Werosys Compact Finishing

Werosys Compact comes in numerous configurations, from an entry level digital finishing solution with semi-rotary die cut, to a fully configured hybrid printing and converting solution combining flexo and digital printing with semi-rotary or laser die cutting for one-step label production.

All Compact lines are built with the highest grade components available in the market today, using high-quality servo drives in all web handling combined with state-of-the-art Beckhoff PLC control system.

The PLC system allows superior precision and high speed with a central control of all functions from one central HMI screen. By controlling everything from the central PLC, you are offered a completely automatic job change-over and minimal operator involvement.

The Compact is designed in anodized aluminium and stainless steel and is built for long-term durability and corrosion resistance. The converting line is completely modular which enables us to continuously offer new functionality via software upgrades and new modules.

Consequently, Werosys offers the most versatile and future-proof platform in the industry, where lines already installed in the field can be continuously upgraded and expanded as customer demands change, or as new technology is made available with new modules.

Technical specifications

  • Web width up to 350 mm.
  • Servo-driven unwinder module (up to Ø680 mm).
  • Servo-driven rewinder module (up to Ø650 mm).
  • Different running speed configurations – up to 65 m/min semi-rotary and 200 m/min full-rotary.
  • Servo-driven compensator system with direct drive.
  • High-speed servo-driven no-contact waste matrix rewind with plasma coated rollers.
  • 15-25 inch magnetic cylinder.
  • 2-25 inch repeat length.
  • Advanced HMI control panel with full integration with existing IT infrastructure.
  • Intelligence through full data integration, e.g. CERM, LabelTrax, XML and barcodes.
  • Stainless construction: extensive use of anodized aluminium and stainless steel.
  • Balancing dancer system enables processing of delicate material – below 50μm.

Servo-driven unwinder with splice table

A built-in web guide ensures that the paper runs correctly and precise into the machine. When the machine starts the unwinder automatically pre-tensions the web for superior web handling and reduced waste. The unwinder automatically stops on low diameter to prevent web break when the roll is empty. The unwinder is equipped with air shafts, meaning that air pressure keeps the up to 680 mm substrate roll in place at any time.

The splice table is magnetic and made in stainless steel for longevity and corrosion resistance. Ergonomically designed for better work posture. Pneumatic clamps for automatic fixing of web during splicing are optional.

Balanced rotating dancer system

Unlike traditional machines, Werosys Compact has a unique balanced rotating dancer system, for higher stability. The balanced system provides superior web tension control and prevents the dancer system from dropping out of control in the event of web break. Moreover, it ensures very low and stable tension which enables processing of delicate material – down to and below 50µm.

Lamination station with pneumatic silencer arm is optional.

Digital print engine

The digital print module is able to run both cost efficient water-based CMYK ink print engines, e.g. Trojan print engine based on Memjet technology; and up to 6 colour high speed UV based ink print engines, such as HAPA print engine based on Konica Minolta technology.

Servo-driven compensator system

Werosys Compact uses direct drive, which enables higher speed and a more precise and reliable operation. Unlike most systems in the market, we do not use belts, as belts may stretch, lose accuracy, or break; causing waste of valuable production time and material.

Flexo print-varnish

The flexo print-varnish module is a dual servo-driven print system which is electronically adjustable from the central HMI. This provides quick job change-over and no manual calibration is required.

Register control is integrated and the module comes with a number of optional features.

Semi and full-rotary die cut

The semi-rotary die cutter and full-rotary die cutter have pneumatic pressure setting, abandoning the need for mechanical adjustments. This removes the risk of overloading the tool or not getting sufficient pressure.

It is very easy to change die plates between jobs, simply by pressing a pedal and lifting the plate from the cylinder. Mount the new plate at the guide line and press the pedal again to pull it onto the cylinder. Dispro factor correction for re-use of existing die plates. Accurate side adjustment is integrated and digitally controlled from the HMI.

A fully automatic optical 2D length and side register control is available as an option, allowing continuous side adjustment without operator involvement.

Laser die cut

The laser die cut enables fast and format-free job changes using ERP/MIS integration, powerful low noise smoke extraction, and high cutting quality with small spot size. It provides kiss-cut and through-cut capability, as well as marking and engraving functions.

The laser system has 330mm wide cutting area, short web path, and minimal waste, thanks to the integrated servo-driven no-contact waste rewinding.

No-contact waste matrix rewind

Werosys Compact uses a no-contact high speed waste matrix rewind system that reduces the risk of matrix break. The use of fewer rollers combined with non-stick coating allows the Compact converting line to run at very high speeds with a very delicate waste matrix.

It is possible to change between jobs with a minimum of waste, because of the small distance between the die cutter and the waste matrix removal.

Oscillating slitting knives

Werosys offers three different knife systems for our converting lines: oscillating razor blades, manually adjusted rotating shear knives, and fully automatic slitting knives.

All systems have pneumatic control and digitally controlled accurate side adjustment, controlled from the HMI. Oscillating razor slitting knives present a lengthened longevity; up to 100 times longer than stationary designs.

