Professional Documents
Culture Documents
Operating manual
Contents
Introduction 5 Order form 15
16
Engraved roller standardization Visual inspection ............................................... 16 Quality test certificate ....................................... 16 Control proof print ............................................ 16 Sample of an engraved roller data sheet ........ 17
18 19 20
Ink viscosity
10
Standardization ink Means of measurement .................................... 10 Inks for high quality 4-color printing ............... 10
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11
23 24 25
Standardization ink Formula .............................................................. 11 Means of measurement .................................... 11 The following parameters influence the increase in tonal value ............................... 11 Printing characteristic curve ............................. 12 Preparation of a printing characteristic ........... 13
Order form
Speed test
Standardization ink
14
Engraved roller standardization Ordering engraved rollers ................................ 25 Order .................................................................. 25 Doctor order ...................................................... 26 Order .................................................................. 26
Contents
Control circuit for printing form production Main exposure 27 55
Standardization film production Repro specifications for UV flexographic ........ 29 Screen dot form ................................................. 29 Distortion of printing plates in general ........... 32 Distortion of printing plates on Arsoma flexographic machines ...................................... 32 Calculation of cylinder periphery, incl. attached printing plate .............................. 34 Calculation of printing plate distortion ............ 35 Distortion factors ............................................... 36
Drying
Standardization printing plate manufacture
58 59 60 60
42
Chemical after-treatment
Standardization printing plate manufacture
Standardization printing plate manufacture Checklist for checking the printing plate copy 48
49
Standardization printing plate manufacture Optical check ...................................................... 49 Measuring checks .............................................. 49 Copying check .................................................... 49
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50
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Standardization printing plate manufacture Delivery .............................................................. 61 Storage ............................................................... 61 Standardization test form Test printing and demonstration forms .......... 61 Outline of composition of a test printing form 61 Image evaluation ............................................... 62 Technical printing parameters .......................... 63 Test forms .......................................................... 64
66
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Standardization printing plate manufacture Definition ........................................................... 51 Wash-out test ..................................................... 51 Wash-out temperatures .................................... 52
Standardization test form Standard densities ............................................ 66 Means of measurement .................................... 66 Measured value density solid area .................. 66 What can be checked ........................................ 66 Standard densities recommended by Gretag, supplemented for label printing ...................... 67
53
Standardization printing plate manufacture Reverse side pre-exposure test ........................ 53 Washing out the test ......................................... 53
Contents
Increase of tonal value 68
Standardization test form Formula .............................................................. 68 Means of measurement .................................... 68 The following parameters influence the increase in tonal value ............................... 68 Printing characteristic curve ............................. 69 Preparation of a printing characteristic ........... 70
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Introduction Standardization
Meaning of standardization
In the section on standardization we have endeavoured to provide instructions and help for standardization in UV flexographic printing. Of course, it always only represents a general standard for Gallus/Arsoma machines, which require a further fine adaptation depending on customer requirements or applications. The findings described here were prepared within the scope of a UV flexographic project, in close collaboration with market partners. Since these results have been prepared closely related to practice, Gallus is able to offer all UV flexographic printers competent starting assistance. The user can also check and/or improve his method of working with these instructions.
Standardization specifications
Since there are still no standardization specifications for UV flexographic printing, we have used the offset standard as a basis. The offset specifications are certainly no poor criteria, since UV flexographic results are often and favourably compared with offset results. Users will therefore look for an approxima-tion to the offset result with UV flexographic printing. In order to achieve a result comparable to offset, the following points for example are important, which summarise our basic idea: same standard densities same ink quantity on substrate reproduction of same ink space similar increases in tonal values The optimum must be obtained from all the materials available to achieve the ambitious objectives. The results should not be laboratory values, but values which can be reliably reproduced in daily practice.
General
As already described in the introduction, we also firmly base the standardization of the inks on the offset data. Reasons: Offset is the best standardized printing process. UV flexographic printers want to achieve a printing result comparable with offset. UV flexographic is often compared with offset. UV flexographic machines are superseding offset machines. Substantial improvements in UV flexographic materials in the past few years.
