Challenges of High Quality Flexo Printing Sector Group
- Slides: 35
Challenges of High Quality Flexo Printing Sector Group Printing Inks German Paint and Printing Ink Association (Vd. L)
Contents General Information on High Quality Flexo Printing & Printing Inks High Quality Flexo Printing & Printing Plate Exposer High Quality Flexo Printing & Anilox Rollers Other Quality related Factors Summary drupa 2016 Slide 2
Contents General Information on High Quality Flexo Printing & Printing Inks High Quality Flexo Printing & Printing Plate Exposer High Quality Flexo Printing & Anilox Rollers Other Quality related Factors Summary drupa 2016 Slide 3
What „High Quality“ means to Flexo Printing • It is the future of flexo printing. • The future development of flexo printing has been frequently discussed in the past. Since then, the available technologies have evolved considerably. • On the one hand the quality of image illustration has improved. On the other hand the ongoing development of printing inks lead to a quality level which lives up to classical gravure and offset printing qualities. • It’s all about the application profile. On top to the general requirements for the printing inks used in flexo printing, some special adaptations of the printing inks are necessary to enable high quality flexo printing. drupa 2016 Slide 4
High Quality Flexo Printing – It‘s all in the Mix High quality flexo printing is a technological development based on the combination of… • … 4. 000 dpi high resolution optics, • …Round Top Dot (RTD) or Flat Top Dot (FTD) technologies and • …Microcell screening technology for solid tone areas. drupa 2016 Slide 5
The Advantages of High Quality Flexo Printing • Perfect illustration of finest tonal values and color spreading in flexo printing. • Practically zero unwanted spreading. • Clean print result on both negative and positive text motives. • Minor dot bridging • Improved layers of printing inks • High color densities at reduced film thicknesses drupa 2016 Slide 6
The Interaction of High Quality Technologies The printing ink shows the interaction of high quality technologies ! Reproduction + Plate Technology Ink Technology Operator + Flexographic printing press + drupa 2016 Setup Plateadapter + Mounting- tape High Quality Flexo! Image source: Flint Group / Sun Chemical Doctor blades + Anilox roller Slide 7
High Quality Flexo Printing Image source: Flint Group Examples for a good and bad print result ? ? Image source: Sun Chemical drupa 2016 Slide 8
Contents General Information on High Quality Flexo Printing & Printing Inks High Quality Flexo Printing & Printing Plate Exposer High Quality Flexo Printing & Anilox Rollers Other Quality related Factors Summary drupa 2016 Slide 9
High Quality Flexo Printing – Relevant Parameters for the Printing Ink • Color strength • Flowability of printing ink • Drying speed • Performance characteristics drupa 2016 Slide 10
High Quality Flexo Printing- Screen Rulings • 3 34 L/cm 44 L/cm 54 L/cm 70 L/cm drupa 2016 Image source: Siegwerk Slide 11
High Quality Flexo Printing and Printing Inks How to meet the Requirements? Reduction of ink tranfer and adjustment of drying speed anilox roller L/cm cell volume anilox roller cm³/m² amount of ink transferred g/m² dry design selection colors (screen / solid) white 500 2, 9 0, 3 HQ Flexo 400 5, 0 0, 5 Process screen 300 7, 5 0, 7 screen / solid 220 9, 0 0, 9 screen/ solid / white 140 12, 0 1, 2 white gravure standard 1, 2 Image source: Siegwerk drupa 2016 Slide 12
Printing Inks - Impact of Low Ink Transfer 12 cm³/m² 9 cm³/m² 7, 5 cm³/m² 2, 9 cm³/m² Image source: Siegwerk drupa 2016 Slide 13
High Quality Flexo Printing – Printing Ink Requirements • Higher color strength • Optimized flowability • Slow drying speed • Adaption of performance characteristics (e. g. rub off resistance) drupa 2016 Slide 14
Contents General Information on High Quality Flexo Printing & Printing Inks High Quality Flexo Printing & Printing Plate Exposer High Quality Flexo Printing & Anilox Rollers Other Quality related Factors Summary drupa 2016 Slide 15
Precise Reproduction - 1: 1 Copy O 2 O 2 UV UV Digitally imaged LAMS layer e. g. nyloflex® NEx. T O 2 O 2 O 2 1: 1 copy Image source: Flint Group drupa 2016 Slide 16
