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The HELL production system for engraving packaging gravure cylinders 
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The HELL production system for engraving packaging gravure cylinders offers maximum standardization and automation. Constant development continually increases the productivity of engraving machines and improves the quality of gravure cylinders and their print products.
Importing directly from Artpro and PDFs
HelioCom is the only layout workstation that supports prepress data directly from Artpro without any format conversion. It also has a powerful PDF interpreter to transfer packaging data from other prepress systems.
MIS connection
Job data from MIS systems is transferred by a JDF interface for engraving job preparation with HelioDisk.
Job preparation with HelioDisk
TIFF direct engraving enables simple and flexible cylinder engraving. HELL has taken this global standard a step further with job tickets, ensuring even greater productivity and transparency. Each component in the system takes job parameters from the job ticket, created using HelioDisk, and adds further details as necessary. This enables HelioFormproof and HQH to run in the background without any operator intervention. Mounting the cylinder is the only manual step required for engraving with a HelioKlischograph or Cellaxy. The AutoCon production line even runs without any involvement at all on the part of the operator.
Complete form processing with visual control
In HelioCom, cylinder layouts are assembled under visual control. To enable this, the single repeat is repeated and assembled complete with all register and control marks. Compressed TIFF data is subsequently generated.
Customized layout proofing
For layout control purposes, a full-color proof can be created directly from HelioCom on large-format output devices. As an alternative to direct proofing, HELL offers the HelioFormproof system, specially developed for packaging gravure.
Flexibility all the way to the output stage
The workflow in the HELL production system is based on output-neutral TIFF engraving data. As a result, the output method – vibration engraving with K5/K50/K500, XtremeEngraving with K50/K500 or direct laser engraving with Cellaxy – can be decided on just before engraving. Because TIFF engraving data and job tickets are processed independently of each other, job data can also be modified at any point until immediately before engraving starts on the HelioKlischograph or Cellaxy.
Interfaces
HELL offers a range of solutions for integrating old HelioKlischograph systems and engraving units from third-party manufacturers into modern TIFF direct engraving. What makes this special is that in many cases cylinders from upgraded systems can be mixed with state-of-the-art HelioKlischograph systems such as the K5, K50, K500 or even Cellaxy.
Accurately reproducible cylinders
Job tickets and TIFF engraving data can be archived using standard software and are available at all times. This enables repeat jobs to be reproduced very simply and accurately.
Quality
HELL has developed a series of processes to achieve a sustainable increase in the quality of electromechanically engraved cylinders:
- High Quality Hinting (HQH) is a quality-enhancing process that examines engraving data for fine lines and text and optimizes this according to preset criteria.
- CellEye is a new cutting procedure for HelioKlischograph systems that is based on the measurement of engraving cell volumes and enables unique repeat accuracy for packaging gravure cylinders.
- XtremeEngraving is an innovative engraving process for producing extremely high contour definition combined with high print density.
Based on Innovation.
HELL solutions satisfy the toughest demands in terms of print quality, cylinder service life and printing speeds. Printing forms engraved using HELL equipment benefit from simplified color matching, minimal start-up waste and optimum engraving results with high print densities, soft vignettes, brilliant contones and razor-sharp lines.
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XtremeEngraving
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XtremeEngraving is an engraving process developed by HELL to produce extremely high contour definition combined with high print density. XtremeEngraving separates the write resolution of the engraving machine from the selected screen. In principle, the HelioKlischograph works like a laser imagesetter. This means that ultrafine resolutions can be combined with high ink applications. XtremeEngraving is used very successfully to reproduce logos, bar codes, labels, drug packaging, micro lettering, security features, and cigarette packaging.
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In general, conventional vibration engraving and XtremeEngraving are combined with each other. Cylinders that contain only image elements are engraved in the conventional manner; cylinders that contain text or fine graphic elements as full tones are engraved using XtremeEngraving. The two procedures can also be combined on one cylinder. HelioXtreme engraving systems generally support the two operating modes vibration engraving and XtremeEngraving.
Take, for example, a black cylinder that has an image area and a barcode. The image is engraved as normal using the 70 l/cm screen employed in conventional vibration engraving. Then the barcode is engraved in high resolution using XtremeEngraving. The engravings are carried out automatically one after the other using sequential engraving. The fast crossfeed results in extremely rapid engraving of the barcode.
XtremeEngraving makes no special demands in terms of the engraving copper. The system uses the same engraving styli as employed in conventional engraving. As normal, TIFF complete forms from the HelioCom cylinder layout workstation are used for the engraving process. The engraving machine can be easily parameterized via job tickets.
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A comparison
conventional engraving (left)
with XtremeEngraving (right)
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A comparison
conventional engraving,
70 l/cm screen, angle 4 (left)
XtremeEngraving (right)
graph paper
in comparison (center)
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CellEye
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The innovative CellEye cutting procedure for HelioKlischograph systems is based on the measurement of engraving cell volumes and enables unique repeat accuracy for packaging gravure cylinders. The calculation of the actual cell volume factors in the real stylus angle and stylus wear and compensates fluctuations in the engraving copper. Using CellEye leads to a significant reduction in the amount of paper waste during startup.
