CENTRAL DRUM FLEXO PRESS

FLEXO F2
EFFICIENCY FOR YOUR BENEFIT

FLEXO PRINTING GRAVURE PRINTING LAMINATING SLITTING ENVIRONTMENT & LOGISTICS

COMEXI GROUP, ALWAYS AT YOUR SIDE SINCE 1954 EFFICIENCY IN FLEXO

Comexi and its holding company COMEXI GROUP were set up as
a business venture guided by a spirit of excellence.
Our nature as a family business moulds our values and marks the
Group with the legacy of its founder to pursue long term sustainable
activities. Our strategy is to become a global leading provider of
machinery and services for the flexible packaging industry by offering
highly specialized services in each product line (printing, laminating,
slitting, rewinding and logistical and environmental solutions) that
complement each other and thus give our customers end-to-end
solutions with maximum synergies.
Our philosophy is aimed at constantly adapting to the demands of
the market and continuously striving for excellence in order to fulfill
our customers’ needs.
At Comexi, we understand that efficiency is not limited to
productivity. Efficiency goes beyond that. For Comexi, efficiency
is a philosophy – a philosophy of creating solutions that help our
WHAT DO OUR CLIENTS HAVE TO SAY ABOUT THE PRINTING INDUSTRY?
- These days, many industries view printing as a “commodity”;
therefore, new markets need to be developed in order to escape
from the price wars.
- There is a trend towards reducing the length of runs.
clients- and by developing new technologically integrated products,
we can deliver competitive advantages to our customers.
- We need to create sustainable procedures and use energy saving
machines and processes to reduce carbon footprints.
- Customers desire harmonization of flexographic printing processes
to make them more predictable.

MARKET
- Customers demand flexographic presses that are easier to
operate, and this represents an ongoing process of improvement
and a perpetual challenge in our line of business.

Efficiency in Flexo means guaranteeing solutions and providing answers to these real life issues.

Starting in 1989, we developed the first 8-color CNC flexographic
press because you needed it. That same press provided a new level
of printing quality and created new business opportunities for our
flexographic converting customers.
Then in 2000, we launched the world’s first 10-color gearless
machine, which represented a quantum leap for the industry. Once
again we listened to you, learned from you and created what you
needed.
In 2004, the FI and FW presses were unveiled at Drupa and K trade
fairs and they represented a significant step forward in Comexi
press performance. These models have evolved and continue to do
so today in order to adapt to our customers’ needs.
In 2006, Comexi Group took the industry by surprise with the
debut of EB (electron beam) Flexo printing. Because you needed
a differential process with high printing quality and a minimum
environmental impact, we created EB Flexo for you.
DEVELOPING MARKETS
The FLEXO F2 press has the capacity to print at greater lineatures, Flexo must mean reduced costs with machinery best suited to the
thus opening the door to markets that were previously out of challenges presented by current trends. All this requires ingenious
reach until now. This is achieved without increasing costs per solutions that reduce downtime and maintenance time. These
square meter as compared to your current conventional printing solutions must come with a high degree of automation, while also
system. Furthermore, printing quality in short as well as long runs is reducing job change times and increasing profit margins on the final
maintained, and this is exactly where the concept of reproducibility product. The FLEXO F2 helps you confront these challenges and
is most critical. decrease change times with the new doctor blade support design
patented by Comexi which boasts, easy accessibility for maintenance
and the tool-less concept inherited from the F4 FLEXOEfficiency.
MEDIUM AND LONG RUNS
However, this is not enough. The systematic reduction of run
lengths is a reality in most markets, as is the need for presses to Flexo efficiency
maintain printing coherence and improve productivity. Efficiency in is here
In 2010, Comexi Group once again shocked the market by launching
the FLEXO F4 with its FLEXOEfficiency concept. Because you
needed productivity in short runs, and you needed to offer label
manufacturers eCOMEXI solutions with EB Flexo technology
applied to high performance flexographic printing, we created the
FLEXO F4 for you.
And we continued to listen when we created the new FLEXO
F2 press. This new development meets the needs of medium and
long runs for retailers, on the one hand, and the needs of packaging
converters for wholesalers, on the other.
To top it all off, our customers are well-supported through
our extensive sales network, that includes branch offices in five
countries, a manufacturing facility in Brazil and sales representatives
in more than 65 countries.
For more than 50 years we have been at your side helping your
business grow thanks to your commitment to innovation.

