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Gravure Printing

Gravure Printing

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Gravure Printing

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  1. Gravure Printing Cale Polkinghorne

  2. Historical Background • Italian Renaissance 1300’s. • Engravings and etching into soft copper. • A channel or sunken area is left, this holds the ink. • Intaglio is the term used to describe gravure printing (Italian for printing in a sunken surface)

  3. “Roto” Gravure • Roto means Round. • Term used for Industrial Intaglio. • Roto Gravure is printing from a cylinder. • Web Fed • Slitter ( devise used to cut sheets at the end of of the press)

  4. Gravure Industry • Simplest of all printing systems. • Fastest press start up. • Very little paper waste (half the paper waste of lithography). • Speed is extremely high. • 45,000 copies an hour.

  5. Gravure Industry (continued) • Some run 20 million copies without cylinder wearing out. • Highest quality image.

  6. Industry Organization • 3 types of printing • Packing Printing • Publication Printing • Specialty Printing

  7. Packaging Printing • This includes producing and folding. • Cartons • Boxes • Bags • Gift wrappers • Labels

  8. Publication Printing • This includes Printing • Newspaper Supplements • Magazines • Catalogs • Mass Mailing Advertisements

  9. Specialty Printing • Used to Print such materials as • Wallpaper • Vinyl • Floor covering • Textiles (decoration and clothing)

  10. Methods of Cylinder Prep • Diffusion etch • Direct Transfer • Electromechanical Process • Laser cutting

  11. Diffusion-Etch Process • Image exposed much like developing a plate for regular offset printing except negative in transferred. • Acid Bath • Copper cylinder • Cylinder then chromed (prolong life)

  12. Direct-Transfer • Light Sensitive Mask • Acid Bath • Chrome plating

  13. Electromechanical Process • Replaced chemical engraving • Basically Done by a computerized mill that etches a digitally scanned image.

  14. Laser-cutting Process • Chemically etched holes are made. • Plastic is used to cover holes. • Same process as electromechanical is used except a laser does the cutting instead of a tool bit.

  15. Well Formation • Gravure Transfers from small wells that are etched or cut in the cylinder • Cylinder rotates through a fountain of ink • Excess ink is wiped off by a doctor blade

  16. Gravure Well Variables • Depth • Bottom • Opening • Bridge

  17. Depth • Bottom of the well to the top surface of the cylinder

  18. Bottom Obviously the bottom of the well

  19. Opening • Distance across the well

  20. Bridge • Surface of the cylinder between wells

  21. Well Design • Conventional • Wells have exactly the same opening size • Amount of ink is controlled only by the depth of the well

  22. Well Design (continued) • Lateral hard-dot • Can create half tone images • Well opening sized differ • Well depth stays the same

  23. Cylinder Construction • Most cylinder cores are made of steel • Some companies prefer aluminum • Lighter • Less expensive • Easier to ship

  24. Cylinder Design • Axis (center line of shaft) • Shaft (what the cylinder spins on) • Diameter • Circumference (one impression) • Face Length (printing width)

  25. Two forms of Cylinders • Mandrel (removable shaft) • Integral (shaft mounted permanently) $$$$

  26. General Info • An impression roller presses paper to Cylinder • Gravure printing allows high-quality images on low-grade papers.