FAQs

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General

  • Highcon is an Israeli company, founded in 2009, that invented the first digital cutting and creasing machines for folding carton finishing and commercial applications – the Highcon Euclid series. Our vision is to bridge the gap between design creativity and production capability with innovative digital technology that unleashes the power of paper.
  • Around 30 machines installed all over the world (May 2016)
  • No, it doesn’t matter how the sheets are printed, analog or digital.
  • The Highcon digital cutting and creasing technology enables packaging (folding carton and microflute), commercial applications, greeting cards, sheetfed labels, promotional materials, folders, stationery, point-of-sale, display and a wide variety of 3D applications.
  • The Highcon technology replaces a complex, expensive and slow die-making and setup process, with an in-house controlled digital system, delivering improved responsiveness, design flexibility and enhanced efficiency.
  • The Highcon machines crease and cut in one pass – and both processes are digital. Advantages vs laser are productivity, creasing, format, substrates thickness and digital stripping
    Also, lasercutters use a half cut to produce a crease, which is frequently not acceptable in the packaging market and reduces the speed.

Highcon Products

  • The Highcon product portfolio includes the Highcon Euclid series, the Highcon Beam, Highcon Pulse, and the Highcon Axis. The Highcon Shape is a technology preview that was shown at drupa 2016.
  • The Highcon Beam handles B1 sheets up to 5,000 sheets per hour and takes digital cutting and creasing into mainstream production.

    It is suitable for:

    • Mid-large folding carton converters

    • Large commercial printers (B1)

    • Large trade finishers


    Main Benefits:
    High productivity enables strong ROI through analog to digital conversion and introduction of new high value opportunities with a wide range of paper/carton thicknesses
  • The Highcon Euclid III is a third generation machine that offers application versatility by digital cutting and creasing .

    It is suitable for:

    • Small Folding Carton converters

    • Commercial printers (B1)

    • Trade finishers


    Main Benefits:
    A wide range of new, high value applications (Variable Data Cutting, 3D Modeling and intricate designs) and a solution for short to medium runs at affordable price.
  • The Highcon Pulse offers digital cutting and creasing in a B2/29 in. format at an affordable price
    It is suitable for conventional converters and commercial printers working in B2 format as well as offering a complete end-to-end digital workflow for digital print service providers.

    Main Benefits:
    All of the capabilities and opportunities of digital cutting and creasing with smaller footprint and entry level cost
  • Highcon Axis is a 2D to 3D software solution that brings the benefits of a web-to-print system to all the players in the complex paper or carton board production supply chain. It was developed in partnership with Xmpie – the world’s leading web to print platform provider, and Esko that leads packaging workflow. It allows customers to streamline orders from existing clients as well as enabling them to open an online store.

    XMPie delivers the graphical rule engine that enables the graphic personalization, while Esko provides the structural rule engine which automatically applies those rules to the 3D product.
  • Following are the maximum speeds:

    Beam          5,000 B1 sheets/hour
    Euclid III      1,500 B1 sheets/hour
    Pulse           2,000 B2 sheets/hour
    Speed is a function of layout imposition and substrate.
  • Up to 20,000 on the Beam and the Euclid, up to 5,000 on the Pulse.
  • We expect that on average, it will take around 15 minutes for a B1 job, which is a fraction of the current conventional process. The Highcon digital process means that the set up become much easier and shorter.
  • The speed is set automatically on the machine but the operator can adjust the speed according to requirements
  • They are consistent up to 20,000 sheets. The crease varies according to the type of substrate, like conventional die-cutting.
  • Highcon Euclid III

    Cardboard and label thickness (µ)     200-600 (8-24pt.)

    Microflute (mm)                                      N+F+G up to 1.2 (47pt.) cutting and creasing

    Highcon Beam

    Cardboard and label thickness (µ)       120-900 (5-36pt.) cutting
    200-650 (8-26pt.) creasing

    Microflute (mm)                                       N+F+G cutting and creasing

    Corrugated (mm)                                     up to 2mm (78pt.) cutting and creasing

    Highcon Pulse

    Cardboard and label thickness (µ)        120-600 (5-24pt.)
  • In addition to the core digital cutting and creasing, all the machines have optional modules:
    CAD Light Editor, Highcon Integrated Digital Stripping (HIDS), Variable Data Cutting (VDC), and 3D Modeling.

    The laser is capable of cutting, etching, kiss cut, half cut, and perforation.

    CAD Light Editor
    The machine will run with Esko ArtiosCAD, Adobe Illustrator, EngView Package Designer – any software that you already use that can export a DXF file.