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Unique repeat
accuracy for cylinders
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Significant advantages
The old method does not take adequate account of the geometric distortions in a cell:
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left:
CellEye divides the cell
into numerous slices
right:
Factoring in the real
stylus angle, CellEye calculates
the volumes of the individual
slices and adds these up to
determine the cell volume
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SprintEasy
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The use of CellEye in conjunction with SprintEasy provides the best results when it comes to the repeat accuracy of engraving cylinders. Engraving styli are subject to wear that is also reflected in a change of stylus angle. The change can be as much as +4°. With the SprintEasy measuring station, the current stylus wear is recorded and the changed stylus angle transmitted directly to the touch memory of the engraving head. The repeat accuracy of the cylinder engraving is therefore assured, even with a highly worn stylus. This means that, with SprintEasy, the service life of engraving styli can be significantly increased.
SprintEasy also offers users further benefits. Slide shoe setting can be performed very quickly and accurately outside the HelioKlischograph. There is no longer any need for “scratch tests” on a test cylinder and the attendant risk of breaking the stylus.
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Longer stylus
service lives
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High Quality Hinting (HQH)
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HQH software delivers much better print results for text and fine elements. Repro data is often prepared in line with specific engraving requirements using manual correction. HQH automates this process by examining engraving data for fine lines and text and automatically optimizing these elements according to preset criteria. The intelligent character recognition function ensures that the characteristics of letters and symbols remain unchanged.
The hardware platform is a PC with Windows operating system. HQH works in the background without any operator intervention by combining hot folder technology with job ticket control.
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A comparison
without HQH (left)
with HQH (right)
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Engraving systems
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HELL offers the ideal engraving head for all applications. Systems are optimized for engraving depth and achieve cell depths of up to 110 µm in a 32 l/cm screen, as is necessary for technical rollers. B systems are optimized for engraving depth, high dynamic response, and engraving speed and are mainly used in the packaging and decorative sector. C systems are optimized for high dynamic response and engraving speed and are the most frequently used. D systems are optimized for maximum precision and consistency and are designed for security printers.
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The 12 kHz HelioSprint III
is the fastest engraving
system worldwide
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In detail
HELL standard engraving systems
HELL standard engraving systems engrave at speeds of up to 4.4 kHz and can be used on all HelioKlischograph systems:
- Standard engraving system A* (40 – 48 l/cm screen)
- Standard engraving system B (48 – 60 l/cm screen)
- Standard engraving system CX (60 – 100 l/cm screen)
- Standard engraving system D (100 – 148 l/cm screen)
* 32 l/cm screen on request
HelioSprint high-performance engraving systems
HelioSprint high-performance engraving systems engrave at speeds of up to 8 kHz and can be used on HelioKlischograph K50 and K500 systems and on machines equipped with the TIFF Upgrade Kit:
- HelioSprint B (54 – 80 l/cm screen) / 6 or 8 kHz
- HelioSprint C (60 – 100 l/cm screen) / 8 kHz
- HelioSprint D (100 – 148 l/cm screen) / 8 kHz
HelioSprint III engraving systems
HelioSprint III has an engraving frequency of 12 kHz and can be used on the latest K500 model:
- HelioSprint III (60 – 100 l/cm screen) / 12 kHz
HelioXtreme 32 high-performance engraving systems
HelioXtreme 32 high-performance engraving systems can be used on HelioKlischograph K50 and K500 systems. These engraving systems can be operated both in XtremeEngraving and conventional vibration engraving modes:
- Vibration engraving (60 – 100 l/cm screen) / 8 kHz
- Xtreme engraving (100 – 230 crossfeed) / 12 kHz
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AutoCon – Fully automatic cylinder production
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The HelioKlischograph K500 and the Cellaxy laser engraver are the perfect partners for creating the fully automatic AutoCon production line. AutoCon is a joint project between HELL Gravure Systems, Bauer-Logistik-Systeme and K.Walter.
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In detail
Most innovative components
A master computer controls all stages of cylinder production, from electroplating – including central supply of chemicals – to surface treatment, engraving and cylinder logistics. This is the only systematically integrated end-to-end solution of its kind. AutoCon comes equipped with the best components on the market and its cutting-edge technology sets a new standard in cylinder production.
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Seamless integration
into fully automated
processes
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The professional production system
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Digital engraving with HelioCom can be gradually upgraded from the entry-level solution to a professional workflow system. The workflow is based on output-neutral TIFF engraving data, so that the output method (vibration engraving, XtremeEngraving or direct laser engraving) does not need to be decided on until just before engraving. Another special feature is that job data can still be modified just before engraving starts.
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