CapamaBlog
Part 1: Selection
1. What's the difference between a roll-to-roll screen printer and a flatbed screen printer?
A roll-to-roll (R2R) screen printer feeds material continuously from an unwind roll through printing, drying, and rewinding in one pass. A flatbed screen printer feeds sheet by sheet manually or automatically.
| Comparison | Roll-to-Roll | Flatbed |
|---|---|---|
| Feed method | Continuous roll | Sheet by sheet |
| Speed | ~7,000 iph | 500-1,500 iph |
| Automation | Fully automatic | Semi-automatic |
| Best for | Large volume (10k+) | Small volume (hundreds) |
| Operators | 1-2 per shift | 2-4 per shift |
2. Should I choose 320mm or 520mm width?
- Small labels, electronics, nameplates → RR-320S (320mm web width, 220V/25A)
- Appliance panels, automotive badges, large decals → RR-520S (520mm web width, 220V/32A)
Pro tip: leave 20-30mm margin beyond your widest product.
3. How much does a roll-to-roll screen printer cost?
CAPAMA roll-to-roll screen printers range from $25,000 to $170,000 USD, depending on:
- Number of printing stations (1 to N modular units)
- CCD automatic registration system (optional)
- UV curing type (standard UV or LED-UV)
- Configuration of tunnel dryer, laminating module, corona treatment
4. What materials can be printed?
CAPAMA screen printers handle 0.02mm to 15mm thick roll materials:
- Paper labels, PET, PVC, PP, PE films
- Aluminum foil, copper foil (FPCB)
- Nameplate materials (acrylic, PC, stainless steel film)
- Battery labels, cosmetic packaging, daily chemical labels
5. Can you print 4-color process?
Yes. CAPAMA's modular design supports 1 to N color stations. 4-color process printing is a standard configuration. For tight registration, the optional CCD automatic registration system is recommended.
Part 2: Technical
6. What's the maximum printing speed?
15 meters/minute maximum, approximately 7,000 impressions/hour. Actual speed depends on:
- Material drying time (UV is 2-3x faster than hot air)
- Print coverage area and complexity
- Number of colors (slowest station dictates speed)
7. What servo system do you use?
CAPAMA uses Yaskawa servo motors (Japan) across all models. The printing stations are independently servo-driven with a 10-inch touchscreen HMI for easy parameter adjustments.
8. Do I need the CCD registration system?
Recommended when you need multi-color high-precision registration:
- 3+ color printing
- Front-to-back registration on transparent/dark materials
- Security labels, electronic circuit printing
For simple 1-2 color printing, manual registration works fine.
9. UV drying vs tunnel dryer — which one?
| Method | Advantages | Best For |
|---|---|---|
| UV drying | Instant, compact, energy efficient | Standard labels, UV inks |
| Tunnel dryer (0-150C) | Special inks, thermosetting inks | PVC/PE shrink materials, thick ink |
10. What are the laminating module and corona treatment?
- Laminating module: in-line lamination of protective film, reducing work-in-process
- Corona treatment: improves ink adhesion on low-surface-energy materials (PE, PP)
Part 3: Installation & Setup
11. What floor space is needed?
- RR-320S: approx 4m x 2.5m (single station)
- RR-520S: approx 4.5m x 2.8m (single station)
- Each additional station adds ~1.5m in length
- Reserve 0.8-1m access space
12. What are the power requirements?
- RR-320S: 220V single phase, 25A
- RR-520S: 220V single phase, 32A
- A voltage stabilizer is recommended for consistent registration
13. How long does installation take?
Standard installation: 3-5 working days: positioning, electrical connection, trial printing, calibration, and operator training.
Part 4: Operation & Maintenance
14. What's the daily maintenance routine?
| Frequency | Tasks |
|---|---|
| Daily | Clean screens, check squeegee, remove ink residue |
| Weekly | Lubricate rails/bearings, check servo connections |
| Monthly | Calibrate tension sensors, replace squeegee blades |
| Quarterly | Electrical cabinet dusting, servo drive cooling check |
15. How long do screens and squeegees last?
- Screen mesh: 3,000-10,000 impressions
- Squeegee blade: 5,000-20,000 impressions. Replace when jagged wear appears.
- Keep 2-3 spare squeegees to minimize downtime.
16. Common problems and solutions
| Problem | Likely Cause | Solution |
|---|---|---|
| Misregistration | CCD uncalibrated, tension unstable | Recalibrate CCD, check tension |
| Ink bridging | Ink too viscous, wrong angle | Adjust viscosity, check angle (55-75 deg) |
| Blurred print | Insufficient squeegee pressure | Increase pressure, check gap (3-6mm) |
| Web wandering | Edge guide sensor fault | Clean sensor, calibrate tension |
17. What are the consumable costs?
- Screen mesh: $7-28/screen
- Squeegee blades: $7-20/blade
- UV lamps: $40-110/lamp (1,000-2,000 hours lifespan)
- Inks: $10-28/kg
Part 5: Applications & Capacity
18. Which industries need roll-to-roll screen printing most?
Cosmetic/label converters, electronics (FPCB, battery packaging), nameplate manufacturers, automotive dashboard labels, household appliance panels. Any business producing high-quality labels or nameplates in volume.
19. How many labels per day?
RR-320S daily capacity estimate:
- 7,000 iph x 80% efficiency x 8 hours = ~44,800 impressions/day
- At 100x80mm label size = ~35,000 finished labels/day
20. Cost advantage vs digital die-cutting?
Screen printing offers significant cost advantages for volume production:
- Low per-impression cost (~$0.001-0.007/print after screen amortization)
- Ink costs ~1/5 to 1/3 of digital ink
- 10+ year equipment life with proper maintenance
CAPAMA's SMART ZH-CW65 digital die-cutter complements screen printing for short-run, variable-data jobs — they're a production pair.
Summary
A roll-to-roll screen printer is the backbone of label production. Choose the right width and configuration, maintain it properly, and it will serve your business for a decade or more.
For personalized consultation, contact the CAPAMA technical team.