Gallus Labelfire
Diamond Core
Series

Diamond Core is the heart of every Labelfire. This refers to the digital print unit, which prints with a native resolution of 1200 x 1200 dpi using the UV inkjet process. This printing unit is available as a 4- or 7-colour Diamond Core and can be optionally equipped with a print head row for digital white. This makes brilliant printing results possible even on transparent material. A production speed of up to 70 m/min*Printing speed with digital white: 47 m/min, the speed mode of 70 m/min can lead to limitations (color gamut, substrate variety, iVDP, repetition length of die cut) can be achieved, with or without die-cutting unit.

Lowest cost-per-label

Maximum productivity in conjunction with competitive ink prices and the efficient colour management of Prinect enable the printer to produce labels at an excellent price/performance ratio.

Quality

The best available resolution of 1200 × 1200 dpi (native) at 70 m/min*Printing speed with digital white: 47 m/min, the speed mode of 70 m/min can lead to limitations (color gamut, substrate variety, iVDP, repetition length of die cut) and camera-based quality assurance ensure perfect print quality. The Single Color Pinning process ensures sharp printing results even with extra fine lines and very small fonts. The 7-colour printing unit is capable of simulating up to 94%**ΔE ≤ 3 of PANTONE® PLUS colours. Constant colour stability throughout the entire production life of the machine guarantees exact reproducibility for repeated print jobs.

Ease of use

One control panel for everything. Gallus Labelfire’s integrated register control and Human Machine Interface (HMI) stand for simple and intuitive operation. The conventional modules are controlled with the same operating logic as the digital printing unit. In addition, camera-based quality monitoring and nozzle error detection and compensation ensure the highest inkjet print quality.

Comprehensive carefree package

With the Gallus Labelfire, we offer comprehensive service. With the purchase of this machine, all maintenance work in the first year of operation is included in the price, including the exchange of all parts to be replaced, labour and access to the 24/6 help desk. Corresponding service packages are available for every mode of operation for the following years.

4-colour UV
inkjet printing
roll-to-roll

1200 x 1200 dpi

Digital White
optionally
available

Single Colour
Pinning for
sharp print
results

Vision
system HMI
print and
register
control

diamond-core

Gallus Labelfire D1

4-colour digital printing on an industrial scale

  • 4-colour roll-to-roll UV inkjet printing (CMYK) plus optional digital white
  • Best print quality with 1200 x 1200 dpi native, corresponds to 2400 x 2400 dpi optical
  • Single Colour Pinning for sharp print results
  • Vision system HMI (print and register control)
  • Fast and stable: up to 70 m/min production speed*Printing speed with digital white: 47 m/min, the speed mode of 70 m/min can lead to limitations (color gamut, substrate variety, iVDP, repetition length of die cut)
  • Optional: Digital white with high opacity

Print sample applications

Sharp letters
and characters in 4c

Stepless gradients down to 0%

Best print quality with 1200 x 1200 dpi native

Single Color Pinning for sharp printing results

Digital White optionally available

7-colour UV
inkjet printing
roll-to-roll

1200 x 1200 dpi

Digital White
optionally
available

Single Colour
Pinning for
sharp print
results

Vision
system HMI
print and
register
control

diamond-core

Gallus Labelfire D2

7 colours for best print quality and a perfect price/performance ratio

  • 7-colour roll-to-roll UV inkjet printing (CMYK OGV) plus optional digital white
  • Covers up to 94%*ΔE ≤ 3 of simulated PANTONE® PLUS colour scale
  • Best print quality with 1200 x 1200 dpi native, corresponds to 2400 x 2400 dpi optical
  • Single Colour Pinning for sharp print results
  • Vision system HMI (print and register control)
  • Fast and stable: 70 m/min production speed**Printing speed with digital white: 47 m/min, the speed mode of 70 m/min can lead to limitations (color gamut, substrate variety, iVDP, repetition length of die cut)
  • Optional: Digital white with high opacity

Print sample applications

Sharp letters and characters in 7c

Stepless gradients down to 0%

Best print quality with 1200 x 1200 dpi native

Single Color Pinning for sharp printing results

7 colours for natural, beautiful skin tones

Digital White optionally available

4-colour UV
inkjet printing

Increased
flexibility
thanks to inline
processing

Digital White
optionally
available

Die-cutting unit

Cold foil
embossing
unitOptional equipment

Varnish and
lamination moduleOptional equipment

Double
rewinderOptional

Flexographic-
printing unit

4

5

Gallus Labelfire D3

Gallus Labelfire D3*contains optional equipment with lamitation unit, varnish flow path and additional corona for perfect gloss

Gallus Labelfire D3*contains optional equipment with integrated cold foil system

Labelfire D3

Labelfire D3 vl

Labelfire D3 cf

diamond core

Gallus Labelfire D3

Printing, inline finishing, embellishment and die-cutting in a single pass

  • 4-colour UV inkjet printing (CMYK) plus optional digital white
  • Best print quality with 1200 x 1200 dpi native, corresponds to 2400 x 2400 dpi optical
  • Single Colour Pinning for sharp print results
  • Vision system HMI (print and register control)
  • Fast and stable: 70 m/min production speed*Printing speed with digital white: 47 m/min, the speed mode of 70 m/min can lead to limitations (color gamut, substrate variety, iVDP, repetition length of die cut)
  • Optional: Digital white with high opacity
  • Inline processing: Fully printed, embellished and stamped label in a single pass

