Category: Blogs

Doctor Blade Metering: The What and How of Ink Metering

Tony Donato, author of “Doctor Blade Metering: The What and How of Ink Metering” (2014), brought a blend of mechanical engineering and business expertise to the printing industry, that still resonates today. With degrees from Purdue and Winthrop University, Donato has navigated roles from Application Engineer at Benton Graphics to Product Development Engineer at Harper Corporation of America, leveraging his background to contribute significantly to the field.

Take a deep dive into doctor blade metering with Tony Donato’s presentation. Differentiate between forward and reverse doctoring, brush up on ink metering terms that can drastically affect your print quality, and understand the importance of doctor blade stiffness and thickness when it comes to metering.
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Flexo Paves the Way for Digital Package Printing
In today’s fast-changing, on-demand marketplace, the economic benefits and flexibility of digital printing technology cannot (and should not) be disputed. These presses are “on their feet” with minimal set-up required, empowering them to produce short runs and customized work with fast turnaround times. The computerized process delivers perfectly aligned images with crisp edges and no color overlapping. Traditional flexo technology, on the other hand, is fast, cost-effective for large runs, versatile with regard to substrate options, and offers numerous choices for decoration. While each printing method has its strengths, the possibilities increase exponentially when the two are used together.

Flexo printing

In a mechanical process like flexo printing, an anilox roll, metered by a doctor blade, delivers ink to the substrate by way of a printing plate. How the anilox roll and doctor blade interact has a large impact on the quality of the finished print. Factors such as anilox cell configuration, doctor blade material and tip, and dyne levels of the components throughout the ink delivery system play key roles.

Digital printing

Digital printing presses deliver an electronic image directly to the media using either inkjet or electrophotographic technology. In digital inkjet presses, the ink is delivered through a print head and jetted onto the substrate in an on-demand or continuous basis. The inks are engineered with lo w viscosity formulations, to prevent clogging of the print head nozzles, and specific adhesion properties to control dot spread and image quality.

Electrophotography, or laser printing, technology uses electrostatic energy to apply charged wet (HP Indigo) or dry (Xeikon) toner particles to the substrate. Electrical charges attract or repel the particles from the areas to be printed. The particles are then permanently adhered or “fused” using heat, pressure, light or a combination.

Applying digital printing technology to packaging

As the demand for customization and shorter runs crosses into the flexo packaging industry, there are obvious benefits to adopting digital printing. But there are disparities that have to be overcome. The two printing processes require different ink characteristics in order to execute a clean replication of the image in print, for example. Also, consumer packaging substrates have to meet requirements such as strength, barrier and resistance while holding up to print, finishing and conversion.

Digital inks and toners are not always compatible with packaging substrates such as labels, plastic film, folding carton and corrugated board. The heat used to fix dry toner to the substrate can dehydrate the media. When it comes to wet toner, ink wetting, or how the toner droplets interact with the surface of the substrate, has to be precise. If wetting is too low, the ink droplets spread too little, and the printed image contains gaps that appear as lines or bands in the image. If wetting is too high, the droplets merge with one another and the image loses edge definition. When applied to a substrate such as paper or board, the ink or toner can penetrate the material, leaving less on the surface and reducing color strength. With non-porous substrates, such as plastic and metallic films, the ink or toner tends to sit on top and not adhere properly to the material. This printed surface is left vulnerable to rubbing and scratching.

Primers, varnishes and special effects coatings

Digital converters can use flexo technology to apply layers of coating to bridge the gap between packaging substrates and digital inks or add embellishment.

Primers

To prepare materials – both paper and plastics – for digital printing, a “priming layer” is applied to the surface of the substrate to improve its adhesion properties and make it more receptive to ink or toner. Primers fix surface tension to improve adhesion and hold-out, reduce bleed and mottle, and provide a foundation for specialty coatings. Primed surfaces can support higher-quality graphics with sharper images and more vibrant colors. A coating of primer also seals the substrate for a consistent, finished look and enables faster drying.

Priming solutions are formulated based on the properties of both the substrate and the ink and can be applied inline, offline or by the supplier before the stock arrives in the pressroom. Equipment producers and consumables suppliers are working together to simplify this process. Some press manufacturers, such as HP, are providing inline priming units to optimize the performance of their equipment. Ink companies are engineering formulas for specific use with primers, and materials producers are innovating substrates suited to digital printing.

