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Available Print Process

Available Print Process. The End Result. Rotogravure. PLUS. IMPRESSION. * Simple proven process. WEB. ROLL. * Quick make-ready. * low speed sensitivity. * low impression. DOCTOR. sensitivity. BLADE. * variable ink film (better. fidelity). * consistent long runs. ENGRAVED. MINUS.

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Available Print Process

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  1. Available Print Process

  2. The End Result

  3. Rotogravure PLUS IMPRESSION * Simple proven process WEB ROLL * Quick make-ready * low speed sensitivity * low impression DOCTOR sensitivity BLADE * variable ink film (better fidelity) * consistent long runs ENGRAVED MINUS CYLINDER * Cylinders expensive * Cylinders take time to INK make

  4. Lithography PLUS INK * Proven process DUCT * Highest quality process print INK TRAIN MINUS PLATE * High manning CYLINDER DAMPING * High skill level needed TRAIN WEB * Color control issues BLANKET * Not in line with die CYLINDER cutting etc. IMPRESSION CYLINDER

  5. MINUS Flexography PLATE ENCLOSED INK CHAMBER IMPRESSION ANILOX ROLL WEB PLUS * Low cost presses * Process print quality * In line capability * Variable industry * Quick make-ready capability * Less manning/skill level * Consistent color

  6. Ink Types 1.Physical Form - Liquid - Paste 2. Composition and Chemistry - Oil base - Solvent Base - Water Base - Radiation Cure

  7. Ink Formulation – Water Base • FLEXO • GRAVURE TYPICAL PROPERTIES Viscosity 50-100 centipoise Solids 35% Tack Very low Drying Absorption/evaporation Trap Wet on dry Cure Immediate VOC < 1% by wt. Odor Very low Cost OK

  8. Ink Formulation – Solvent Base • FLEXO • GRAVURE SOLVENT TYPICAL PROPERTIES Viscosity 50-100 cps Solids 35% Tack Very low Drying Absorption/evaporation Trap Wet on dry Cure Immediate VOC 65% by wt Odor Low Cost OK (65%) 1.3#/Ream 80% ALCOHOL 20% ACETATE Wet Ink 2#/Ream .1#/Ream ADDITIVES (5%) Dry Ink POLYAMIDE .2#/Ream .7#/Ream RESIN (10%) .2#/Ream NITROCELLULOSE RESIN (10%) .2#/Ream PIGMENT (10%)

  9. Ink Formulation - UV • FLEXO • LITHO SOLVENT (30%) .6#/Ream TYPICAL PROPERTIES Viscosity 10-200 poise Solids 97% Tack Moderate to very high Drying Free radical cure Trap Wet on Wet, or Wet on Dry Cure Immediate VOC <3% Odor Moderate Cost High ACRYLATE MONOMER ADDITIVES (5%) Dry Ink .1#/Ream Wet Ink 2#/Ream 1.1#/Ream ACRYLATE PREPOLYMER (55%) .2#/Ream PIGMENT (10%)

  10. Ink Formulation – Oil Ink • LITHO .2#/Ream DISTILLATE 10% .1#/Ream DRIERS/WAX 5% Viscosity 100-200 poise Solids 90% Tack Very high Drying Absorption/ oxidation Trap Wet on Wet Cure Overnight VOC 10% Odor Moderate Cost OK QUICKSET 1.5#/Ream RESIN 75% Dry Ink 1.8#Ream PIGMENT (10%) .2#/Ream

  11. Ink-Substrate Interface

  12. Litho Inks – Oil Base or UV High viscosity ink and planographic image carrier 1. Low dot gain 2. Uneven solid areas (limited impression) 3. Weak metallic inks (limited ink film)

  13. Flexo Inks: Solvent, Water, UV Low visc ink and raised, resilient image carrier 1. Dot gain very impression dependent 2. Smooth solid areas, even on rough stock 3. Strong metallic inks

  14. Roto Inks: Solvent or Water Base Low viscosity ink and recessed cells image carrier 1. Low dot gain 2. Uneven solid areas (limited impression) 3. Very sensitive to rough stock (skip outs)

  15. Comparing Roto and Flexo * less make-ready * less speed sensitivity * less impression sensitivity * variable ink film (better fidelity) * consistent long runs * lower cost (plates) * quicker response * growing industry focus

  16. Comparing Roto and Flexo

  17. THE LITHOGRAPHIC PRINTING PROCESS Offset Printing

  18. THEORY OF LITHOGRAPHY LITHOGRAPHIC PLATE NON IMAGE AREA IS WATER LOVING (HYDROPHYLLIC) IMAGE AREA IS WATER REPELLANT (HYDROPHOBIC)

  19. LITHOGRAPHIC PRINCIPLE Image Image Non-image Water rejecting Water rejecting Water receptive Hydrophobic Hydrophobic Hydrophylic Ink receptive Ink receptive Ink rejecting Oleophylic Oleophylic Oleophobic LITHOGRAPHIC PLATE

  20. Dampening of plate Dampener Roller Water on non-image area LITHOGRAPHIC PLATE

  21. INKING OF PLATE Ink roller Water on non-image area Ink on image area LITHOGRAPHIC PLATE

  22. PLATE CYLINDER Inking rollers Plate Dampening Rollers Fountain Solution

  23. OFFSET LITHO PRESS CONFIGURATION Ink Distribution Rollers (oscillating) Plate Cylinder Blanket Cylinder Dampening Rollers Sheet or Web Fountain Solution Impression Roller

  24. SHEETFED OFFSET PRESS Plate Inking rollers Blanket Dampener Impression

  25. WEB HEATSET PRESS Plate Inking rollers Oven Dampener Blanket Impression Rewind Unwind

  26. OFFSET PROOFING Difficult to accurately control ink film thickness from hand roller to plate. This will cause some variation when transfering to substrate. Plate is inked up by a hand roller Blanket roller picks up ink from plate Transfers it to substrate Substrate Plate

  27. LITTLE JOE PROOFING PRESS

  28. LITTLE JOE PROOFING PRESS

  29. PRUFBAU PROOFING PRESS

  30. PRUFBAU INKING MECHANISM Back roller oscillating to distribute ink evenly Blanket roller Blanket roller Distribution roller

  31. LITHOGRAPHIC DAMPENING SYSTEMS

  32. CONVENTIONAL (DUCTOR) DAMPENING SYSTEM Form roll Vibrator Plate cylinder Ductor Fountain roll Form roll Fountain solution

  33. CONTINUOUS-FEED (DALHLGREN) DAMPENING SYSTEM Second ink form roll Oscillator roll First ink form roll Plate cylinder Slip nip Metering roll Chrome transfer roll Fountain solution

  34. BRUSH DAMPENING SYSTEM Ink form rollers Chrome vibrator roll Plate cylinder Brush roll Metering roll Fountain solution

  35. DUOTROL DAMPENER Ink form rollers Chrome vibrator roll Plate cylinder Metering roll Fountain solution

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