Values measured on high-gloss substrate (the values are some 0.10.2 lower on PE with the same plateink-adhesive-substrate combination, since the surface tension of the substrate is different).
Means of measurement
The solid area density is measured with a densitometer in the colors cyan, magenta, yellow and black. Measurement setting: density Secondary colors should not be measured with a densitometer, since this only has filters for the above-mentioned, standard colors. If measurement is nevertheless performed, the results are not valid and can at best be used as points of reference. For secondary colors the filter should be selected for the densitometer which indicates the highest measured value.
Means of measurement
The viscosity of the UV inks cannot be measured with a measuring cup, since the ink is highly viscous. A rotary viscosimeter is required for the purpose. Unit: dPas
10
Means of measurement
The increase in tonal value can be measured with a densitometer. Measurement setting: increase or surface coverage. The increase in tonal value TWZ is found from the difference between the measured screen tonal value in the impression FD and the screen tonal value in the film FF. The screen tonal value in the film must be known, however, or be measured with a transmitted light densitometer in the reproduction. Only the colors cyan, magenta, yellow and black can be measured. The measured value for secondary colors is not valid.
Film exposure (also film density) Dot form Screen width Printing plate: Hardness of printing plate Construction of printing plate Plate copy Resolution of printing plate Swelling behaviour with respect to UV ink Printing adjustment to engraved roller and substrate Ink transfer of printing plate (plate surface) Printing plate base:
Hardness Thickness Reset behaviour Combination with printing plate Substrate: Surface (closed, rough) Absorbency Ink receptivity (also surface tension)
11
80
70 60 50 40 30 20 10 0
12
80
70 60 50 40 30 20 10 0
13
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Order
Ink series: Ink type: Ink no.: Drying process: Pantone no.: Application: Resistance/fastness required:
PMS kg Date: Number of lines: Scoop volume: Supplier: Supplier: Substrate type: Pre-treated: Enclosed: Enclosed:
Substrate:
Printing specimen: The following reference material must be supplied with the ink:
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This test proof is used as a reference impression and is therefore like the fingerprint of a roller. This impression should be measured by densitometer and preserved. An engraved roller data sheet should be opened based on the data measured, on which later modifications, measurements, cleaning and maintenance operations on the engraved roller can be recorded. The engraved roller is therefore always under control. It is then easier to resolve uncertainties and problems while printing, e.g., it can very quickly be decided whether the roller is worn out or only very soiled. The reference impression can be reproduced at any time. The roller can also be continually assigned to another application when worn. An example of an engraved roller data sheet is shown on the next page.
16
1.50
17
The cell diameter of the engraved roller should be smaller for half-tone printing than the smallest screen dot fixable on the printing plate.
18
In this table only the 110% screen tonal values have been taken, since these have the smallest diameter and are more difficult to fix on the plate. E.g., it is already very difficult with the 60s screen to fix a 13% screen dot, depending on the type of printing plate. The table also shows well that if the engraved roller is to support a 2% screen dot in the 60s screen, an engraved roller with min. 360380 lines per centimetre is necessary (see table of cell diameter on engraved roller).
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Samples for engraved roller inventory list / reference list Engraved roller standardization
L/cm 320 320 320 320 300 300 280 280 240 240 160 160 140 100 100 m m3/m2 URMI 2.7 3 3 3 3.5 3.5 4 4 5.5 5.5 7.5 7.5 9 12 14 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 Roller no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Paese/ Cell Supplier Praxair Lightlox Praxair Lightlox Praxair Lightlox Praxair Lightlox Praxair Lightlox Praxair Lightlox Praxair Lightlox Praxair Lightlox Praxair Lightlox Praxair Lightlox Praxair Lightlox Praxair Lightlox Praxair Lightlox Praxair Lightlox Praxair Lightlox Application Screen Screen Screen Screen Screen Screen Screen Screen Type/surface Type/surface Surface Surface Surface/varnish Surface/varnish Surface/varnish
This list can also be used as a reference list for an 8color UV flexographic machine. The specifications generally correspond to the state-of-the-art in 1998. The data can vary somewhat from one engraved roller manufacturer to the next, since the measuring systems of the manufacturers differ in their evaluation. It is recommended to consult a specialist of the engraved roller manufacturer before ordering. It is also recommended to work with the same manufacturer later, so that the same specifications can always be ordered again and the rollers are therefore mutually adapted in application. At present, many engraved roller manufacturers are introducing a new laser technology which permits the production of even finer engraved rollers with very high scoop volumes (e.g., 500 l/cm with approx. 4.0 cm3/m2).