Varnishes (protective coatings)

We know that digital printing technology is capable of transferring a high-quality image and that substrates can be treated to “accept” the image flawlessly. However, digital inks are not as resistant as flexo inks, and digitally-printed surfaces are vulnerable to dirt, smudges, fingerprints, rubbing, scratching, scuff, moisture, heat and other damage from their environment.

A transparent layer of coating can be applied post-print to “seal” the image and protect it during transporting, storing and handling. Also known as overprint varnishes (OPVs), protective coatings are essentially transparent layers of solutions consisting of durable resins, anti-scuff agents and other additives applied in-line or offline. Flood coating is applied to the full sheet to protect the surface from damage, add a creative dimension or create a desired look or finish. Spot coatings can be used to bring shine and depth to certain areas of the design. Protective coatings can also help maintain the integrity of substrates – such as to prevent curling – and are best applied on top of primed stocks whose surfaces support the top-coat and prevent absorption.

Special effects coatings

In recent years, consumer packaging has taken on the role of marketing in addition to containing, protecting and describing what’s inside. Manufacturers look for ways to differentiate their brands and improve the shelf-appeal of their products over competitors’. A large variety of special effect coatings can be used to add tactical, visual or olfactory dimensions to packaging and improve sales:

Glitter Iridescent Crackle

Soft-touch Gloss Scratch-off

Pearlescent Matte Grit

Sand Frost Scent

Metallic Glow-in-the-dark Satin

Texture Thermochromic Dull

Coating formulas

Aqueous – or water-based – coatings are the most common, economical and eco-friendly option. They are available in gloss or matte finishes and can only be used in flood applications. Aqueous coatings can be applied in-line and are dried using hot air and infrared dryers. Aqueous coatings provide good abrasion and rub resistance, prevent yellowing and protect metallic inks from tarnishing. They are generally safer to utilize with safer clean-up as well and more easily recycled in municipal waste systems.

UV coatings, a more expensive option, can also be applied in-line and offer additional protection and dramatic decorative appeal. They are cured through exposure to ultraviolet light and typically contain components to limit yellowing, cracking, scuffing and peeling over time. UV coatings are available in gloss, matte or tinted finishes and can be used to cover the entire sheet or to highlight certain areas of the design (known as spot coating).

Selecting a coating formula

When selecting a coating formula, there are several factors that should be considered according to Kurt Hudson, an independent consultant to the printing industry and founder of Solutions Logic. “More times than not, the question is – ‘What is the object to be coated, in what environment will it need to be used, what are the specific requirements for the printed product to be effective in the end use environment, and what is the cheapest way to get there?’” Generally, Hudson believes the packaging use should drive the decision: “If one is producing for direct contact food packaging, then aqueous is the only choice. If one needs exterior durability, then UV is the only choice.” Beyond that, he suggests using cost as a guideline: “One uses UV coatings when aqueous products can no longer provide the required benefits,” said Hudson. He believes that look or feel is rarely the deciding factor as good mattes, textures and gloss can be achieved with aqueous and UV (with the exception of 3D tactile which requires a UV formula). He acknowledges that sometimes, but not often, productivity, ease of use and residual odor are considerations.

Coating application

The application of primer, protective coatings and special effects coatings is done via a flexo process which uses an anilox roll and doctor blade. The application of these formulas can be challenging and using the right doctor blade will have a big impact on quality and efficiency.

Primers and special effects coating formulas tend to have high viscosities – up to 5-7 times that of water and solvent-based ink formulas – or contain large particulates which can make it difficult for the printer to accurately control the amount being applied. The mass of the highly-viscous coating applies extra pressure to a steel metering blade as the anilox roll turns, especially at high press speeds. The result is hydroplaning or “spitting,” which wastes materials and requires downtime for clean-up. A customized blade product with sufficient stiffness and abrasion-resistance is recommended to control the lay-down of coating and prevent spitting.

TruPoint Orange® doctor blade with MicroTip®

The harsh chemical compositions of the viscous and abrasive coating formulas described above, along with the coarse anilox surfaces required to deliver them, quickly wear out steel doctor blades. In these applications, a blade constructed from a durable material that can stand up to the rigorous coating properties is necessary. By engineering a modified lamella tip, known as a “MicroTip”, on an advanced polymer material, Flexo Concepts has created an innovative plastic blade solution – TruPoint Orange – that has proven valuable in the application of priming and coating. The blade is compatible with all coating formulas, safe for anilox rolls and press operators, and does what plastic blades are known to do best: last longer.