In 2009, we launched the FPLUS, an innovation that meets the needs COMEXI GROUP,
of converters working with a wide range of printing developments the meeting point
and requiring high performance at a competitive price. of sustainable innovation

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FLEXO F2 CI FLEXO PRESS

EASY MAINTENANCE

QUALITY PRINTING

PRODUCTIVITY

REPRODUCIBILITY

ENERGY EFFICIENCY

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PRINTING BODY: PRINTING DECKS
The printing body, manufactured at the Comexi Group facilities,
is the heart of the machine. It consists of two cast frames each
80mm/3.1’’ thick and stabilized to eliminate internal stress. The
central printing decks are arranged horizontally on the frame and
the lower and upper printing decks are inclined at a 20 degree
angle, occupying minimal space to create a truly compact machine.
Monoblock frame
The technological innovation and development of Comexi offer
you the most cutting-edge technologies in flexographic press design,
such as our MONOBLOCK frame concept – a technology that
integrates the printing decks into the resilient frame for a complete
integration of components, minimizing vibration and consequently
improving print quality.
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PRINTING BODY: PRINTING DECKS
The FLEXO F2 uses 8 printing decks adapted for reverse or surface
printing. They are horizontally mounted in a radial pattern around
the central drum. This compact arrangement makes the printing
decks easily accessible and is specially adapted for presses with
widths greater than 1.2 meters.
Its design meets today’s demands for accessibility in order to
perform maintenance and daily operations with ease. Thanks to
New doctor blade support
Side detail of printing decks
the FLEXOEfficiency concept, everyday regular operations can be
completed rapidly and easily. The grids can be effortlessly moved
aside, remaining inside the machine. In addition, a new doctor blade
support has been designed which can be removed without having
to disconnect the inking system lines. Both concepts are patented
by Comexi.
Front detail of printing decks
The contact/separation printing movement of each printing deck
is controlled via servomotors in a new preloaded ball screw
system, specially designed to withstand the most adverse industrial
conditions. We integrate the highest precision technology into the
unit by using encoders on each motor. Additionally, the strength of
the structure has been enhanced with preloaded linear guides..
These design enhancements improve the pressure control on the
plate and result in the highest quality print possible.
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CENTRAL DRUM: THE STRATEGIC PART VIRTUALMASTER: THE ORCHESTRA CONDUCTOR

No other flexographic press manufacturer so Not all “gearless” systems are created equal. VIRTUALMaster signals, which results in deviations between the master shaft and the
strictly controls the manufacturing process of this technology – used by Comexi throughout our entire product range synchronized shafts. The consequence of these two disadvantages
highly important component. As part of our policy – unites all motors electronically and controls them via a common is a variation in machine speed.
to internally manufacture the key components of virtual signal that ensures registration even during the acceleration
our flexographic presses, Comexi dedicates part and braking stages of the machine. These two disadvantages are resolved with the patented
of its industrial process to the production and VIRTUALMaster system. This system generates a virtual signal,
In a typical system, adjusting the motor position requires a reference created digitally by the Motion Control Processor (MCP). The
quality control of the central drum.
signal obtained from an encoder located on a reference shaft (Real virtual signal is transmitted to all the shafts simultaneously, thereby
Master). This type of system has two main disadvantages. First, any eliminating the concept of a “master” shaft. In this way, the signal is
During this industrial process, the drum is stabilized,
reading error from the reference signal is transmitted to the rest generated without errors and, consequently, without affecting the
balanced and adjusted to meet the tightest
of the shafts that are synchronized to it. Second, the true signals rest of the synchronized shafts.
tolerances in the market. These adjustments are
include a set of delays in the readings and retransmission of the
conducted at working temperature maintained
via an internal temperature stabilization circuit.
Stabilization is conducted at 30ºC/86ºF via an
automatic system integrated into the press.
Additionally, an anti-corrosive Hastalloy coating is
applied to the central drum to protect it against
oxidation.