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Order
Machine manufacturer: Machine type: Drawing no.: Number of rollers: Deadline: Roller quality: Roller coating: Roller spigots: Roller specifications: hardened/unhardened Number of lines engraved per cm: Engraving depth: Engraving angle: Scoop volume: Bridge/cell ratio: Field of application of roller: Tolerances: True-running: Scoop volume max. The following data must be supplied with the roller: Quality record with: 0.05 mm +5% photo of engraving measured roller specifications date/signature l/cm or l/inch cm3/m2 1: Pcs.: Date:
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Order
Machine: Number of doctors: Deadline: Doctor blade length: Doctor blade width: Lamella thickness: Lamella grinding angle: Pcs.: Date: mm mm 60
60 Width Lamella Length Doctor quality: Steel hardened/unhardened plastic Doctor blank: exactly to size specified Piece goods
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3. Checking of film and proof print receipts for observance of reproduction specifications and if not observed early detection of expected shortcomings
2. Preparation of unmistakable copying and printing technology specifications from the production sector
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12. Number of colors 13. Color sequence 14. Repeat length 15. Repeat area 16. Number of repeats: longitudinal and lateral repeat 17. Bridge widths: longitudinal/lateral
18. Substrate: width, quality, material 19. Proof / proof print / sample / clean drawing 20. Correct data format 21. Printing plate distortion: flat or circular exposure 22. Copying cylinder diameter 23. Printing machines type etc.
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But no film angle must be at 60. These are: Cyan: Magenta: Yellow: Black: 75 45 90 105
Color sequences 1st sequence 1. Cyan 2. Magenta 3. Yellow 4. Black Ink receptivity problems can sometimes arise when printing magenta and cyan on yellow. Trapping problems can be excluded with this sequence. The black printed at the end provides a good image contrast. A dark color in the 1st printing unit is always good as reference color for the register. 2nd sequence 1. Magenta 2. Yellow 3. Cyan 4. Black The advantage of this sequence is the somewhat warmer pictorial effect and a good image contrast by the black printed last.
60 l/cm 60 l/cm 54 l/cm 44 l/cm 5460 l/cm 5460 l/cm 54 l/cm 48 l/cm 48 L/cm
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This also applies to vignetted screens. Standard densities Refer to test form section Printing characteristic Refer to test form section Overlappings 0.1 mm should be observed for overlappings on good, register-stable substrates. More should be allowed for difficult materials. UCR (Under-Color Reduction) UCR is increasingly used for 4-color flexographic work. It is also ensured that no more than 270% color is superimposed in multi-color printing. Images of this kind can also be obtained with less color variation, since black is used intensively as a contrast color.
order ink distortion factor plate type plate thickness manufacturer operation, etc.
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Printing plate
Printing cylinder
Printing cylinder diameter, incl. printing plate and plate adhesive tape
= 121,367 mm
Calculation of printing cylinder periphery Printing cylinder diameter x = cylinder periphery Example: 121,367 mm x (3,1415927 mm) = 381,314 mm
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Repeat length distortion factor = corrected film length Example: 381.000 mm (Z-120) 9.08 mm (plate 1.70 mm) = 371.920 mm or distorted film in %: 371.920 mm x 100 : 381.000 mm = 97.617% This calculation theoretically includes practically all the factors which can influence the distortion of the printing plates. The effects of printing plates with printing parts of different size have not been considered. Nor can these be calculated during film and plate production.
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40
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3,175
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45
46
3,175
47
3. 4.
5. 6.
7.
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Copying check
Every new plate batch should be retested. The first quick check is preferable performed with a line job, in which little can normally go wrong and the printing plate can be used without difficulty following the test. The printing plate is copied under the same conditions as for the old batch. A test wedge (e.g., Stouffer wedge) is copied at the same time. The relief height is checked.