TruPoint Orange blades can be engineered to a full range of size and profile combinations to optimize metering performance with higher viscosity and large particulate formulas. They range in thickness from .027”/.7mm to .050”/1.25mm to offer varying degrees of stiffness, rigidity and deflection. These properties combined with the innovative MicroTip edge allow the blades to achieve a fine contact area with the anilox roll and deliver a fluid transfer of coating to the plate with no spitting or slinging – even at high press speeds. With a range of MicroTip options (M10, M15 and M25), the blades can be customized for a “perfect fit.”

Doctor blade optimization

The choice of blade thickness and tip will be determined by the anilox configuration, which is driven by the viscosity and solid load of the coating. Typically, higher line screens and lower cell volumes will require a smaller MicroTip (an M10 or M15 for dull/satin/gloss coatings for example). But, as line screens decline and volumes increase, a MicroTip providing a larger contact area (M15 or M25) will perform better. By selecting the appropriate MicroTip for a particular application, printers are able to achieve longer blade life than with steel blades.

OEMs supporting TruPoint Orange

A number of digital finishing and hybrid press producers have found that their press productivity and output quality are optimized when using a TruPoint Orange doctor blade:

A B Graphic International

AzTech Converting Systems

Bar Graphic Machinery

Cartes Srl

Focus Label Machinery

Gonderflex International

Grafisk Maskinfabrik

Mark Andy

REFINE Finishing

Wenzhou Ryguan Machinery

Many of these manufacturers have chosen Orange to demonstrate the effectiveness of their equipment at Labelexpo shows worldwide, and a number are shipping their equipment standard with the blade.

Summary

As the package printing sector continues to embrace customization and personalization, combining the power of flexo and the versatility of digital will deliver strong competitive advantage to the converter. The use of primers, varnishes and special effects coatings aligns the two processes, bringing efficiencies and almost unlimited design possibilities to the pressroom. Industry suppliers have rallied to support this evolution; manufacturers have introduced new innovations ranging from hybrid presses, new substrates, state-of-the-art coating formulas and an advanced polymer doctor blade called TruPoint Orange with MicroTip edge technology.
Plastic Doctor Blade Materials Are Way Better Than Steel

Market pressures continue to challenge the printing industry to deliver products that differentiate and delight. Doctor blade manufacturers have stepped up, introducing plastic blade technology that offers a viable alternative to steel and delivers a competitive edge. Here are some of the reasons that plastic doctor blade materials are way better than steel.

Safety

Steel blades cause a lot of pressroom injuries. Press operators put themselves at risk of being cut anytime they’re handling steel blades, but never more than when they are removing them from the press. The blades’ edges become honed as they wear, leaving razor-sharp tips.

By comparison, the properties of polymer materials prevent plastic blades from ever developing dangerous cutting edges. Even when worn, plastic blades are never sharp enough to injure press operators. Switching from steel to plastic blades will reduce lost-time accidents and save a printer a lot of money in workman’s compensation expenses, medical bills, labor replacement costs and press downtime.

Performance

While safety is the hallmark of a plastic doctor blade, in the past, printers sometimes had to forego this benefit for the wiping capability of steel. Traditional plastic blades needed thickness to provide rigidity. They were unable to achieve a fine area of contact with the anilox roll in high-graphics applications, and steel blades were the only option.

But now, next-generation polymer materials and innovative tip technology can be combined to provide stiffness at thinner gauges. As a result, today’s plastic blades are able to maintain a fine contact area with the anilox roll and deliver metering performance on par with steel. The lower surface tension of polymers also facilitates an easier transfer of ink or coating to the plate. These properties enable plastic blades to resolve many press issues – such as UV spitting – that are commonly experienced with steel blades.

Durability

Plastic blades are durable and last longer than steel. The material is incredibly tough and stands up to abrasive chemistries like high titanium white inks and special effects coatings. The blade material is also self-lubricating with a low coefficient of friction to resist mechanical wear. Reducing the frequency of blade changes with plastic blades means presses can run longer without interruption.

