Werosys Compact

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.

Compact Hybrid

Werosys Compact now qualifies as a true digital print and finishing line, thanks to the automated workflow software combined with the state-of-the-art fully automatically adjustable flexo printing module, the Trojan CMYK inkjet module, or the UV inkjet with up to 6 colours.

All setup is done electronically from one screen, allowing you to produce labels from approved artwork to finished labels in minutes. All necessary information is retrieved from a standard artwork file (pdf or similar) and all stations are automatically set through the workflow software, including the digital inkjet printer, laser die cut and fully automatic slitting system.

By combining digital and conventional flexo press printing with inline converting and digital workflows, you will get a flexible and highly productive digital hybrid label production system.

Extra modules

All Werosys Compact modules can be delivered as part of a fully digital converting solution, added later, or retrofitted to existing Compact lines.

With the addition of our newest modules, the Digital Print Module and the Laser Die Cut Module, we can now offer a complete CMYK digital label production system at an affordable price – and as with all our modules they can be added to Werosys Compact whenever your production requires it.

All currently available modules are listed to the left and new modules will continuously be added in the coming years to future proof our client’s investment.

Technical specifications and design features

  • 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

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.

Splice table

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.

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.

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.

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.

Optional features:

  • Pneumatic clamps for the splice table.
  • Lamination station with pneumatic silencer arm.
  • Fully automatic 2D length and side register control for the die cutter.
  • Oscillating razor blades – with up to 100 times longer longevity than stationary designs.
  • A second rewinder, offering higher flexibility.