The engine control is also another key area in

which Comexi relies on the most sophisticated
technology. In a joint effort with Siemens, we
have integrated the Gearless DDDrive, CNC and
servomotors into the only technology platform
in the market based on the SIMOTION control
system. This “direct-drive” system is the most
advanced in the market, reaching the highest levels
of precision and eliminating all types of mechanical
transmission (e.g., belts or gears).

DDDrive controls the motor via a high-

resolution hollow shaft encoder, directly coupled
to the drum axle. The encoder is designed for
easy access, which makes maintenance easy.

Machine acceleration Precision

DDDrive

VIRTUALMaster ALSO PROVIDES THE FOLLOWING ADVANTAGES: ADVANTAGES

- Perfectly aligns the surface speeds of the material, the plate
cylinder and the anilox, improving print quality.
- Performs direct, automatic and rapid positioning of longitudinal
registration between printing decks, decreasing the waste
generated in adjustment.
- Regulates and memorizes the positions of longitudinal registration
for future projects, thus saving adjustment time prior to printing
jobs.
- Can slightly vary the plate cylinder and anilox speeds in relation
to the material in order to specifically and precisely adapt the
printing development tolerances.

Access to central drum encoder

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SLEEVE CHANGES: NEVER BEEN THIS EASY A BODY OF STRENGTH
IN A WIDE BAND MACHINE
The system as a whole demonstrates
Changing anilox and plate cylinder sleeves is just a matter of minutes.
an extraordinary durability. The plate
The clamps, manufactured in a single cast iron block, are opened
cylinder shafts and anilox are held in
manually, simply and quickly.
place by conical and needle bearings
specially sized to allow overhanging
suspension, and they incorporate
pneumatic supply which forms an
air barrier. These two elements are
essential for performing quick sleeve
changes.

This bearing positioning ensures a

high degree of stiffness and permits
transverse movement of the plate
cylinder roller for transverse registration
between colors.

Comexi also utilizes DDDrive

technology for driving shafts. Absolute
encoders directly coupled to the shafts
control the alternating current motors,
which use no mechanical transfer.
These technological advancements
improve registration and, in turn, the
quality of printing. Anilox sleeve changeover

Plate cylinder sleeves changeover

Clamp opening sequence

Shutter coupled to the clamp

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DOCTOR BLADE: COMEXI’S NEW DOCTOR BLADE SUPPORT SYSTEM
The doctor blade is assembled in a closed swinging chamber
mounted on linear guides. In turn, the doctor blade automatically
moves horizontally thanks to the low friction pneumatic cylinders.
The entire system is perfectly designed to maintain the inking
position with a minimum blade pressure against the anilox and to
offer a high response capacity.
DOCTOR
BLADE
Extracting the doctor blade
Blade extraction
The system can be easily disassembled without having to disconnect
the inking lines, greatly simplifying all cleaning and changing tasks.
Additionally, the doctor blade is anodized for improved cleaning.
It weighs less than 12.5 kg (1250mm in width) which facilitates
changes and minimizes risks of injury for the operator.
Changing the blade is fast and safe thanks
to the MAGNETBlade technology
patented by Comexi consisting of a tool-
less magnetic changing system. Changing
the seals is also conducted without tools
so that changes can be completed quickly
on or outside the machine.
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PLATFORM: EXTREME USER-FRIENDLINESS AND ERGONOMY
The FLEXO F2 represents excellence in ergonomics and usability.
The press is equipped with an overhead platform that allows
access to all elements requiring maintenance in order to simplify
the replacement of parts, maintenance and cleaning in areas such
Video threading
Access to central drum for cleaning
as the central drum and refrigeration and drying systems, among
many others.
In standard configuration, the press incorporates an automatic
threading system which includes chill rolls, dancer rolls, a viewing
system and a corona treater (if included in configuration).
The viewing system consists of an illuminated double screen that
allows the operator to inspect front and back side printing at a
comfortable height.
A ladder has been completely integrated into the machine to allow
access to this area.
In addition, the press can be configured with an automatic drum
cleaning system as an option.
Overhead platform
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DRYING: POWER AND ACCESSIBILITY UNWINDERS AND REWINDERS: CHANGEOVERS WITHOUT DEAD TIMES DOWNTIMES

