The innovative digital printing system has been thriving in the market since 2015, offering the best of both realms: the flexibility and adaptability of digital printing, alongside the reliability and precision of traditional printing and subsequent processing technologies.
With the Gallus Labelfire inline, users can seamlessly print, varnish, finish, and process labels from roll to finished die-cut labels in a single production run.
The Hybrid Power
The Gallus Labelfire not only offers conventional printing capabilities but also provides additional finishing options and inline further processing such as varnishing, laminating, and die-cutting. With the semi-rotary die-cutting unit, printers can benefit from reusing existing die-cutting plates, reducing the need for new ones and lowering procurement costs. Our fair, consumption-dependent business model ensures that ink prices and service provision align with market conditions, providing direct benefits to customers through process optimization.
Digital Flexibility
The Gallus Labelfire seamlessly integrates digital printing with conventional printing and further processing, offering an end-to-end logical operating concept. Labels are produced inline in a single production operation, from the unprinted roll to the matrix-stripped end product. One of the key advantages of the Gallus Labelfire press system is its exceptional flexibility. The digital printing unit enables cost-effective production of runs with variable data, versioning, and short runs.
Gallus Labelfire 340
This 4- (plus optional white) or 8-color inkjet system achieves up to 94 percent of the simulated PANTONE® PLUS color scale* in outstanding quality.
All digital print unit configurations: Native resolution of 1200×1200 dpi ensures optimum quality at speeds up to 70 m/min.”
Inline Processing in a Single Step
The integrated Gallus ECS modules, proven and tested, enhance the digital flexibility of the Gallus Labelfire 340 printing unit, ensuring superior print quality. By combining the strengths of digital printing with the inline further processing capabilities of a conventional label printing press optimized for digital printing, a myriad of possibilities emerge. For the first time, labels can undergo varnishing, laminating, cold foil embellishment, and die-cutting in a single operation. The conventional modules facilitate the use of primer, spot colors, security or cold foil features, varnish, or lamination without disrupting production, regardless of label complexity. Even before digital printing, the Gallus Labelfire can incorporate special effects such as metallic or neon colors and flexo white, as well as add spot colors.
Maximum Integration for Ultimate Productivity
As a highly efficient industrial production system, the Gallus Labelfire excels in short and medium runs and beyond. From substrate to the finished roll of labels, a single operation suffices, eliminating the need for production or machine stops for completion or further processing.
Matte and Gloss Effects Alongside Spot Coating with the Digital Embellishment Unit
The Digital Embellishment Unit (DEU) digitally applies UV inkjet technology for inline coating, offering matte, gloss, and tactile spot coating effects in various thicknesses to the substrate web. This results in shorter setup times, reduced cleaning efforts, and no additional tool costs.
Dependable Reliability
For over 90 years, Gallus has embodied the motto “success and security for the label printer.” Collaboration with Heidelberg, a partner with decades of experience in digital prepress and robust press engineering, has laid the foundation for the development of a unique industrial inkjet production system in the form of the Gallus Labelfire.
Enhanced Resolution and Offset Quality
The new Gallus Labelfire 340 digital production system empowers label printers to achieve print quality levels comparable to high-resolution offset printing. This is evident in its native (physical) resolution of 1200 × 1200 dpi, with a droplet size of just 2 pl and four different drop sizes, resulting in a visual resolution of 2400 × 2400 dpi. The high physical resolution of the inkjet heads provides a distinct advantage, especially for small symbols, characters, fine lines, and gradients down to zero percent. The smallest droplet size in the printing industry to date ensures smooth, satin-finished surfaces, improved ink adhesion and curing, and minimal ink consumption. The uniquely shaped inkjet print head enables seamless inkjet head stitching, delivering a uniform print across the entire web. Combining digital white, CMYK, color scale enlargement colors like orange, violet, and green, along with 7-color separation, the Gallus Labelfire 340 press system can reproduce a significant portion of the simulated PANTONE® PLUS color scale. This achievement is facilitated by specially developed screen and color management algorithms that Heidelberg has successfully utilized in its offset prepress solutions for decades.
A Comprehensive System from One Provider
Maximizing Efficiency in Label Printing This compact digital production system seamlessly integrates cutting-edge UV inkjet print quality with the efficiency of digital printing, the inline productivity and speed of flexographic printing, and the advantages of screen printing. Achieved through drop-on-demand inkjet technology combined with proven conventional finishing units, and complete integration into the Prinect workflow. Available in four- or seven-color printing systems for an expanded color gamut, including digital white.
The Latest Inkjet Technology with Unique Inkjet Compensation
The Gallus Labelfire merges the cutting-edge and highly innovative Fuji Film UV drop-on-demand inkjet technology with the reliable Gallus ECS 340 modules, serving as the foundation of the machine. Additionally, the digital system features inkjet print heads designed for multi-year service life, even in rigorous two-shift or three-shift operations. Automated maintenance and cleaning cycles further bolster system reliability and uptime.
Moreover, the Gallus Labelfire employs an exclusive process for detecting and compensating for malfunctioning nozzles in the inkjet print heads. Through the synergy of camera detection within the digital printing unit and specially crafted algorithms, issues such as “white lines,” “dark lines,” and even the “ghosting” effect are effectively eliminated. This ensures flawless labels and narrow-web packaging of impeccable quality.