    The Highcon CAD Light Editor add-on software module, powered by Esko or EngView, allows operators to take full advantage of the flexibility of digital technology by enabling:

    • Last minute editing of crease and cut lines

      • Corrections, design changes, optimization



    • Nick optimization

      • Increasing or decreasing size of nick

      • adding and removing nicks



    • Stripping lines

Optional modules

  • The Highcon Integrated Digital Stripping Unit removes fine decoration cutting waste from as small as 2x2mm and up to 60 x 60 mm and can handle text, signs, small and complicated shapes. Activated by the press of a button, the HIDS removes waste between items. There is no need to buy a tool for each job or to set it up.
    2 brush sets mechanically remove the waste: the top brush separates the waste particles by rotating, the bottom brush hits the hanging waste and removes it, dropping it into a waste bin below which only needs changing about once every 2,000 sheets.
  • In addition to the registration of the sheets mechanically on the machine, in the new advanced registration module sensors align the page to a printed mark placed at least 7mm from the sheet edge, to reduce errors that can occur in the printing. This is particularly relevant for digital printing as it compensates for inaccuracies of the alignment between the printed image and the sheet leading edge.
  • This new optional module has the ability to perform variable cutting per up as well as per sheet enabling customization, personalization and serialization and security applications.

    Customers generate a multi-page PDF, load to the machine DFE and the VDC software maps to Highcon cutting layers.

    • Customer generates a multi-page PDF

    • Load to the Euclid DFE

    • The VDC software maps to Highcon cutting layers

  • Highcon 3D Modeling software adds a brand new high value application to customers’ arsenal, which leverages the key advantages of Highcon technology. The Highcon digital technology includes high speed, accurate digital cutting of paper and paper based substrates. The cutting can be made using variable data for each single sheet. Customers have no need for any previous knowledge of 3D printing.

    Highcon has developed a dedicated workflow allowing the conversion of standard 3D models to separate layers that can be cut on Highcon machines. Assembly is carried out offline and can be done either by mechanical assembly. or by gluing sheets (not part of the package)

Technology

  • Yes, we have dozens of patents and patent applications covering our products
  • Highcon’s proprietary polymer technology replaces the traditional die. (Highcon patented Digital Adhesive Rule Technology - ‘DART’) and the laser cutting performance reduces burn marks and haze effects.
  • We use high power CO2 lasers combined with the most advanced scanning system and unique optics design. This enables high quality cutting as well as the unique capabilities of intricate shapes and personalized cartons.

    Partial cutting is also simple and can be performed by defining in the software. . It is also possible to do perforation, marking and of course because of the digital technology you can cut on a crease and produce kiss cuts.

    The Highcon Beam has 3 1,000 watt lasers
    The Highcon Euclid III has 3 400 watt lasers
    The Highcon Pulse has 1 880 watt laser
  • In order to maximize the coverage of the lasers’ field of view without having to add another laser.
  • Highcon uses completely new and unique DART (Digital Adhesive Rule Technology) to rapidly lay down or place high quality crease lines. The lines are created using a sophisticated writing head designed to selectively deposit a 3D creasing rule made by a UV curable resin. The writing head velocity is 8.5m/min and then the foil is cured with UV light, making this an extremely fast process, especially in comparison to anything that exists today. The nozzle can be adapted to suit thicker substrates.
  • There are only 3 consumables required to create the DART:
    • The DART polymer (UV curable resin) which creates the 3D crease lines.
    • The DART Foil on to which the crease lines are written. These foils vary from machine to machine.
    • The DART Counter substrate which supports the high quality creasing and is replaced only after approximately 500,000 impressions or 6 months.
  • No, you may encounter registration issues, and lose DART foil flexibility, and rules can collapse.
  • Temp - 15°C < T < 30°C
    Expiry – if stored according to recommended conditions, the polymer will last for six months from delivery date. The foil and counter will last for 24 months
  • The written DART Foil and the DART Counter can be disposed of in the municipal garbage as defined by the local regulations. The DART canister and the purge container of the writing system must be treated as chemical waste and disposed of as required by the local regulations regarding disposal of chemicals.

Quality

  • We have performed numerous tests with Twin Albert equipment checking folding force, erection force and spring force which prove that our technology yields results comparable to conventional technology.
    Products from our machines work seamlessly with folding/gluing machines and filling lines.
  • The written rules on the DART foil act as the male. The counter is a specially developed material with mechanical and elastic properties that take on the shape to the pressure depths of the rule and returns to its original state after the creasing has been completed.
  • The Highcon rules react similarly to the conventional creasing but we have an advantage in the ability to control the rule shape and the pressure.
  • In order to optimize crease quality with different types of inks or coating, we can control the drum pressure or the nozzle shape.

    We currently support most types of enhancement (varnish, UV curable coating,) but of course there is always room to test new and different coatings
  • The Highcon machines use a number of new technologies and designs to optimize productivity and quality. For example, we optimize the speed of the laser, control the air regime under the conveyor belt and other technological solutions which reduce the effects of the laser heat and produce results comparable or better than other laser cutting devices.

    We continue to test and improve the range of substrates handled, and have had great feedback from customers and prospects

Support

  • Highcon Customer Support is a global operation dedicated to providing first class customer support for the entire lifecycle of Highcon products. From initial installation preparation, through implementation, application and ongoing daily support, we ensure the customer's system is fully operational and productive. The support service is based on a combination of direct and partner access.
  • All machines come with one year full warranty. Following this customers have a choice whether to take a service contract or Ad Hoc service.

     
  • The laser life span is very long and the laser, like all other parts of the machine, is covered by Highcon's optional service agreement.
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