The drying system is composed of two circuits that evaporate
the solvent or water content of the ink by blowing hot air at high
speeds.
The first circuit is used for drying between printing groups. The
screen lip can be freely withdrawn from the machine by disconnecting
the tubes from the inside, and the casing incorporates an inspection
port, thus making maintenance comfortable and simple. Both
concepts are patented by Comexi.
The configuration of the FLEXO F2 is designed for high productivity. There is also the option of incorporating an in-line slit unit in the
To achieve this, the unwinders and rewinders best suited to your unwinder.
productive system are composed of a turret system that automatically
changes and splices the reel at production speeds.

Duplex rewinder Duplex unwinder

SIMOTION AND THE CONTROL CONSOLE: THE BRAIN OF THE MACHINE

The FLEXO F2 press is designed so that the majority of functions

Access to the cleaning port of the drying screen between printer groups
can be controlled from the control console. Similarly, our
COMPACTronic concept, based on the SIMOTION platform,
creates a high degree of electronic integration, eliminating electronic
equipment containers and simplifying maintenance tasks.
The second circuit consists of the 5 m-long drying tunnel, equipped The entire drying system is located on a platform which creates
with carefully positioned line pipes to reduce heat loss and made comfortable access for maintenance tasks, especially when accessing The control system is totally integrated in a graphical environment
up of sixteen drying screens each with a blower lip, the screens can the set of rolls at the end of the tunnel that simplifies operation and understanding.

DRYING
be easily disassembled for cleaning. In addition, a specific opening
in the tunnel has been designed to allow rapid threading of the Many operations can be conducted through the EASYTouch
machine. display, such as advancing/reversing the printing decks, placing all
accessories in operation, tension selection, machine speed and
temperatures, inserting change orders at a pre-established footage,
operations and more.

Additionally, production data can be obtained for later analysis,

such as the quantity of quality footage, the quantity of waste, work
time, stoppage time, printing time and average real speed, among Control console
others.

As the operator is able Additionally, job tickets

to assign reasons for can be created for the
stoppages, statistics purpose of increasing
can be gathered on the efficiency of job
the distinct causes of changes, enabling the
downtimes and the operator to later recover
duration of each one. these job tickets
All the data can be
stored in the computer
memory and/or on
discs as necessary.

Register deck control Printing deck control

Drying tunnel

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EXCITINK: SELFCLEANING AND INKING SYSTEM ENERGY EFFICIENCY

Excitink technology is essential for controlling the inks (viscosity,
temperature and, optionally, pH) so that the selfcleaning system
remains efficient during changeovers. This technology maintains a
balance between supply ink and return ink and can thus print with
an optimal pressure in the inking chamber.
The inking system comes in 3 versions: LITE, PREMIUM, and EXCEL
which meet different viscosity and temperature control needs. Each
The structure is completely integrated into the machine’s cowling At Comexi, we focus on innovation that is socially and environmentally technology and it allows us to save enormous amounts of energy
and the ink tanks are located on the exterior. These tanks use responsible. That’s why we have developed the ENERGYSavvy and, consequently, drastically reduce CO2 emissions.
NATURALMixing technology to eliminate air consumption in the concept. It is applied to a set of electrical and electronic control
pneumatic agitators (pneumatic agitation is an option).
The selfcleaning process is fast and easy, with a complete wash
cycle taking as little as 4 minutes (*).
(*) In the 8-color PREMIUM version with options. 0,0070

version comes with various levels of automation. 0,0060

0,0050 -58%

NATURALMixing
0,0040
The evolution of reducing

Kg CO2 / m
emissions with the Comexi 0,0080

ENERGYSavvy concept 0,0030

0,0020

0,0010

0,0000
Electricity consumption

0,0070 0,0070

0,0060 0,0060

0,0050 0,0050

0,0040 0,0040
-72%

Kg CO2 / m
Kg CO2 / m
0,0080 0,0080

0,0030 0,0030

0,0020 0,0020
Autowash and inking system Ink tanks
0,0010 0,0010
-80%
0,0000 0,0000

