HELL automates engraving
At drupa taking place from May 18 - 31, 2000 in Dusseldorf,
Germany, HELL Gravure Systems will be present in Hall 17, booth no
C 42. The focus will be set to automating functions and workflow
improvements within the two digital production lines of engraving
cylinders in packaging, product and label on one hand and
publication on the other hand. For flexo printing HELL will come up
with a world premiere: the computer-to-plate imager HelioFlex F2000
with a high performance laser head that sets new standards
regarding beam quality and exposing speed. Besides for flexo
cylinders the machine can be used for halftone gravure as well.
Innovations for all production lines
Innovations for packaging, product and label engraving
- HELL Quality Plus
Under the name "HELL Quality Plus" HELL will offer for the
first time a range of products, functions and measures to improve
the engraving quality. In packaging engraving a new process to
control the HelioKlischograph will be demonstrated that allows
the user to influence engraving of text and image in a brand new
- Workflow Integration
At drupa, HELL will show one standardized workflow solution
for CtP-production in various printing processes. This solution
will cover the whole range from halftone to semi-halftone gravure
to flexo and offset printing.
The HelioPackaging production line to be shown on drupa
Innovations for flexo printing
The work preparation station HelioCom is used for the
import of various data formats as well as for the creation of the
cylinder layout under visual control. Job tickets which contain
all production parameter and enable an automated workflow from
design to engraving can be created with the optional software
HelioDisk. Calculation of ink volume and engraving time for each
cylinder is as well part of the performance.
At drupa the following new functions will be demonstrated:
allows the import of PDF-data version 1.3.
checks all incoming PostScript data, creates a record and
warns in case of critical settings.
allows the testcut to be exactly positioned at a free
selectable area within the cylinder layout under visual control.
The coordinates are calculated automatically and transferred to
the engraving machine in the job ticket.
- HelioFormproof Packaging
The unique function MultiProof allows to print the cylinder
layout prior to engraving in order to control placement and
completeness for all colors
-separately or together - on a large format plotter.
The innovations on drupa are:
- Output of the testcut layout
The testcut positioned into the cylinder layout on HelioCom
can also be printed into the cylinder proof. This offers a higher
safety for the engraving especially if the testcut is placed
inside the cylinder layout.
- Seamless proof
For the first time it is possible to check seamless
engravings in advance.
- Windows 2000
HelioFormproof is now available in a new version being
compatible to Windows 2000.
HelioFormproof now supports the Heidelberg Color
- Connection to Epson 9000
HelioFormproof now supports output to the large format
printer Epson 9000.
- HelioKlischograph K500
The compact engraving machine has a modular construction
which allows configurations from manual production up to fully
automatic workflow. Engraving is done with the fast engraving
head HelioSprint standing for symmetrical cells and high volume.
The testcut is automatically performed by CellGuard which
guarantees a constant quality.
HelioRobot is HELL Gravure Systems' concept to force ahead
the target of complete HelioKlischograph automation. The
HelioKlischograph K500 already fulfills the requirements to be
integrated into a fully automatic cylinder production line:
- symmetrical design
- mobile bearing blocks
- elevating platform
- automatic engraving support
- automatic testcut with CellGuard
At drupa 2000 HELL will demonstrate the components building
the infrastructure for process automation. These are:
- Production Manager
The Production Manager is a software that controls the
working steps of cylinder production (layout creation, formproof
and engraving). Whether the production is done manually or fully
automatically, the production manager cares for transparent and
safe workflows by recording and listing all process steps. This
information can be used to check the load of each station at a
glance. In addition links to production planning and control
systems (PPS-systems) offer the possibility to import commercial
data to be integrated into the cylinder production as well as to
export production data to be taken for re-estimation of jobs.