Cost-Effectiveness

Plastic materials protect anilox rolls. Installing steel blades incorrectly or with too much pressure can cause fragments of metal to break away and destroy rows of anilox cells as the roll turns. Plus, the friction between a steel blade and anilox surface can erode cell walls. In either case, anilox damage leads to print defects, waste and significant costs to repair or replace the roll. Plastic blade materials, on the other hand, are non-abrasive. In the same way they will not cause injuries to operators, they will never damage rolls or cause premature anilox wear.

Sustainability

Last, but not least, using plastic doctor blades reduces a printer’s carbon footprint. Today’s next-generation polymer blade developers strive to create products that help their customers achieve their sustainability goals. Many new polymerizing methods use recaptured carbon monoxide (often from steel mills!), preventing the release of CO2 into the atmosphere. The process of producing plastic is much less energy-intensive than steel, emits less greenhouse gases, and has a smaller transportation component for raw materials and finished goods.

Early doctor blade chamber systems were designed for use with steel blades. But, to address the increasing demand for plastic doctor blades, chamber manufacturers, like TRESU, have introduced new blade holder systems that fit a range of blade thicknesses. With an interchangeable clamp apparatus, press operators have the flexibility to run plastic or steel or easily switch back and forth depending on their job requirements.

Printers looking for innovations to streamline their processes and keep pace with market demands are finding the solution in plastic doctor blades. Polymer blade materials provide durability and sustainability, and drive performance that exceeds steel – all while staying true to what made them great in the first place: safety. As the market continues to appreciate the benefits of plastic, industry suppliers will no doubt continue to develop products that help make them an option in every pressroom.
Installing TruPoint: 3 Key Elements for Success

Installing your TruPoint Orange doctor blade incorrectly will result in disaster. Well, not really. But it will create headaches for the press operator and waste valuable resources. It will also prevent you from getting the maximum value from your doctor blade investment.

The TruPoint Orange doctor blade is a lifesaver in many pressrooms when it comes to eliminating UV ink spitting and start-up lines, reducing the frequency of blade changes and offering a safe alternative to steel blades. However, the blade requires a bit more finesse than steel when it’s being installed in order to work its magic.

Principles of proper doctor blade installation

It goes without saying that the surface the blade will rest on should be clean, so the blade can firmly rest against the blade stops. Also, tightening the blade clamp screws starting in the middle and working outward is a good way to get a uniform fit.

But, if we had to name the three most important factors to keep in mind when installing a TruPoint Orange doctor blade, it would be handling, orientation and pressure. That’s not to say that other considerations such as angle and alignment aren’t important. It’s just that these particular variables, if not executed properly, will almost always foretell the failure of the blade.

1. Protecting the blade edge

A press operator should take care to protect the integrity of any doctor blade (and his or her own safety when using steel) during blade transit, storage and installation. But particular caution should be exercised to keep a MicroTip® edge from coming in contact with anything that may damage it.

The MicroTip on an Orange blade is amazing in its ability to achieve and maintain a fine area of contact with the anilox roll surface. After all, this is the driving force behind the blade’s ability to match the metering performance of a steel blade. Its material is also incredibly tough, able to stand up to the abrasiveness of even the harshest chemistries like high titanium white inks and special coating formulas. But some of the same characteristics that give the TruPoint Orange doctor blade its awesome wiping power and durability also make its MicroTip vulnerable to nicks when handled or stored improperly. Once the edge is compromised, the blade can cause printing defects such as continuous streaks, marks and lines on the substrate. Keep the blade safe and always run your finger along the leading edge of the blade to ensure no imperfections are present before locking it into place. (Remember, there is no danger of cutting yourself with a TruPoint Orange doctor blade!)

2. Correct blade orientation

To reap the full performance benefits of the TruPoint Orange blade, the blade must be installed with correct orientation. When they are manufactured, TruPoint Orange blades are imprinted with text to guide you when you install them. It is important that the MicroTip edge is pointed away from the roll, with the text facing towards you and the arrows pointing to the anilox. It’s simple – if you can’t read the text, the blade is installed the wrong way. A blade that’s installed “backwards,” (with the MicroTip facing towards the roll), will not make even contact along the anilox roll and result in streaking on the printed piece. If your Orange blade is beveled, the bevel should face the inside of the chamber, or away from the roll, when properly installed. If using a doctor blade chamber, the containment blade should be the first to touch the anilox roll and the metering blade, second.