Simplified and Integrated – Prinect DFE Software Workflow Management
The Gallus Labelfire comes as a fully equipped, production-ready solution, with both software and hardware seamlessly integrated. Heidelberg’s Prinect workflow software serves as the Digital Front End (DFE). This DFE is an essential component of the digital printing system, enabling printers to focus entirely on production while the pre-press prepares data in optimal quality for printing.
Unparalleled Substrate Flexibility
The Gallus Labelfire digital press system provides label printers with an extensive range of substrates, eliminating the need for additional priming or varnishing. Equipped with coated path rollers, pressure arms, and a cooling roller, this industrial inkjet system is capable of processing temperature-sensitive and thin substrates with ease.
One Control Panel for Everything – the Gallus Labelfire Human Machine Interface (HMI)
Following pre-press preparation, job change data can be easily uploaded with the press of a button using the Gallus HMI touchscreen control panel. Your benefits include simple, intuitive operation and control of all modules with the same interface as the digital unit.
The unique shape of the inkjet print head allows for seamless mounting, ensuring consistent, streak-free print quality across the entire web width. The printing system offers remarkable flexibility in applications, eliminating the need for additional digital color changes, such as digital white. Job change data can be effortlessly uploaded via the integrated Gallus HMI touchscreen control panel, which also governs both digital and conventional Gallus Labelfire modules with the same user-friendly logic.
Regardless of the material and die-cutting line length, the semi-rotary die-cutting unit can handle most common substrates. Direct matrix removal guarantees clean and consistent print results, even for intricate die-cutting contours, at speeds of up to 70 m/min.
Printing Capabilities
The digital front end of the Gallus Labelfire offers a range of practical and impressive functions, such as spot color matching, the PDF Toolbox, and Prepress Manager. These functions ensure efficient production of short runs by optimizing setup times, minimizing waste, and reducing tool costs. Furthermore, the double rewinders facilitate quick changeovers and allow for cross winding of small narrow rolls, further enhancing setup efficiency.
The main advantages of the Gallus Labelfire
Lowest Cost per Label
Achieving maximum productivity, coupled with competitive ink prices and efficient color management through Prinect, allows the printer to produce labels at an outstanding price-performance ratio.
Quality
With the highest available resolution of 1200 × 1200 dpi (native) at 70 m/min*, and camera-based quality assurance, the Gallus Labelmaster ensures impeccable print quality. The Single Color Pinning process delivers sharp printing results, even with extra fine lines and very small fonts. The 7-color printing unit can simulate up to 94%** of PANTONE® PLUS colors. Consistent color stability throughout the machine’s entire production lifespan ensures precise reproducibility for repeated print jobs.
Ease of use
One control panel for everything. Gallus Labelfire’s integrated register control and Human Machine Interface (HMI) stand for simple and intuitive operation. The conventional modules are controlled with the same operating logic as the digital printing unit. In addition, camera-based quality monitoring and nozzle error detection and compensation ensure the highest inkjet print quality.
Technical data
| Digital Print Unit | |
| Printing Method | UV – Piezo DoD – InkJet |
| Production Speed | up to 70 m/min |
| Productivity | max. print output 1428 m²/h |
| Resolution | 1200×1200 dpi native @2pl droplet size, perceived approx. 2400x2400dpi, > 200 grey scales |
| Number of Digital Printing Modules | |
| Gallus Labelfire 340 | Different configurations available: 8 (CYMK + GOV + White) 7 (CYMK + GOV) 5 (CYMK + White) 4 (CYMK) |
| Number of Colors | |
| Gallus Labelfire 340 | 4 to 8 colours Depending on configuration: CMYK + GOV + White, CYMK + GOV, CYMK + White, CYMK |
| Print Width | max. 340 mm |
| Substrates | Monofoil , Paper and composite materials 50 – 350 microns |
| Special substrates | Cardboard, tube laminates and thin foils: 20 – 450 microns |
| Dimensions | 11’500 x 4’500 x 2’200 mm (Basic Configuration) |
| Variable Data Printing | iVDP (industrial variable data processing, such as barcodes, data-matrix codes, alphanumeric text…) full VDP (full variable data printing) for unique labels, every pixel colour gamut, full resolution 1200 dpi |
| Interfaces | to all widely used pre-press software solutions for label printers |
| Low Migration | Swiss Ordinance, Nestlé Guidance, Eupia, GMP |
| Conventional Inline Production Platform | |
| Reel Diameter | |
| Number of conventional process platforms | 5 + die-cutting |
| Repeat (conventional flexo unit) | 254 – 508 mm (10″ – 12″) |
| Substrate Conditioning | web cleaner (direct contact and contact-free), corona, antistatic, full & spot flexo, primer (if necessary), delam-relam, printing on glue |
| Finishing Capabilities | Flexo, screen printing, varnish, coldfoil, laminater, die cutter, matrix rewinder, slitter, Digital Embellishment Unit (DEU) |
| Die Cut | Semi-rotary, format range: 152 – 508 mm (6” – 20”), fully rotary 152 – 508 mm (6″ – 20″) |
| Supply Data | |
| Connection power | 121 kW (3P + PE) |
| Voltage | 400 V / 50 Hz |
| Compressed Air | 350 l/min; 7.5 to max 10 bar, oil- and waterfree |
| Exhaust | approx. 2670 m³/h; exhaust temperature max. 50°C / Ozon emission in operation approx. 0.8 mg/m3 |
| Conformity | CE, GS (UL possible) |
| Remote Access | Yes |
Further information on this machine can be viewed by visiting this link https://www.heidelberg.com/gb/en/products_4/label_printing_1/label_printing.jsp
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