Servo-driven rewinder

Servo-driven rewinders offer superior web tension control, even when running delicate materials. The rewinder has wide tension range; from small rolls of unsupported films to large rolls of heavy label substrates (up to 600 mm). There is automatic adjustment of rewind tension, dependent on roll size, which ensures perfect winding quality in every roll.

The rewinder is equipped with 3”-6” air shafts that keep the rolls in place. An extra rewinder is offered as an option, providing greater flexibility.

Turret rewinder

The turret rewinder is servo-driven with flange spindle adapters for quick spindle change. It can be retrofitted on any Werosys Compact and is fully integrated and controlled from existing HMI/PLC. As an optional feature we offer laser pointers for easy core placement.

Digital spot varnish & foil module

The digital spot varnish & foiling module enables fast and format-free job changes using ERP/MIS integration. The system has digital cold foiling capability, high build varnish effects, and “screen print” effects. It can be used for cosmetic labels, security labels, tickets, or counterfeit protection.

Servo-driven unwinder with splice table

A built-in web guide ensures that the paper runs correctly and precise into the machine. When the machine starts the unwinder automatically pre-tensions the web for superior web handling and reduced waste. The unwinder automatically stops on low diameter to prevent web break when the roll is empty. The unwinder is equipped with air shafts, meaning that air pressure keeps the up to 680 mm substrate roll in place at any time.

The splice table is magnetic and made in stainless steel for longevity and corrosion resistance. Ergonomically designed for better work posture. Pneumatic clamps for automatic fixing of web during splicing are optional.

Balanced rotating dancer system

Unlike traditional machines, Werosys Compact has a unique balanced rotating dancer system, for higher stability. The balanced system provides superior web tension control and prevents the dancer system from dropping out of control in the event of web break. Moreover, it ensures very low and stable tension which enables processing of delicate material – down to and below 50µm.

Lamination station with pneumatic silencer arm is optional.

Digital print engine

The digital print module is able to run both cost efficient water-based CMYK ink print engines, e.g. Trojan print engine based on Memjet technology; and up to 6 colour high speed UV based ink print engines, such as HAPA print engine based on Konica Minolta technology.

Servo-driven compensator system

Werosys Compact uses direct drive, which enables higher speed and a more precise and reliable operation. Unlike most systems in the market, we do not use belts, as belts may stretch, lose accuracy, or break; causing waste of valuable production time and material.

Flexo print-varnish

The flexo print-varnish module is a dual servo-driven print system which is electronically adjustable from the central HMI. This provides quick job change-over and no manual calibration is required.

Register control is integrated and the module comes with a number of optional features.

Semi and full-rotary die cut

The semi-rotary die cutter and full-rotary die cutter have pneumatic pressure setting, abandoning the need for mechanical adjustments. This removes the risk of overloading the tool or not getting sufficient pressure.

It is very easy to change die plates between jobs, simply by pressing a pedal and lifting the plate from the cylinder. Mount the new plate at the guide line and press the pedal again to pull it onto the cylinder. Dispro factor correction for re-use of existing die plates. Accurate side adjustment is integrated and digitally controlled from the HMI.

A fully automatic optical 2D length and side register control is available as an option, allowing continuous side adjustment without operator involvement.

Laser die cut

The laser die cut enables fast and format-free job changes using ERP/MIS integration, powerful low noise smoke extraction, and high cutting quality with small spot size. It provides kiss-cut and through-cut capability, as well as marking and engraving functions.

The laser system has 330mm wide cutting area, short web path, and minimal waste, thanks to the integrated servo-driven no-contact waste rewinding.

No-contact waste matrix rewind

Werosys Compact uses a no-contact high speed waste matrix rewind system that reduces the risk of matrix break. The use of fewer rollers combined with non-stick coating allows the Compact converting line to run at very high speeds with a very delicate waste matrix.

It is possible to change between jobs with a minimum of waste, because of the small distance between the die cutter and the waste matrix removal.

Oscillating slitting knives

Werosys offers three different knife systems for our converting lines: oscillating razor blades, manually adjusted rotating shear knives, and fully automatic slitting knives.

All systems have pneumatic control and digitally controlled accurate side adjustment, controlled from the HMI. Oscillating razor slitting knives present a lengthened longevity; up to 100 times longer than stationary designs.

Servo-driven rewinder

Servo-driven rewinders offer superior web tension control, even when running delicate materials. The rewinder has wide tension range; from small rolls of unsupported films to large rolls of heavy label substrates (up to 600 mm). There is automatic adjustment of rewind tension, dependent on roll size, which ensures perfect winding quality in every roll.

The rewinder is equipped with 3”-6” air shafts that keep the rolls in place. An extra rewinder is offered as an option, providing greater flexibility.

Turret rewinder

The turret rewinder is servo-driven with flange spindle adapters for quick spindle change. It can be retrofitted on any Werosys Compact and is fully integrated and controlled from existing HMI/PLC. As an optional feature we offer laser pointers for easy core placement.

Digital spot varnish & foil module

The digital spot varnish & foiling module enables fast and format-free job changes using ERP/MIS integration. The system has digital cold foiling capability, high build varnish effects, and “screen print” effects. It can be used for cosmetic labels, security labels, tickets, or counterfeit protection.