10 CI-flexo printing decks. Two ink systems. One integrated chamber and ink handling solution.

Project summary: NOVA XLS chamber systems with ESS and EPQ pump solution on Allstein CI flexo press

A German flexible packaging printer operating a 10-color Allstein Hydro CI flexo press at 1,400 mm print width required a fully customized chamber doctor blade and ink supply solution for high-quality printing on low-absorbing plastic film substrates with both water-based and solvent-based inks.

AkeBoose engineered and installed 10 NOVA XLS stainless steel chamber systems, each equipped with an End Seal Spray System (ESS) to prevent ink from drying in the end seal area – a critical requirement for film substrates. Additional spare chambers were supplied to enable ultra-fast job and color changes with minimal press downtime. A customized EPQ pump solution for all ten print stations was developed with an integrated cleaning process supporting the alternating use of water-based and solvent-based inks, including connection to the customer's solvent recovery system.

The project required solving significant mechanical integration challenges – including a custom pivoting chamber suspension to match the press opening movement – as well as ATEX compliance for solvent ink operation. The result is a high-performance, fully integrated ink metering and supply system engineered precisely around the customer's press and production requirements.

Initial Situation / Challenge

High-quality printing on low-absorbing plastic film is one of the most demanding disciplines in flexographic printing. For a German flexible packaging producer running a 10-color Allstein Hydro CI flexo press at 1,400 mm print width, the challenge was compounded by an additional layer of complexity: the press needed to run both water-based and solvent-based inks – sometimes alternating between jobs – while consistently delivering premium print quality on film substrates.

The machine-side chamber systems in place were not performing to the customer's expectations. Water-based ink was drying out in the end seal areas – a known and critical problem on low-absorbing substrates where ink cannot penetrate the material and instead accumulates at the chamber ends, causing leakage and print defects. Job changes and ink changes were taking too long, eating into productive machine time. And with solvent inks in the process, the entire ink supply system had to meet strict explosion protection requirements.

The customer needed more than a replacement chamber system. They needed a fully engineered solution.

Approach & requirements

AkeBoose developed a complete, customized ink metering and supply system built around the specific demands of this press and this production environment.

At the heart of the solution: ten NOVA XLS stainless steel chamber systems, one per print station, each equipped with an End Seal Spray System (ESS). The ESS continuously moistens the end seal area during production, preventing water-based ink from drying out and eliminating the leakage and defects that had plagued the previous setup. Stainless steel construction was specified for chemical resistance and durability across both ink systems.

To maximize productive uptime, additional spare chambers were supplied for the print stations. When a job or ink change is required, operators simply swap the chamber – the used chamber is removed and cleaned at a separate station while the press keeps running. What previously required extended downtime is now a matter of minutes.

The ink supply side presented its own engineering challenge. A customized EPQ pump solution was designed for all ten print stations, with an integrated cleaning process that supports the alternating use of water-based and solvent-based inks. The system connects directly to the customer's solvent recovery infrastructure – a requirement for both operational efficiency and regulatory compliance.

Mechanical integration added further complexity. The Allstein Hydro press opens with a pivoting movement – meaning a standard fixed chamber suspension would create a collision risk during press opening. AkeBoose engineered a custom pivoting suspension that moves with the press, allowing safe and unobstructed operation. Full ATEX compliance was implemented throughout the solvent ink components to meet explosion protection standards.

Outcome

The result is a 10-color CI flexo press that runs reliably, efficiently and with the flexibility to handle different ink systems without compromise.

Ink leakage at the end seals has been eliminated. Job and ink changes happen faster, with less press downtime and less manual effort. The integrated cleaning process makes switching between water-based and solvent ink systems straightforward, and the connection to the solvent recovery system supports a cleaner, more controlled production environment.

For the customer, this project delivered exactly what high-output flexible packaging production demands: consistent print quality, maximum machine availability, and an ink system that keeps pace with the press, not the other way around.The customer's response confirmed it: the system has been performing to their full satisfaction and AkeBoose's installation team explicitly received special recognition for their professional on-site work.

For AkeBoose, it is a benchmark project that demonstrates what is possible when engineering goes beyond standard configurations. Every challenge on this press – from end seal drying to ATEX compliance to the pivoting suspension – was solved with a purpose-built answer.