Gruppo Cerutti

Dr. Cerutti at last ERA Packaging & Decorative Conference

09  December  2017

New generation drying system officially presented in front of the printers community.

This year’s ERA Packaging and Decorative Gravure Conference took place in Barcelona at the beginning of November. Main topics were the latest developments and trends in technologies and markets for packaging and decorative gravure printing.
Besides these traditional items, there was a special focus on digital printing technology which is used for instance by some decorative printers complementary to the gravure process. The Conference looked also into the emerging markets such as Asia and China.
Dr. Giancarlo Cerutti, Chairman and CEO of Cerutti Packaging Equipment, gave an interesting highlight on gravure key role among the printing technologies: despite the competition from other processes, rotogravure still remains predominant in those areas of the world where there is a strong growth, like Asia Pacific, India and China. Customers confirm that, where printing quality is imperative, gravure is the answer. Shorter run lengths, thinner material thicknesses, low solvent retention, energy savings and environmental friendliness: these are the issues Cerutti is working hard on in order to give the market more and more profitable answers.
The R98X model, with its 348 printing units installed or on the way to be delivered, is the best proof of the market trust in Cerutti and it perfectly explains what the word “innovation” means for the Italian producer.
Dr. Giancarlo Cerutti in his speech gave one significant example of Cerutti proactive attitude: “The market has always acknowledged that our ventilation system is extremely efficient. However, we are already one step ahead: we are currently launching a new generation of drying hoods improved with new features concerning energy savings, ergonomics and integration of machine control with the new industry 4.0 technology. In particular, we have run tests at a speed higher than 500 mpm, a residual solvent lower than 5 milligrams with an energy saving of about 10%, with respect to the previous generation of dryers.”

Riccardo Montagnini is Cerutti’s Chief Technical Officer. The Company’s recent success with the new, improved ventilation system just launched is the result of his Team’s massive work and commitment to the issues of innovation and research.

Riccardo, Dr. Giancarlo Cerutti has just announced the launch of a new generation of drying system, with additional features with respect to the previous one, that was already the recognized benchmark for the market. In few words, could you explain us the advantages of the new solution?
Almost all the presses we supplied during the last ten years were based on a patented concept of 3D holes, that has shown in practice its efficiency when running with high speed productions and with the most challenging solvent retention requirements. Starting from this consolidated background of very good feedbacks coming from our customers, we decided to confirm these key features in the new design, including also the material of the hoods itself (that will be again realized in stainless steel, the perfect solution for ensuring the maximum life time). The general layout of the press has been completely reviewed in order to ensure a perfect accessibility to all the components of the upper part: for example, the hoods will pneumatically  open, leaving a corridor of constant width to let the operators have full access to the idlers and nozzles in the dryers. The philosophy has been not only to design the press to fulfill its production performances during the run, but also to make easy and fast all the complementary activities to be performed, like cleaning and maintenance.

In which way the new drying system ensures improved efficiency, energy savings and less consumption?
I cannot reveal all our “secrets” but… I can say that, thanks to a number of tests run in our R&D Center, we were able to make significant steps forward in all the key areas of the ventilation system. Starting from the geometry of the hood and its nozzles, we worked on the distribution of the 3D holes to increase the drying effect. Acting on the recirculation ducts, we played with the  pressure drops to reduce the energy needed to drive the air, improving also at the same time the system for capturing solvents directly in the area of the printing cylinder. The heat losses have been analyzed also, thus leading to improvements in the insulation. Moreover, a new system for measuring the thermal consumption in each dryer has been designed and tested: each production data will be stored and managed by our Data Management System 4.0,  providing a unique and easy-to-use tool for exploiting at the maximum all the thermal capacity of the line.