High Resolution improves Reproduction Quality Image source: Flint Group 2 % highlight dots at 2540 dpi 2 % highlight dots at 4000 dpi A higher image resolution improves the image contrast due to additional gray scales. It can also improve the dot definition. drupa 2016 Slide 17
Surface Screening – Ink Laydown Solid tone areas show improved ink laydown by using Microcell screening technology Image source: Flint Group Solid tone area without screening drupa 2016 Solid tone area with screening Slide 18
Surface Screening – Ink Laydown Solid tone areas show improved ink laydown by using Microcell screening technology Image source: Flint Group Solid tone area without screening drupa 2016 Solid tone area with screening Slide 19
Examples of possible High Quality Workflows • Flint Group nyloflex® NEx. T • Kodak • Mac. Dermid LUX ® • Du. Pont • Esko drupa 2016 KODAK FLEXCEL NX Cyrel® Digi. Flow Inline - UV Slide 20
Contents General Information on High Quality Flexo Printing & Printing Inks High Quality Flexo Printing & Printing Plate Exposer High Quality Flexo Printing & Anilox Rollers Other Quality related Factors Summary drupa 2016 Slide 21
High Quality Flexo Printing – Requirements for Anilox Rollers • Reduction of ink volume • Fine engraving to be fit for 70 L/cm process screening • Optimized emptying behavior drupa 2016 Slide 22
High Quality Flexo Printing – Cell Structures of Anilox Rollers • Hex pattern 60° • Long Cell structure • Slalom Ink Channel structure drupa 2016 Slide 23
Anilox Rollers - Hex Pattern 60° Image source: Jörg Rohde, Kurt Zecher Gmb. H Usable for high quality flexo printing < 5 cm³ volume drupa 2016 Slide 24
Anilox Rollers - Long Cell Patterns Image source: Jörg Rohde, Kurt Zecher Gmb. H Usable for high quality flexo printing < 5 cm³ volume drupa 2016 Slide 25
Image source: Jeanine Graat , Apex Europe B. V. Anilox Rollers - Slalom Ink Channels Usable for high quality flexo printing < 5 cm³ volume drupa 2016 Slide 26
High Quality Flexo Printing – Anilox Rollers Requirements Anilox rollers have to be adjusted for high quality flexo printing Image source: Siegwerk drupa 2016 Slide 27
Anilox Rollers - Screen Resolution on Flexo Printing HQ screen 70 L/cm dot size dot size Tone 10% 4% 3% 2% 1% HQ Flexo 52µm 32µm 29µm 23µm 16µm Anilox Cup Size 500 17µm 17µm 450 20µm 20µm 400 23µm 23µm 340 26µm 26µm Smallest printing dot must be bigger than the cup of the anilox roller! drupa 2016 Slide 28
Contents General Information on High Quality Flexoprinting High Quality Flexo Printing & Printing Inks High Quality Flexo Printing & Printing Plate Exposer High Quality Flexo Printing & Anilox Rollers Other Quality related Factors Summary drupa 2016 Slide 29
Further Quality Factors of High Quality Flexo Printing Mounting tape and Plate adapter Reproduction Doctor blade Elastomer-sleeve Process- Operator Flexo printing press Images: Sun Chemical / Windmöller & Hölscher KG drupa 2016 Slide 30
Contents General Information on High Quality Flexoprinting & Printing Inks High Quality Flexoprinting & Printing Plate Exposer High Quality Flexoprinting & Anilox Rollers Other Quality related Factors Summary drupa 2016 Slide 31
Summary Positive print results Image source: Sun Chemical drupa 2016 Slide 32
Summary Positive print results Image source: Flint Group drupa 2016 Slide 33
Summary • If all parameters are perfectly matched, an optimal print result on high quality flexo printing can be achieved. • High quality flexo printing offers opportunities for the packaging printing market… o. . . to achieve similar high quality printing results as gravure printing or offset printing. o. . . to develop new markets or strengthen existing business for brand owners and customers with very high quality requirements. o. . . to meet the higher quality standards in this market segment. drupa 2016 Slide 34
Thank you for your attention! Sector Group Printing Inks German Paint and Printing Ink Association Mainzer Landstraße 55 60329 Frankfurt am Main Germany Phone: E-Mail: Web: © Sector Group Printing Inks of the German Paint and Printing Ink Association (Vd. L) +49 69 2556 -1411 vdl@vci. de www. druckfarben-vdl. de Image source front page: https: //de. fotolia. com
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