3. Minimal blade pressure

Assuming a doctor blade chamber is properly aligned, much less blade pressure is needed to get a clean wipe of the roll with a plastic doctor blade than with a steel one. For best results, find the minimum amount of blade pressure required to contact the anilox surface when installing TruPoint Orange. Unlike with steel, TruPoint Orange should generate few or no streaks on the anilox when starting up. Minimizing blade pressure against the anilox roll will not only ensure print quality but also extend blade life (and end seal life if applicable).

A good way to gauge the correct amount of doctor blade pressure is to look at the roll once it’s inked. Before the clamp is tightened, the anilox roll will appear glossy – a sign that too much ink is remaining on the surface. Blade pressure should be increased gradually until a satin ﬁnish appears on the surface of the roll. A dull sheen is a good indication that the correct amount of pressure has been achieved and the doctor blade is eﬀectively shearing the excess ink from the roll. If pressure is increased beyond this point, the doctor blade edge will bend, and contact area with the roll will grow. The anilox surface will begin to look glossy again or show light streaks or lines because it is being ﬂooded with too much ink. At this point, lessening blade pressure, rather than increasing it, will alleviate the issue.

When a TruPoint Orange blade is installed properly, its metering power is brilliant in terms of executing consistent print quality over the life of the blade. Take care to ensure the three key elements of success – proper blade handling, correct blade orientation and the right amount of blade pressure – and your TruPoint Orange doctor blade will likely become your press operator’s new best friend.
TruPoint Orange Doctor Blade Offers Numerous Advantages over Steel in Sheetfed Offset Coating Applications

The goal of a sheetfed offset printer, like every printer, is to produce printed pieces efficiently and economically. In sheetfed offset coating applications, selecting the right doctor blade will help keep presses running and minimize costs while maintaining a safe pressroom environment. By replacing steel with a TruPoint Orange doctor blade, a sheetfed offset printer can improve coating laydown, extend blade life, reduce pressroom injuries and eliminate anilox roller scoring.

Specialty and work & turn coatings

More and more, companies are using specialty or “effect” coatings to differentiate their brands and create a tactile and visual experience for consumers. However, formulas such as glitter, grit, soft touch, metallics and pearlescents present particular challenges for the printer. These coatings have high viscosities and contain large particles of solids which make it difficult to accurately control the volume being applied.

When it comes to work & turn coatings, UV formulas offer significantly higher gloss, better consistency, and improved chemical and abrasion resistance than aqueous formulas. But, again, the application of the more viscous formulas can be difficult to control – their higher viscosities apply extra pressure to the metering blade which causes hydroplaning or “spitting,” especially at high line speeds. In these cases, a specialized blade solution is needed to control the lay-down and minimize coating consumption and waste.

TruPoint Orange with MicroTip

By engineering a modified lamella tip, known as a MicroTip, on an advanced polymer material, Flexo Concepts® has created a doctor blade product that can overcome the limitations of steel in offset coating applications – Orange. The blade can effectively meter UV and specialty coating chemistries, is compatible with all coating formulas and delivers the traditional benefits of plastic blades: blade life and safety.

Better coating laydown

When used to apply UV coatings, the Orange blade material is strong enough to withstand the force of these higher-viscosity formulas without flexing – even at high press speeds. Its controlled metering keeps the coating from sliding underneath the blade and spraying or “spitting’ onto the sheet and surrounding area. The material also has a lower surface tension than steel, decreasing the attraction of the coating to the blade and allowing for a smoother transfer to the blanket.

Longer blade life

Applying UV coatings and coating formulas that contain pearlescent flecks, glitter, sand or other abrasive particles requires a tough, durable doctor blade that can withstand their harsh properties and the coarse anilox roll surfaces required to transport them. Unlike steel blades, which are subject to accelerated blade wear in these applications, Orange blades are abrasion and corrosion-resistant and offer superior longevity. The blade’s MicroTip has a long, slow wear period and delivers a consistent application of coating for the duration of the job. The blade material is self-lubricating, with a low coefficient of friction to resist mechanical wear, so blade life is extended in every application and presses can run longer.

Improved safety for operators

As steel blades wear, their edges become honed through contact with the anilox roller, leaving razor-sharp tips that can cause serious cuts. Press operators need to be extremely careful and wear protective gloves when removing the worn blades from the press to avoid injuries.