Print sample applications

Sharp letters
and characters in 4c

Stepless gradients down to 0%

Best print quality with 1200 x 1200 dpi native

Single Color Pinning for sharp printing results

Cold foil embellishment

Inline processing: Fully printed, embellished and die-cut label in a single pass

Digital White optionally available

7-colour UV
inkjet printing

Increased
flexibility
thanks to inline
processing

Digital White
optionally
available

Die-cutting unit

Cold foil
embossing
unitOptional equipment

Varnish and
lamination moduleOptional equipment

Double
rewinderOptional

Flexographic-
printing unit

4

5

Gallus Labelfire D4

Gallus Labelfire D4*contains optional equipment with lamitation unit, varnish flow path and additional corona for perfect gloss

Gallus Labelfire D4*contains optional equipment with integrated cold foil system

Labelfire D4

Labelfire D4 vl

Labelfire D4 cf

Diamond Core

Gallus Labelfire D4

Printing, inline finishing, embellishment and die-cutting in a single pass

  • 7-colour UV inkjet printing (CMYK OGV) plus optional digital white
  • Covers up to 94%*ΔE ≤ 3 of simulated PANTONE® PLUS colour scale
  • Best print quality with 1200 x 1200 dpi native, corresponds to 2400 x 2400 dpi optical
  • Single Colour Pinning for sharp print results
  • Vision system HMI (print and register control)
  • Fast and stable: 70 m/min production speed**Printing speed with digital white: 47 m/min, the speed mode of 70 m/min can lead to limitations (color gamut, substrate variety, iVDP, repetition length of die cut)
  • Optional: Digital white with high opacity
  • Inline processing: Fully printed, embellished and stamped label in a single pass

Print sample applications

Sharp letters and characters in 7c

Stepless gradients down to 0%

Best print quality with 1200 x 1200 dpi native

Single Color Pinning for sharp printing results

Cold foil embellishment

Inline processing: Fully printed, embellished and die-cut label in a single pass

7 colours for natural, beautiful skin tones

Digital White optionally available

Diamond Core Overview

 

N Standard Optional

 
Digital Print Unit (DPU) D1 D2 D3 D4
         
Colors
CMYK (cyan / magenta / yellow / black)
N N N N
Colors gamut extension
GOV (green / orange / violet)
  N   N
Digital white (up to 47 m/min)
high opacity & speed mode
Single color pinning after each print bar
sharpness and intercolor bleeding control
N N N N
Automatic cleaning system
contact-free cleaning (<180s)
N N N N
Vison system
Visualizing on HMI
N N N N
Digital print control
missing nozzel detection & compensation / density unevenness detection & compensation
N N N N
Substrate qualification
automatic inline qualification (100% system supported)
N N N N
Digital register automatic
for all colors
N N N N
Web video function
Inspection via screen in front of the rewinder
   
Industrial variable data printing (iVDP)
e.g. barcodes, QR codes, alphanumeric text
N N N N
Insetting
accurate imprinting of pre-printed substrates
Workflow
D1 D2 D3 D4
Digital Front End (DFE)
3x Prinect cockpits
N N N N
Server hardware
Pre and post calculation
ink consumption
N N N N
Color Proof
integration in proofing workflow (Prinect Color Proof Pro 75)
MIS integration
MIS to DFE Pack
Color Toolbox full license
ICC profiles and device link profiles, quality monitor
Kanji Fonts
Extension by 5 high resolutions kanji fonts
Conditioning
D1 D2 D3 D4
Unwinder
max. 40” (1016 mm), max. 250 kg
N N N N
Lift
Splice control
Automatic print bar lifting
N N N N
Teknek web path cleaning
front and reverse side
N N N N
Active web path cleaning (vacuum system)
contact-free
N N N N
Corona
front or reverse side
N N N N
Antistatic system
contact-free
N N N N
Inline Converting
D1 D2 D3 D4
Flexo Unit
254–508 mm (10”–20”)
    N N
Register control     N N
Cold Foil System    
Lamination Unit
with varnish flow path and additional corona for perfect gloss
   
Rail system     N N
50 m/min Semi Rotary Die-Cutting Unit
supported formats: 152–508 mm (6”–20”), vmax: 381 mm (15″)
   
Adjustable anvil cylinder
Acustrike
    N N
Matrix rewinder     N N
70 m/min Semi Rotary Die-Cutting Unit
supported formats: 152–508 mm (6”–20”), vmax: 305 – 508 mm (12″ – 20″)
   
Adjustable anvil cylinder
K&B (oil system)
    N N
Matrix rewinder     N N
Web video    
Longitudinal slitter in razor blade design
3 blades
Rewinder max. 40” (1016 mm), 250 kg N N N N
Lift
Pressure arm / Hold down device
with antistatic device
Double rewinder
with inspection desk
   