- Helio Remote Interface K500
The Helio Remote Interface K500 enables the
HelioKlischograph K500 to be controlled by an external place. In
this case the software continuously checks data that is coming
into a hotfolder being created for this purpose. As the data
format is open every host computer suitable can be used to
control the HelioKlischograph K500 and connect it to a fully
automatic cylinder production line.
Innovations for the publication sector
- HelioKlischograph K406
The engraving machine works with up to 16 engraving
channels simultaneously. These can be equipped with normal
engraving heads as well as with the fast HelioSprint engraving
heads. Besides HelioSprint the following automation functions are
automatically executes the testcut for all engraving heads.
This is made possible by a camera which records the testcuts for
all engraving channels in a succession. The CellGuard software
then measures the cell geometry and adapts this automatically and
in a minimum of time to the target values. Use of one single
camera for all channels ensures a very high degree of consistency
between the ribbons.
the automatic positioning of engraving heads enable a
precise start position for each ribbon.
With the preparation station HelioForm impositioning
schemes and cylinder layouts can be created under visual control.
Register and control marks are loaded from the archive or can be
created directly. Image and text data are automatically imported
into the impositioning scheme according to the page names. Once
an impositioning scheme has been created it can be re-used for
all further products by setting a link to the new page contents.
At drupa, a new software version containing interesting new
functions will be demonstrated:
- Integration of special geometries as e. g. center fold
- Symbol fade-in with form specific contents (e.g. ribbon
number, segment number, engraving machine)
- Automatic back-up concept for two or more stations
The software HelioPlan can be run on the HelioForm station
or on an external computer. It is used to create the
impositioning scheme and already covers standards as well as a
huge amount of special functions (e.g. export of page list,
support of up to 32 ribbons, overview of signature structure,
combination of several forms a single cylinder, optimized
collection sequences, special pagination etc.).
Now two further functions have been realized that again
improve quality and operation:
- Generation of pre-settings that cover individual printing
machine parameters to be considered during engraving.
- Automatic generation of page names
- HELL MultiServer
The HELL MultiServer is the central data pool for all
pages. Besides import of complete pages, conversion of data
formats, the storage and administration of packs of data,
standardizing and printing form relevant output of pages as well
as automation of process steps are the main tasks of the HELL
At drupa 2000, HELL will step into a new market segment by
showing their new HelioFlex F2000 for the first time. The HelioFlex
F2000 is a brand new computer-to-plate imager for digital
production of flexo printing forms. The high performance laser head
of HelioFlex F2000 sets new standards regarding beam quality and
exposing speed. Besides for flexo cylinders the machine can be used
for halftone gravure as well.
The HelioFlex F2000 is characterized by the following
- Automation functions for easy loading · PC control,
Windows NT operation system, touch screen
- Processing of plates and sleeves
- Formats up to 1.200 x 1.600 mm2
- Exposure of TIFF and LEN data
- New high performance laser head with excellent beam quality
and depth of focus
- High exposing speed
- Modular upgradability to higher performance
- Strong front-end
- Processing of Artpro, TIFF, PDF and PostScript data
- Integrated flexo specific functionality
- Connection of Barco systems via PostScript or LEN
- Easy maintenance and worldwide service
- Outstanding price / performance ratio
By entering the flexo market HELL is reacting to the
continuously increasing requirements for flexo plates and sleeves.
The fundamental knowledge about constructing and building of
engraving machines, scanners and film recorders as well as writing
of software for digital workflows makes HELL a competent supplier
in this field. The superior price / performance ratio of HelioFlex
F2000 will support computer-to-plate becoming a standard in flexo
as it is in gravure already.
Research and development for the gravure market will be
continued with full capacity. HELL's innovations to be shown at
drupa reflect the long term trend which can - not only in gravure -
be seen in a good balance between automation and flexibility. HELL
as a moving force in this industry is continuously working on
solutions to improve productivity and quality for their customers
worldwide and to strengthen their competitiveness. (The components
for CellGuard, automatic engraving support as well as automatic
loading are currently not available in the USA.)