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1 Available Print Process 2 The End Result 3 * Simple proven process * Quick make-ready * low speed sensitivity * low impression sensitivity * variable.

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Presentation on theme: "1 Available Print Process 2 The End Result 3 * Simple proven process * Quick make-ready * low speed sensitivity * low impression sensitivity * variable."— Presentation transcript:

1

2 1 Available Print Process

3 2 The End Result

4 3 * Simple proven process * Quick make-ready * low speed sensitivity * low impression sensitivity * variable ink film (better fidelity) * consistent long runs * Cylinders expensive * Cylinders take time to make PLUS MINUS ENGRAVED CYLINDER IMPRESSION ROLL DOCTOR BLADE WEB INK Rotogravure

5 4 WEB BLANKET CYLINDER PLATE CYLINDER DAMPING TRAIN INK TRAIN IMPRESSION CYLINDER INK DUCT * Proven process * Highest quality process print * High manning * High skill level needed * Color control issues * Not in line with die cutting etc. PLUS MINUS Lithography

6 5 MINUS * Low cost presses * In line capability * Quick make-ready * Less manning/skill level * Consistent color * Process print quality * Variable industry capability PLUS WEB PLATE IMPRESSION ROLL ENCLOSED INK CHAMBER ANILOX Flexography

7 6 2. Composition and Chemistry - Oil base - Solvent Base - Water Base - Radiation Cure 1.Physical Form - Liquid - Paste Ink Types

8 7 TYPICAL PROPERTIES Viscosity centipoise Solids 35% Tack Very low Drying Absorption/evaporation Trap Wet on dry Cure Immediate VOC < 1% by wt. Odor Very low Cost OK FLEXO GRAVURE Ink Formulation – Water Base

9 8 SOLVENT (65%) 80% ALCOHOL 20% ACETATE Wet Ink 2#/Ream Dry Ink.7#/Ream POLYAMIDE RESIN (10%) NITROCELLULOSE RESIN (10%) ADDITIVES (5%) PIGMENT (10%) 1.3#/Ream.1#/Ream.2#/Ream TYPICAL PROPERTIES Viscosity cps Solids 35% Tack Very low Drying Absorption/evaporation Trap Wet on dry Cure Immediate VOC 65% by wt Odor Low Cost OK FLEXO GRAVURE Ink Formulation – Solvent Base

10 9 ADDITIVES (5%) SOLVENT (30%) ACRYLATE MONOMER Wet Ink 2#/Ream Dry Ink ACRYLATE PREPOLYMER (55%) PIGMENT (10%).6#/Ream 1.1#/Ream.2#/Ream.1#/Ream TYPICAL PROPERTIES Viscosity 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 FLEXO LITHO Ink Formulation - UV

11 10 Viscosity poise Solids 90% Tack Very high Drying Absorption/ oxidation Trap Wet on Wet Cure Overnight VOC 10% Odor Moderate Cost OK PIGMENT (10%) QUICKSET RESIN 75% DRIERS/WAX 5% DISTILLATE 10%.2#/Ream 1.5#/Ream.1#/Ream.2#/Ream Dry Ink 1.8#Ream LITHO Ink Formulation – Oil Ink

12 11 Ink-Substrate Interface

13 12 High viscosity ink and planographic image carrier 1. Low dot gain 2. Uneven solid areas (limited impression) 3. Weak metallic inks (limited ink film) Litho Inks – Oil Base or UV

14 13 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 Flexo Inks: Solvent, Water, UV

15 14 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) Roto Inks: Solvent or Water Base

16 15 * 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 Comparing Roto and Flexo

17 16 Comparing Roto and Flexo

18 THE LITHOGRAPHIC PRINTING PROCESS Offset Printing

19 18 THEORY OF LITHOGRAPHY NON IMAGE AREA IS WATER LOVING (HYDROPHYLLIC) IMAGE AREA IS WATER REPELLANT (HYDROPHOBIC) LITHOGRAPHIC PLATE

20 19 LITHOGRAPHIC PRINCIPLE LITHOGRAPHIC PLATE Image Non-image Image Water rejecting Water receptive Hydrophobic Hydrophylic Ink receptive Ink rejecting Oleophylic Oleophobic

21 20 Dampening of plate LITHOGRAPHIC PLATE Water on non-image area Dampener Roller

22 21 INKING OF PLATE LITHOGRAPHIC PLATE Ink on image area Water on non-image area Ink roller

23 22 PLATE CYLINDER Dampening Rollers Fountain Solution Inking rollers Plate

24 23 OFFSET LITHO PRESS CONFIGURATION Blanket Cylinder Plate Cylinder Dampening Rollers Fountain Solution Impression Roller Sheet or Web Ink Distribution Rollers (oscillating)

25 24 SHEETFED OFFSET PRESS Impression Blanket PlateInking rollers Dampener

26 25 WEB HEATSET PRESS Impression Blanket PlateInking rollers Dampener Unwind Rewind Oven

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

28 LITTLE JOE PROOFING PRESS

29

30 PRUFBAU PROOFING PRESS

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

32 LITHOGRAPHIC DAMPENING SYSTEMS

33 32 CONVENTIONAL (DUCTOR) DAMPENING SYSTEM Fountain roll Ductor Vibrator Form roll Plate cylinder Fountain solution

34 33 CONTINUOUS-FEED (DALHLGREN) DAMPENING SYSTEM Plate cylinder Fountain solution Metering roll Chrome transfer roll Slip nip Oscillator roll First ink form roll Second ink form roll

35 34 BRUSH DAMPENING SYSTEM Fountain solution Metering roll Brush roll Chrome vibrator roll Ink form rollers Plate cylinder

36 35 DUOTROL DAMPENER Fountain solution Metering roll Chrome vibrator roll Ink form rollers Plate cylinder


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