1

OFFSET

ROTOGRAVURE

FLEXO

Available Print Process

2

The End Result

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

MINUSENGRAVED CYLINDER

IMPRESSION ROLL

DOCTORBLADE

WEB

INK

Rotogravure

4

WEBBLANKETCYLINDER

PLATECYLINDERDAMPING

TRAIN

INK TRAIN

IMPRESSIONCYLINDER

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

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

6

2. Composition and Chemistry

- Oil base

- Solvent Base

- Water Base

- Radiation Cure

1.Physical Form

- Liquid

- Paste

Ink Types

7

WATER(65%)

Wet Ink2#/Ream

Dry Ink.7#/Ream

1.3#/Ream

.1#/Ream

.2#/ReamSOLUTIONRESIN (10%)

EMULSIONRESIN (10%)

ADDITIVES (5%)

PIGMENT (10%) .2#/Ream

.2#/Ream

TYPICAL PROPERTIESViscosity 50-100 centipoiseSolids 35%Tack Very lowDrying Absorption/evaporationTrap Wet on dryCure ImmediateVOC < 1% by wt.Odor Very lowCost OK

•FLEXO

•GRAVURE

Ink Formulation – Water Base

8

SOLVENT(65%)

80% ALCOHOL

20% ACETATEWet Ink2#/Ream

Dry Ink.7#/Ream

POLYAMIDERESIN (10%)

NITROCELLULOSERESIN (10%)

ADDITIVES (5%)

PIGMENT (10%)

1.3#/Ream

.1#/Ream

.2#/Ream

.2#/Ream

.2#/Ream

TYPICAL PROPERTIESViscosity 50-100 cpsSolids 35%Tack Very lowDrying Absorption/evaporationTrap Wet on dryCure ImmediateVOC 65% by wtOdor LowCost OK

•FLEXO

•GRAVURE

Ink Formulation – Solvent Base

9

ADDITIVES (5%)

SOLVENT(30%)

ACRYLATE MONOMER

Wet Ink2#/Ream

Dry Ink

ACRYLATEPREPOLYMER (55%)

PIGMENT (10%)

.6#/Ream

1.1#/Ream

.2#/Ream

.1#/Ream

TYPICAL PROPERTIES

Viscosity 10-200 poiseSolids 97%Tack Moderate to very highDrying Free radical cureTrap Wet on Wet, or Wet on DryCure ImmediateVOC <3% Odor ModerateCost High

•FLEXO

• LITHO

ADDITIVES (5%)

Ink Formulation - UV

10

Viscosity 100-200 poiseSolids 90%Tack Very highDrying Absorption/ oxidationTrap Wet on WetCure OvernightVOC 10% Odor ModerateCost OK

PIGMENT (10%)

QUICKSET RESIN 75%

DRIERS/WAX 5%

DISTILLATE 10%

.2#/Ream

1.5#/Ream

.1#/Ream

.2#/Ream

Dry Ink1.8#Ream

• LITHO

Ink Formulation – Oil Ink

11

OFFSET

ROTOGRAVURE

FLEXO

Ink-Substrate Interface

12

steel blanket cylinder

substrate

ink

High viscosity ink and planographic image carrier1. Low dot gain2. Uneven solid areas (limited impression)3. Weak metallic inks (limited ink film)

Litho Inks – Oil Base or UV

13

steel plate cylinder

substrate

plate ink

Low visc ink and raised, resilient image carrier1. Dot gain very impression dependent2. Smooth solid areas, even on rough stock 3. Strong metallic inks

Flexo Inks: Solvent, Water, UV

14

Low viscosity ink and recessed cells image carrier1. Low dot gain2. Uneven solid areas (limited impression)3. Very sensitive to rough stock (skip outs)

steel base

substrate

ink

Roto Inks: Solvent or Water Base

15

ENGRAVED CYLINDER

IMPRESSION ROLL

ROTO

PLATE

CYLINDER

ENCLOSED INK

CHAMBER

ANILOX

CI DRUM

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

Comparing Roto and Flexo

16

WEBFLEXO

PLATE

IMPRESSION ROLL

ENCLOSED INK

CHAMBER

ANILOX

WEBBLANKETCYLINDER

PLATECYLINDERDAMPING

TRAIN

INK TRAIN

IMPRESSIONCYLINDER

LITHO

Comparing Roto and Flexo

THE LITHOGRAPHIC PRINTING PROCESS

Offset Printing

18

THEORY OF LITHOGRAPHY

NON IMAGE AREA IS WATERLOVING (HYDROPHYLLIC)

IMAGE AREA IS WATERREPELLANT (HYDROPHOBIC)

LITHOGRAPHIC PLATE

19

LITHOGRAPHIC PRINCIPLE

LITHOGRAPHIC PLATE

ImageNon-image

Image

Water rejecting Water rejecting

Water receptiveHydrophobic Hydrophobic

Hydrophylic

Ink receptiveInk receptive

Ink rejectingOleophylic

Oleophylic

Oleophobic

20

Dampening of plate

LITHOGRAPHIC PLATE

Water onnon-image

area

Dampener Roller

21

INKING OF PLATE

LITHOGRAPHIC PLATE

Ink onimage area

Water onnon-image

area

Ink roller

22

PLATE CYLINDER

DampeningRollers

Fountain Solution

Inking rollers

Plate

23

OFFSET LITHO PRESS CONFIGURATION

BlanketCylinder

Plate Cylinder

DampeningRollers

Fountain Solution

ImpressionRoller

Sheet orWeb

Ink Distribution Rollers(oscillating)

24

SHEETFED OFFSET PRESS

Impression

Blanket

Plate Inking rollers

Dampener

25

WEB HEATSET PRESS

Impression

Blanket

Plate Inking rollers

Dampener

Unwind

Rewind

Oven

OFFSET PROOFING

Blanket roller picks up ink from plate Transfers it to substrate

Plate Substrate

Plate is inked up by a hand roller

Difficult to accurately control ink film thicknessfrom hand roller to plate. This will cause somevariation when transfering to substrate.

LITTLE JOE PROOFING PRESS

LITTLE JOE PROOFING PRESS

PRUFBAU PROOFING PRESS

PRUFBAU INKING MECHANISM

Distribution roller Blanket roller

Blanket roller

Back roller oscillating to distribute ink evenly

LITHOGRAPHIC DAMPENING SYSTEMS

32

CONVENTIONAL (DUCTOR) DAMPENING SYSTEM

Fountain roll

Ductor

VibratorForm roll

Form roll

Platecylinder

Fountain solution

33

CONTINUOUS-FEED (DALHLGREN) DAMPENING SYSTEM

Platecylinder

Fountain solution

Metering roll

Chrome transfer roll

Slip nip

Oscillator roll

First ink form roll

Second ink form roll

34

BRUSH DAMPENING SYSTEM

Fountain solution

Meteringroll

Brush roll

Chrome vibrator roll

Ink form rollers

Platecylinder

35

DUOTROL DAMPENER

Fountain solution

Meteringroll

Chrome vibrator roll

Ink form rollers

Platecylinder