Lift     N N
Pressure arm / Hold down device
with antistatic device
    N N
Size
D1 D2 D3 D4
L x W x H 6.4 × 4.5 × 2.2 m 8.0 × 4.5 × 2.2 m
Connected loads
D1 D2 D3 D4
Voltage
400 V / 50 Hz (optional 60 Hz)
       
Connection power
3P + PE
66 kW 66 kW 78 kW 78 kW
Compressed air
7.5 – max. 10 bar, oil- and water-free
350 l/min 350 l/min 350 l/min 350 l/min
Exhaust air
exhaust air temperature max. 50 °C / ozone output during operation approx. 0.8 mg/m³
1500 m³/h 1500 m³/h 1800 m³/h 1800 m³/h
Compliance
CE, GS (UL possible)
N N N N
Remote access N N N N
Technical Data
Print process
UV Piezo DoD – Inkjet
Print speed
up to 70 m/min*Printing speed with digital white: 47 m/min, the speed mode of 70 m/min can lead to limitations (color gamut, substrate variety, iVDP, repetition length of die cut)
Productivity
max. print area 1428 m²/h
Print resolution
1200 × 1200 dpi native at a droplet size of 2 pl, visual resolution approx. 2400 × 2400 dpi
Print width
up to 340 mm
Substrates
mono films, papers and composite materials (50–350 μm)

Following specific adaptions of the individual machine types of Labelfire are possible however not available with the models from the Lablefire Diamond Core series. For further information, please contact your regional Gallus/Heidelberg representative:
Special substrates: cardboard & tubelaminate & thin foils (20–450 μm)
Full Variable Data Printing (FullVDP): every pixel is fully variable
Low migration: Swiss Ordinance / Nestle Guidance / Eupia / GMP

Highest productivity at low costs

Diamond Core makes it possible

Labelfire scores particularly well in the overall assessment of all costs incurred (total cost of ownership). The combination of short set-up times, minimised waste and low ink prices enables extremely economical production even with the smallest runs but also at medium run lengths, and forms the basis for highly attractive prices per label.

The combination of digital technology and Prinect software simplifies the processing of variable data and versioning for label printing. In addition, order-related fixed costs as well as costs for versioning and customisation can be reduced. The result is costeffective production of small and medium-sized print runs as well as significantly reduced unit prices for the customer.

The conventional print functions of the Gallus Labelfire D3 and D4 offer additional options in embellishment and inline further processing. This includes, for example, varnishing, laminating and die-cutting. A fair, consumption-based business model offers market-driven prices for inks and services, thus promising interesting margins and competitive advantages.

Maximum Quality

1200 x 1200 dpi physical resolution

The combination of high resolution, a wide colour spectrum and inline quality management provides the basis for brilliant, precise and perfectly consistent print results.

The native (physical) resolution of 1200 x 1200 dpi with a droplet size of just 2 pl and up to 200 greyscale values enables a optical resolution of 2400 x 2400 dpi. Tiny characters, fine lines and colour gradients can be printed down to zero percent without tearing.

The combination of the process colours CMYK and the colour gamut extension colours orange, violet and green covers up to 94 percent of the simulated Pantone Plus colour space. Highly opaque digital white is the basis for brilliant printing results on transparent substrates, even at high speeds.

The color system

Color sequence in the digital printing system: digital white, green, orange, violet, yellow, magenta, cyan and black

Saphira® Digital UV inks for optimal printing results

  • Lightfastness ≥7 across all colours
  • Up to 94%*ΔE ≤ 3 coverage of PANTONE® PLUS colour gamut for optimal reproduction of special colours
  • Meets general regulatory requirements such as REACH, RoHs and the relevant guidelines for printing inks.

Inline quality management

Thanks to the interaction of camera detection in the digital printing unit and specially developed algorithms, so-called “white lines” and “dark lines” are a thing of the past. This gives you perfect labels in perfect quality.

Gallus Services

The right service package for everyone

Service
Support
Plans After the first year of operation

Silver Gold Silver
 
  Silver Gold Platinum
 
Remote Services
Remote- and telephone support N N N
Helpdesk (hours/day) 12/5 24/5 24/6
Reaction time 6 hours 4 hours 2 hours
 
Preventive Services on Machine / DPU
Preventivce maintance interventions (2 man days / intervention) 2 2 2
Preventive maintenance parts Optional N N
Software updates (hotfix remote) N N N
 
Break Fix Services
Spare parts   N N
Packaging / shipping   N N
Break Fix interventions     N
Average time onsite     24 hours

Feature Coverage Modules Silver Gold Platinum
 
Inkjet Head Bundling
Inkjet print head insurance (parts)   4 Pieces N
Inkjet print head replacement (labor)     N
 
Pinning Bundling
Pinning insurance (parts)   1 Piece N
Pinning replacement (labor)     N
 
Software Upgrades
Prinect software upgrade N N N
 

Details you will find in our service leaflet.

Samples & Appointments

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