.
  • Guarantees precision throughout t the run.
  • Simplifies printing ‘troublesome’ substrates.
  • The system does not ‘over correct’.
  • Improves quality, delivers consistency and reduces waste.

FULL ROTARY DIE CUTTING

Heavy duty servo driven rotary die cut station.

  • Removable anvil roller for top and bottom cutting.
  • Die pressure beam assy.
  • 360 degree motorised linear register.
  • Manual cross-register control.

EMBELLISHMENT

There are a number of options available for embellishment to bring your product to lie.

  • Rail mounted turn bar & web guide / Cold foil, cast & cure, UV lamination module / Rotary hot foil / EFX Print Bar.

FLATBED HOT FOIL

Hot foiling stamping.

FL5 SECURITY

Screen print scratch car/foil/holograms security.

HOT FOIL STATION

Rotary Hot foiling station.

  • Electrical heating shaft for mounting engraved brass dies.
  • Die based rail system.

FDC 600

Web fed Flatbed die cutting for cartons.

  • Single pass carton production.
  • Reduces work in progress.
  • Finished carton in a single pass.

AVT INSPECTION & REGISTRATION CONTROL

100% Inspection.

  • Consistent print pressure on every job.
  • Reduces waste.
  • Provides traceability of production.
  • Reduces inconsistency between operators.

RAIL SYSTEM

Moveable rail system.

  • Additional options such as Turnbar, foiling and cast & cure to be easily moved between print units.

LABEL PACK

Rail mounted delam/relam, Turnbar, cold foil and lamination for carton embellishment.

  • A conventional configuration for the production of self-adhesive paper and film labels, papers, sachets and tickets.

VLS SHEETER

Electronic setting of sheet and perforation length negates the need for multiple sets of tools.

  • Cost saving as no additional tools required.
  • Improves print job efficiency.

LED CURING

LED curing technology reduces total power consumption by up to 75%.

  • Energy efficient and equipped with low energy LED UV curing and automated finishing, for the production of self-adhesive paper and film labels, papers, sachets and tickets.

DIVERGING DELIVERY TABLE

Diverging delivery system enables separation of cartons to minimise waste.

  • Reduction in time and increases efficiency as there is a reduction in double handling.

IR DRYING

Infra Red Drying is an indirect method of drying water-based ink.

  • Shorter drying time and a better final dried product.
  • More energy saving in the process and can be combined with other drying methods.

HOT AIR DRYING

  • High speed drying to ensure the quality of the final product.

NON STOP UNWIND (BUTT SPLICER)

A butt splice will join two webs together, typically, the end of an expiring roll to the beginning of another.

  • A ‘Martin Automatic’ Butt Splicer performs this splicing function without slowing or stopping the process.

PRE CONDITONER

Preparation prior to print i.e. heating of the board.

WEB CLEANER

Single sided or Double sided.

  • Web cleaner unit makes for easy use and simple maintenance, with good access for web threading and cleaning of the elastomer rolls.

CHILL ROLLS

DE CURL OPTIONS

Increase workflow with our range of Print Room Ancillaries

We have a range of print room ancillaries to support your print operation.