CINGULAR MODULES Gas consumption Air consumption

It’s common knowledge that job changes in flexo presses generate
waste and ink that significantly impact the end results. On top of that,
if we add the current trend towards reducing runs, this means more
changes and an increase in total waste generated during adjustments.
Consequently, the press loses in efficiency.
There are various options on the market on how to tackle this
problem. However, no one pays attention to the singularity of their
customers. Each customer is a whole new world with different
investment capabilities, different markets to tend to and an endless list
of peculiarities that makes each one unique.
Comexi Group has launched a symphony of singular solutions onto the
market to adapt to the different challenges our customers face.
The CINGULAR modules offer automatic and semi-automatic
solutions with or without marks that are best suited to the singularities
of our industry.
iREG:
Among different options, we offer a system developed exclusively
for Comexi by AVT, iREG, which enables semi-manual registration
adjustment in less than 30 meters.
CINGULARPress2:
This system adjusts printing pressure at the start of a job. It does
not use marks and is based on the pressure control during the
adjustment process, or in other words, to achieve the kiss point
To make adjustments, the system uses a special algorithm that
determines the correct adjustment from the differences in pressures
which are internal in the machine. This system does not rely on a
printing operator’s experience or skill.

CINGULARDot2:
CINGULAR DOT2 makes adjustments based on the true print of
one 1.5mm dot in less than 90 meters/270 ft.
Registration: Initial dot spreading Pressure: dot spreading Final DOT

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 TECHNICAL SPECIFICATIONS

FLEXO F2
Type GEARLESS

Colors 8

Printing width (mm) 1270 - 1470

Minimum format dimensions (mm) 350

Maximum format dimensions (mm) 850

Maximum speed (m/min) 500

Dimensions (m) 15.70 x 5.51 x 5.65 m

(standard machine with a width of 870mm
and shaftless unwinder and rewinder)

Technical features are subject to change depending on the configurations selected. The picture on
the front page corresponds to the FLEXO F2 8 color press, with additional options. The final image
might differ from the machine offered.

Lay out FLEXO F2

5650
15700

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 - FI, FW, FPLUS, F2 FLEXOEfficiency, F4 FLEXOEfficiency - FLEXO PRINTING

- RG EXCEL, RG PLATINUM - GRAVURE PRINTING

- OPTIMA, POWER, DUAL, EVO, ONE - LAMINATING

- EIKON, E-TURRET, S-TURRET, DUO2/HD, UNO, COMPACK2, BLADE, GUIDE - SLITTING

- SELFCLEANING, AUTOMATIC SLEEVE STORAGE, ECODISTIL, AUTOMATIC ROLL UNLOADER, LASER WASHING UNIT - ENVIRONMENT & LOGISTICS

For more information

comexigroup.com

The information in this brochure may be subject to modifications.

COMEXI NORTHAMERICA, INC. COMEXI LATINOAMERICANA COMEXI DO BRASIL, LTDA. COMEXI ITALIA
142 Doty Circle Calle de Allende, 283Int. 5 Col Clavería Estrada Buarque de Macedo, 4499 Vicolo Cieco Agnello 1,
Dipòsit legal: GI-xxx-2011

MA. 01089 West Springfield 02080 Azcapotzalco, MEXICO Bairro Faxinal 37121 Verona, ITALY
UNITED STATES OF AMERICA Tel: +52 (55) 55368407 Montenegro / RS Tel./Fax: +39 0458015743
Ph: +1 4137893800 Fax: +52 (55) 55368407 CEP 95780-000-BRASIL Mob: +39 3485274616
Fax: +1 4138219988 comexilatinoamericana@comexigroup.com Tel: +55 51 3649-8500 comexi@comexigroup.com
info@comexigroupusa.com Fax: +55 51 3649-8515
comexi@comexibrasil.com.br

© 2011 Comexi Group Industries SAU.

Polígon Industrial de Girona· Avinguda Mas Pins, 135· 17457 Riudellots de la Selva GIRONA (SPAIN)· Tel: +34 972 477 744· Fax: +34 972 477 384· comexi@comexigroup.com · www.comexigroup.com