IF YOU CAN IMAGINE IT, WE CAN PROBABLY BUILD IT
Looking for something out of the ordinary, then talk to Edale’s Special Projects Team who can tailor-make a printing and converting solution to match your specific needs.
The Edale Special Projects teamwork on the cutting edge of what’s possible in continuous production methods. We have deep expertise in web-transport systems, moving material in a continuous multi-stop process, allowing you to deliver quality and consistency at scale.
Many of the projects we work on have never been attempted before or are for entirely new applications removed from standard print production.
IF YOU CAN IMAGINE IT, WE CAN PROBABLY BUILD IT
Looking for something out of the ordinary, then talk to Edale’s Special Projects Team who can tailor-make a printing and converting solution to match your specific needs.
The Edale Special Projects teamwork on the cutting edge of what’s possible in continuous production methods. We have deep expertise in web-transport systems, moving material in a continuous multi-stop process, allowing you to deliver quality and consistency at scale.
Many of the projects we work on have never been attempted before or are for entirely new applications removed from standard print production.
Here is a selection of some of our recent projects
Philip Morris International (PMI)
Philip Morris International is a leading tobacco company with a diverse workforce of around 73,500 people worldwide.
They are dedicated to doing something very dramatic—they want to replace cigarettes with smoke-free products as fast as possible.
They have more than 430 scientists, engineers, and technicians developing less-harmful alternatives to cigarettes at their two research facilities in Switzerland and Singapore.
“It’s the biggest shift in our history. And it’s the right one for our consumers, our company, our shareholders, and society.”
Their Requirement
They were working on a special and complex project to digitise a significant proportion of their print requirement because they identify that a major factor for their success was agility and speed of getting the end product to market, on time and on budget.
The Solution
Richard Price, Manager, Technical Procurement, PMI, comments:
“For any new project, traditionally, there is a lengthy process involved for each stage required, usually between 6 – 12 months from product idea to final output.
For this particular project, we needed to start production very quickly. It was complex and included many suppliers and processes to create the functionality and workflow required.
I contacted Edale and spoke directly to James Boughton, MD, to see if Edale could help us. We needed to fast track our project, and we were looking for a die-cutting solution that would integrate with a digital printing set up and workflow. We needed a solution within 6 months!
We discussed the detail, and within the hour, I was delighted to hear that there was a possibility that Edale could meet the very tight lead time. Other suppliers had quoted between 6 – 12 months which would have been too late for this project.
As a result, we worked closely with Edale on this project and invested in a (Flat Bed Die Cutter) FDC-600.
Edale delivered what we needed within six months, and we were up and running in full production.
We continue to work closely with them on a number of new projects and have invested further in new solutions.”
INCA Digital
Based in Cambridge, UK, Inca develops, designs and manufactures industrial inkjet printers. Focus to date has been on the wide-format printing sector, but more recently the technology has become of interest in a variety of other applications.
Their Requirement
Screen-IJC made contact with Edale back in 2013 when they invested in a Lambda system modified to work with inkjet rather than flexo.
In 2014 they started talking to Edale about a specification they were working on to create a digital print solution for production of laminated corrugated top sheet. The initial spec was for a maximum speed of 50 – 80m/min, with a web width 1.6 meters wide, six colours inkjet combined with analogue primer and varnish.
Many changes occurred between the initial design spec to when it was delivered in 2016 as Screen-IJC subsequently became involved in a different project with a German manufacturer of corrugators, and the focus was on integrating a printer into the equipment of the German company.
The scope of the project changed quite dramatically to become the 'Jetline 1600' ultimately. The initial spec changed from 50 – 80m/min to 300m/min. Up from 6 colour print stations to 8 with digital varnish solutions and several other changes to the configuration however still remained 1.6 meters wide. Other significant changes included pre-treatment stations and increased power from 6 – 8 Volts to 48 kW.
The Solution
Chris Stanyon, Research & Development Engineer, Screen-IJC
"We were drawn to Edale because of their work with AGFA dot Matrix as it showed us their competence and knowledge of making good web transport units for digital printing.
We didn't know much about it; we had developed a sheet feed system before but wanted Edale's expertise as they had been through it before, and we could learn from their experience.
Our collaboration with Edale has enabled us to develop the inks and printing processes we needed to scale up the final customer solution.
We worked closely with the design and technical team, and it's very much a long-term ongoing relationship we have with them during the project and as and when we need it.
This culminated in 8-years working 'on and off' together in various forms to help create a solution for a complex, niche and ever-changing brief.
The main thing about Edale and our partnership with them is their knowledge and flexibility as the original project specification changed dramatically from the beginning to the end.
We hope to be working with them in the future on new projects.”
Reelvision Print
Reelvision is a revolutionary supplier of short-run printed folding cartons.
They were founded in 2007 and are based in Rossendale, Lancashire.
Their Requirement
Edale have a long-standing relationship with Reelvision that started back in 2007 when collaboratively we set about developing a new generation of single-pass flexographic print and flatbed die-cutting technology specifically for the production of cartons, at that time called the Edale Gamma.
The Solution
Managing Director Gareth Bakewell, Reelvision comments:
“We have worked closely with the Edale team over the years to help develop the new generation of single-pass print and die-cutting technology. Due to our continued growth and need for a quick turnaround required by our customers, we decided to invest in an FL5, single-pass printing and converting carton line comprising 8 colours, 540mm width, and an FDC 600 web-fed flatbed die-cutter to join our existing Edale machinery.
The new press development will enable Reelvision to produce large format cartons and this combined with the superb colour consistency that the Edale machine delivers, will ensure our clients receive premium quality for all their carton requirements.
Our investment in the FL5 carton press is 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 latest new future-proofed technology to ensure we bring our customers the best possible packaging solutions.”
AB Graphics
AB Graphics has been manufacturing innovative print finishing equipment for over 60 years.
Their Requirement
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The Solution
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Demax Group
Demax Group, a leading security printer in Bulgaria, invested in its second seventeen 17 colour FL5 Cardline, a custom-built Edale solution to print lottery scratch cards.
Their Requirement
Due to their expansion, Demax required a second Cardline.
Ivan Nestorov, Demax Technical Director comments, “We chose Edale as our partner for our second FL5 Card Line press as we had experienced their accurate engineering and registration, which is critical for lottery card production. Our first FL5 Card Line install was in 2017 and was the first of its kind in Europe and gave us a total solution that was manufactured and supported by Edale.”
The Solution
The Demax Group, Bulgaria, have invested in their second seventeen (17) colour FL5 Cardline, a custom-built Edale solution to print lottery scratch cards.
In addition to Edale’s AiiR print automation system, it will also feature our very latest extended hot air-drying technology, EZ REG camera register control, inspection and integration of variable data printing on the front and back side of the web. In total, this FL5 solution will include a staggering 140 driven motor axes!
This will be the ‘longest Press’ at over 35 meters long, ever designed and manufactured at our UK factory.
Ivan Nestorov, Demax Technical Director comments, “The Card Line has helped us to transform and innovate our lottery card operation and has enabled us to significantly boost our scratch card production and increase capacity outside of Bulgaria. We have now taken on board our second Cardline to support our further expansion.”