Measuring checks
This includes checking the thickness of the raw plates supplied with a thickness measuring unit. The differences must not exceed 0.02 mm within the raw plate format.
If nothing has changed compared with the last plate batch, the plate copy is in order. If major changes are found, the printing plates should be retested. In extreme cases the plate manufacturer should be contacted.
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Finer gradations of passage times can also be used for a 2nd fine setting. 4. The plate pieces are dried for approx. 15 mins. (this drying time only applies to the test). 5. After drying, the thickness is measured at the places washed out. The wash-out depth is obtained from the difference from the reference thickness.
Wash-out test
1. Cut out four plate pieces not exposed on the reverse side, approx. 15 x 20 cm. 2. A small cover plate is placed on each piece of raw plate and the whole area exposed for 10 mins. in the exposure unit. (Image on top) 3. The plate pieces are then washed out with different processing times in the continuous flow washout unit.
Example: Reference thickness washed-out position wash-out depth determined 1700 1000 700
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Example: for required relief depth: correct wash-out depth: 0.7 mm 0.9 mm
Wash-out temperatures
All manufacturers of printing plates supply wash-out agents. They can be used in part for various types of plate from different plate manufacturers. PER/n butanol Nylosolv II Optisol Flexosol 30 C 30 C 2830 C 2830 C
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1st exposure
3rd exposure
2nd exposure
The times for reverse side exposure and wash-out must always be mutually adapted, so that wash-out takes place down to the polymerized base. The reason for the recommended additional time for 0.2 mm extra relief depth is as follows: A transition phase in which the material is partly polymerized takes place between the lower part of the coating polymerized by reverse side pre-exposure and the non-polymerized upper part. This partially polymerized material should be largely washed out, so that the relief platform and base are in a fully polymerized zone. Since this material is detached more slowly, however, it is necessary to prolong the wash-out time.
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Main exposure
1st exposure +2 mins. plate plate test film covering board
After switching on the vacuum pump, the vacuum foil is rolled evenly over the printing plate. The vacuum foil is rubbed on with a roller or an antistatic cloth to prevent the formation of air pockets. This also makes unevenness visible, owing to dust or dirt which must be removed without fail to prevent copying errors. 4. The main exposure time is then determined with a multi-stage test like the reverse side exposure (diagram on following page).
3rd exposure +2 mins. Example: Expose 8 labels for 2 mins. Expose the 1st label, cover the other 7. Expose the 2nd label, cover the other 6. Expose the 3rd label, cover the other 5, 4th exposure +2 mins. etc. When all 8 labels have been exposed, the 1st label is exposed 16 minutes and the 8th label 2 mins. The times stated here are only rough guides. When the approximate main exposure time has been determined after washing-out the plate, a 2nd test can be exposed with a finer gradation. etc. 5. The exposed printing plate is washed out and dried. It should then be evaluated. The correct exposure time can be recognised from the varied formation of the relief.
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Main exposure
The following factors can influence the exposure time: Power of fluorescent tubes Number of fluorescent tubes Transparency of vacuum cloth Caution: Only original films should be used for the exposure test! The times near the upper exposure limit should always be selected for plate production. This ensures that the plate is fully polymerized to obtain the following advantages: Optimum plate hardness Good elasticity Resistance to solvent Resistance to cracking
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Delivery and storage of copied printing plates Standardization printing plate manufacture
Delivery
The printing plates should be supplied as follows: Always laid flat In a cardboard box larger than the plates The soft, white, foamed protective foil of the original packing should be placed between the plates Clean Cut ready to size
Storage
The copied printing plates should be stored like raw plates. The plates should be cleaned and dried before putting into store. The relief layers of the plates should not lie together, but backing foil to backing foil. A soft protective foil should be placed between the relief layers. Caution: Following storage for over 3 months the plate thickness decreases by approx. 1015 m. Old and newly copied printing plates should not therefore be used together for a printing job with difficult registers.