Due to their material composition, Orange doctor blades are safer to handle even when worn. Switching from steel to Orange will reduce lost-time accidents and can save a printer a lot of money in terms of workman’s compensation insurance rates, medical bills, labor replacement expenses and press downtime.

TruPoint Orange won’t damage anilox rollers

Steel blades are also to blame for many cases of anilox roll scoring. Incorrect blade installation or excessive blade pressure can cause small fragments of metal to break away, become trapped against the roller and destroy rows of anilox cells as the roller turns. The score lines run around the circumference of the roller and affect the corresponding areas of coating coverage.

The friction between a steel blade and roller surface can also erode the anilox cell walls, accelerating wear on the surface of the roller. As a result, cell volume is reduced and the anilox roller can no longer transport the precise volume of coating that it was designed to deliver. The printer wastes substrate and coating and has to resurface or replace the roller at a significant cost. Orange blades are constructed from a non-abrasive material and will never score anilox rollers or cause accelerated wear on their surface.

Customizable thickness and tip combinations

TruPoint Orange blades can be engineered to a full range of size and profile combinations to optimize metering performance with UV and specialty coating formulas. They range in thickness from .7mm to 1.25mm to offer varying degrees of stiffness, rigidity and deflection. Add to this an array of MicroTips, and these blades can be customized for a “perfect fit.”

The choice of blade thickness and tip will be determined by the anilox configuration and required coat weight, which is driven by the viscosity and solid load of the coating. Typically, higher line screens and lower cell volumes will require a smaller MicroTip (an M10 or M15 for dull/satin/gloss coatings for example), but as line screens decline and volumes increase, a MicroTip providing a larger contact area (M15 or M25) will perform better.  By optimizing their Orange blades with the appropriate MicroTip, printers are also able to achieve longer blade life in these applications than with steel.

Doctor blade optimization

The TruPoint Orange doctor blade with MicroTip edge technology helps sheetfed offset printers optimize their coating process by offering an effective, longer lasting and safe doctor blade option for a full range of coating applications. Choosing Orange to handle aggressive formulas, minimize blade changes, and reduce waste, mess and injuries can not only simplify the job of the press operator but also significantly enhances a printer’s bottom line.

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Doctor Blade Chambers Play a Key Role in Print Quality and Pressroom Efficiency

After years of being relegated to jobs with low graphics requirements, flexography now rivals other printing methods for quality and efficiency thanks to advances in the ink delivery process. Specifically, doctor blade chamber systems allow for better control over ink film thickness, color consistency, ink consumption, cleaning costs and press run time.

A chamber doctor blade system uses two doctor blades along with an enclosed ink chamber to dispense the ink to the anilox roll. The reverse angle blade acts as the metering blade and wipes excess ink from the anilox roll, and the trailing blade acts as a capture or containment blade and holds the ink within the chamber. Foam, rubber or felt gaskets seal both ends of the chamber and keep ink from leaking out.

The enclosed chamber design provides protection from evaporation of solvents or amines from the ink, depending on whether the ink is solvent or water-based, so a printer can maintain ink viscosity. Also, the ink is sheltered from dust, and slinging and skimming on the surrounding area are minimized. Better control over ink usage means lower ink consumption by as much as 15% per year. The system holds less ink than open pans, so there is less leftover ink at the end of a press run, and this ink can be removed and stored for future use.

Doctor blade chambers also allow for a more efficient and eco-friendly cleaning process than open ink systems. A smaller amount of cleaning solution and water are needed, so cleaning solution and water usage are reduced along with disposal costs. Color changes are quick, speeding up changeover and setup time on a run.

Recently, chamber producers have incorporated innovative engineering concepts and next-generation materials to improve the equipment’s performance and usability. New carbon-fiber constructions are lightweight, strong, durable and temperature-stable, and they reduce press vibrations even on wide format presses. Their surfaces are coated with resin to provide anti-static, corrosion-resistant properties. Advanced clamping systems, like TRESU’s E-Line and P-Line Systems, replace screws with eccentric and pneumatic apparatuses, respectively, to make blade changes faster and easier for operators.

