In this series of profiles on inkjet integrators, Inkjet Insight aims to portray companies focused on offering custom-developed inkjet printing solutions to their customers. Some of the basic considerations have been laid out in the introductory article that will help with understanding the importance of this approach and market.
To establish a market overview, we are examining the company basics and the typical types of solutions offered by each company. Please keep in mind that most companies will happily evaluate solution requirements that are not covered in their core markets and that companies do evolve over time.
Bergstein, the company
Bergstein has quite some history as a solid supplier for the direct printing industry. Founded 56 years ago, the company sold screen and pad printing machines, automations, service, and supplies, where object printing was already an integral part of the business.
In 2002 the company decided to go with the emerging inkjet technology and in 2009 the company Bergstein Digital BV was founded. In the beginning, Bergstein modified Mimaki printers as an OEM-partner, allowed to change the existing hardware and software for printing direct on objects. After some years, the company moved their strategy by developing industrial single-pass digital printers, which are now sold under the Bergstein DIGI-label.
At this moment, Bergstein Digital has 22 employees and is growing every year, with competencies spread across all skills needed for developing, manufacturing, and servicing their inkjet printers. The company has its own R&D department, a Test Print Centre as well as manufacturing in-house. While sales of analogue printing equipment ceased, Bergstein still sells screen and pad printing supplies.
Applications and markets served
In terms of applications, Bergstein is focussed on direct-to-product or direct-to-shape printing. Within that range, a wide variety of products from different industries can be printed on. The focus is on packaging, medical, electronics, consumer, automotive and tooling industry. Printed objects vary from cosmetic bottles and pill boxes to components for tools, car dashboards, and small consumer and medical goods. It also includes unusual objects like disposable gloves, for which two fully automated single pass printers were installed in the USA.
At this moment, Bergstein has installed over 25 print lines around the globe. Mostly industrial customers are served. Bergstein has some high-profile global customers that have installed multiple printers.
Picture of a DIGI-7 printer
Technologies and devices
Bergstein is offering two product lines: the DIGI compact (HC) and DIGI-5/7 systems. The main differences are the size of the transport carriers and the number of modules each handling system can hold. The Compact systems have transport carriers up to 600 x 200 mm (23.6” x 7.9”) in size, while the DIGI 5 and DIGI 7 printers allow for carriers of up to 800 x 300 mm (31.5 x 11.8”). The DIGI-5 has one carrier, while the DIGI-7 has multiple. In the latter case, the carriers move on a flex-link system circling through the printing set-up and back at the backside of the printer – which could even allow for a second print pass. If needed, complex, multifunctional customer-specific jigs can be built on the carriers. Also, the number of slots for the print and pinning modules differs, with the Compact having 15 slots, while the DIGI 7 has 30 slots for the print and pinning modules offered by Bergstein. As a result, the Compact model can have up to 6 colours, while the DIGI5 and 7 allow for 10 colours.
The advantage of interchangeable modules is, that printers can repurposed or upgraded – if empty slots are still available, making the press futureproof.
All systems are set for a print speed of up to 25 m/min (82 fpm) with full-width arrays. So far print heads from Xaar are being used, offering the best performance for the applications targeted.
DIGI-printers are sold as stand-alone models, but also can be integrated into processing lines. Loading and unloading of products on the printers can be challenging, however Bergstein offers a wide range of options from manual loading to fully automations, including robotics from 3rd party suppliers. Bergstein develops the concept as well as delivers the turn-key printer automation.
View inside the DIGI printer Example of a print cassette
Inks and substrates
All DIGI printers are using UV based inks. If necessary, a primer or ink can be modified for a special application case, using an ink lab and a Test Print Centre at Bergstein, in which inks can be re-formulated and tested. Inks, as well as primers and varnishes are manufactured on behalf of Bergstein and sold under its own label.
A wide variety of products can be supported, with a specific combination of pre-treatments, primers and UV technology providing a solution. Their focus is on industrial objects and not on graphic plain substrates such as paper, film, or foil. Essentially, all products to be printed on, need to fit on the moving carriers. (max 300 x 800 x 250 mm)
Sales, service, and geographic coverage
Worldwide, all printers and related automations are sold by Bergstein Digital directly. Although the companies’ base is in Europe, printers have been shipped and installed successfully inmost continents so far. Bergstein services all their printers on-remote.
What differentiates Bergstein Digital?
Bergstein turned its heritage of manufacturing industrial printers into an advantage of providing solid-built, stable, and highly industrialised single pass printing solutions, which are laid out for 24/7 operations.
The company developed a modular concept that allows for a repeatable set of proven capabilities to be easily integrated into print lines. The printers are highly flexible allowing almost endless combinations of modules inside the handling and printing units. With internal R&D, solutions and inks can be adapted to the customers’ requirements.
Contact
Bergstein is based in Kerkrade in the Netherlands
Website:https://www.bergstein.com/
See the first profile in the series, NEOS. This series on inkjet integrators will be continued.