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Image evaluation
Before starting with the technical measuring parameters, the image evaluation must first be considered. We are less concerned with the purpose of use or gradation for reproduction, but more with recognition of technical printing degrees of difficulty. The fine, colored images make the biggest impression. These are also gladly shown very often by most machine manufacturers. Not only because they are beautiful, but mainly because they scarcely show coloring differences. The agreement of original and impression is or would be the measure of quality. The eye is unfortunately not very fair when comparing performance. Every picture consists of more than one hue. If the eye looks at more than one hue simultaneously, it is automatically influenced by their differences. These differences are called contrast. There are combinations of contrasts in every picture: light-dark contrast color contrast formal contrast The more complementary colors meet, the greater the contrast. Since the eye adjusts to existing contrasts, it is not objective with respect to color differences. The stronger the contrast, the less are color variations detected. But despite all this, we are more sensitive to color balance changes than to the picture gradation or contrast magnitudes.
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Class 0 Homogenous, three-color areas. Can scarcely be printed without aberration. Class 1 Pictures with minimum contrasts, mainly compris-ing grey and brown hues. These also include large area skin images. Class 2 Pictures with normal contrasts. These are the majority of pictures. Class 3 Pictures with strong color contrasts.
We should now be able to evaluate pictures or printing samples for their expressive power.
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Values measured on high-gloss substrate (the values on PE are approx. 0.10.2 lower with the same combination of plate, ink, adhesive and substrate. Reason: different surface tension of substrate).
Means of measurement
The solid area density is measured with a densitometer in the colors cyan, magenta, yellow and black. Measurement setting: density Secondary colors should not be measured with a densitometer, since this only has filters for the standard colors listed above. If measurement is nevertheless made, the results are not valid and can at best be used as points of reference. For secondary colors the filter should be selected for the densitometer which indicates the highest measured value.
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The densities in yellow are measured with the 47 B filter. This table is provided as a supplement to and as an overall review of the foregoing table.
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Means of measurement
The increase in tonal value can be measured with a densitometer. Measurement setting: increase or surface coverage The increase in tonal value TWZ is found from the difference between the measured half-tone value in the impression FD and the half-tone value in the film FF. The half-tone value in the film must be known, however, or measured with a transmitted light densitometer in the reproduction. Only the colors cyan, magenta, yellow and black can be measured. The measured value for secondary colors is not valid.
Hardness Thickness Reset behaviour Combination with printing plate Substrate: Surface (closed, rough) Absorbency Ink receptivity (also surface tension)
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80
70 60 50 40 30 20 10 0
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80
70 60 50 40 30 20 10 0
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Machine
Solid area densities flexographic printing Cyan AVT 1,451,60 Magenta AVT 1,401,50 Yellow AVT 1,351,45 Black AVT 1,601,80
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Printing plates + adhesive foils determined from best recommendation or from test
Machine
Solid area densities flexographic printing Cyan AVT 1,451,60 Magenta AVT 1,401,50 Yellow AVT 1,351,45 Black AVT 1,601,80
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TESA
Softprint
52380
Half-tone printing Half-tone printing All-round foil Can be used several times mixed printing forms Surface printing Used with multi-coated printing plates Mounting of printing Plates on sleeve cylinder Half-tone printing Half-tone printing Half-tone printing Half-tone printing All-round foil Foil printing Can be used several times mixed printing forms All-round foil Can be used several times mixed printing forms Half-tone printing Can be used several times Half-tone printing All-round foil Can be used several times mixed printing forms
Printout in surface printing, usable 1 x Shows unevenness of substrate in image More tonal value increase
TESA
Tesaprint
52338
0,38
1,70
Foil printing
TESA
Tesaprint
52916
0,1
Labels Foil printing Labels Foil printing Labels Foil printing Labels
3M
1115
0,38
Printout in surface printing, usable 1 x Shows unevenness of substrate in image Printout in surface printing, usable 1 x Shows unevenness of substrate in image Greater increase in tonal value
3M
1120
0,50
1,70 1,14
3M
1015
0,38
1,70
3M
1020
0,50
1,70
Folding cartons
Greater increase in tonal value Printout in surface printing, Shows unevenness of substrate in image Not suitable for all 1.14 mm plates
Harley
green
0,38
1,70 1,14
Rogers
R/back
0,95
1,14
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