For their latest generation of Digifav laminating machines Spanish manufacturer Bagel Systems S.L.L. has selected an Omron control and automation solution using CP1E PLCs, JX inverters, and NQ3 HMIs.

In the laminating process, a plastic film is applied at high speed to any type of surface and provides strength, protection and an aesthetically appealing touch and appearance for products such as photo books, book covers, business cards, postcards, posters and similar.

Bagel Systems designs and sells industrial laminating machinery, with a focus on the graphics arts sector.

Operating system

Laminating consists of using film with an adhesive layer on one of its sides. The adhesive layer is activated by a heat generated device called a calendar roller and the pressure applied by a different roller referred to as a counter calender roller and located right below the thermal roller, against which it exerts pressure.

Digifav machines can laminate spreads with weights between 130 g/m2 and 350 g/m2 and have been designed to be used with sheet formats between 200 x 200 mm and 520 x 750 mm.  The main challenge lies in the movement carried out by the feeder module, which is the most sensitive part of the machine and requires maximum precision.

The machines comprise three modules:

– feeder module
– main module and calendar roller
– cutting module

Complete integration with Omron technology

The entire machine control system is designed around an Omron CP1E programmable logic controller, and operator communication is provided using an HMI. The functionality offered by the Omron NQ3 HMI allows operators control over a wide range of tasks including this communications task: function buttons, alarms, displays and more.  The HMI also replaces several analogue displays and pushbuttons. The machine incorporates two JX Series frequency inverters to manage the positioning to guarantee maximum precision of movement. The inverters are controlled directly from the CP1E PLC.

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