Early chamber systems were designed for use with steel blades. But, to address the increasing demand in the industry for plastic doctor blades, TRESU worked closely with doctor blade manufacturer Flexo Concepts® to develop the exclusive new Series XL Blade Holder. The interchangeable

Tresu: xl blade holder E-Line Orange

quick-change clamp apparatus can accept slightly thicker TruPoint® plastic doctor blades, giving printers access to a much wider variety of blade options. Those who prefer plastic blades over steel – whether to improve safety, extend blade life or solve press problems like UV ink spitting – have the flexibility to use plastic or switch back and forth between materials based on job requirements.

When selecting a doctor blade chamber, there are several factors to consider in order to maximize the return on investment. The doctor blade chamber and its loading system should prevent blade misalignment and ensure even contact across the face of the anilox roll. It is also important to make sure that the system allows operators to adjust pressure between the doctor blade and anilox roll. Minimum pressure, particularly when using TruPoint blades, is important to optimize print quality, prolong blade life and preserve anilox integrity.

Today’s flexo printers are able to produce attractive packaging in a cost-effective way thanks in part to the benefits provided by doctor blade chambers. These enclosed systems contribute to high print quality and bring considerable efficiency and cost savings to the pressroom. Along with cutting-edge press, ink, substrate and doctor blade innovations, advances in chamber technology have further improved the ink delivery process, making flexography a viable option for today’s most demanding print applications.
How Flexo Concepts® Was Digitally Transformed

Flexo Concepts has completely transformed the way it does business.

Digitally, that is.

It began the way all of our projects do, with a vision – to create a digital cohesiveness throughout our company to optimize our customers’ experience with us – and a plan to make that vision a reality. Together, they led us down a 4-year path of pervasive digital transformation that reached into every corner of our company and united all of our business functions.

“A company’s digital transformation may not be very noticeable from the outside,” said Greg Howell, Flexo Concepts’ president and de facto project leader. “If done correctly, customers won’t notice initially. But over time they will see increasing examples of improved experiences as they engage with suppliers who are transforming.”

A successful digital transformation requires hard work that needs to be done inside the organization, necessitating a sustained, company-wide focus on a long-term goal and plenty of patience along the way. A key player in the company’s transition was Flexo Concepts’ Supply and Customer Experience Manager, Phil Ryan. Together, Greg and Phil piloted a process to attack this initiative over a period of 4 years, leading to countless examples of technology being used in game-changing ways.

From the start, Greg realized the importance of drawing ideas and buy-in from all areas of the company – not just IT or Sales where the initiative started, but also Accounting, Engineering, Operations, Marketing, Manufacturing and Customer Experience. This was important not only to generate the best ideas, but also to ensure that knowledge and capability were distributed throughout the company and not centered around a few people. He was sure that everyone in the organization – from top to bottom and across – needed to work together for this to succeed. And so, our “Digital Transformation Team,” with representatives from each department, was born.

Since the beginning, the team would gather every other week to communicate progress, celebrate “wins”, vet ideas, and plan next steps. Tasks were decided upon, and members would return to their departments after each meeting with tactical to-do lists. Gradually, the assignments were moved from “to-do” status to “completed” and crossed off the list.

Over time, wonderful things began to happen in different parts of the organization. Tighter control over billing and collections, better cost tracking, easier multiple currency billing and simplified sales tax management were achieved in the accounting department, for example. Our engineers started using “cases,” or CRM system tickets, to manage the process of blade analysis. Manufacturing personnel came to enjoy the ease of using an on-platform shipping tool that allowed direct creation of shipments from a sales order within a single application. SOP’s and master batch records created clear, accessible guidelines for daily operation in a digital format. New inventory management automation and a centralized procurement system ensured access to accurate, up-to-the-minute levels of available product, improved cost allocation and better raw material tracking. The customer experience team began using surveys to gauge the company’s performance at not only meeting customers’ current needs, but also to get a sense of new services people would like to see from us.

Internal and external quality issue tracking through digital cases enable us to recognize issues early, investigate them, and resolve problems as quickly as possible. Internal costs savings were realized, too, when the operations department declared “paperless status” in September 2019, eliminating over 87,000 pieces of paper and about $10,000 in related expenses annually! An order is now received, processed, manufactured, packed, shipped and invoiced using only a single piece of paper – the packing slip.

The sales and marketing teams were also rewarded with automated processes to pinpoint customers’ pain points and offer customized solutions. The integration and optimization of software systems provide quick and easy account “snapshot” analysis and tracking via personalized dashboards, providing our salespeople with all the information they need at their (keyboard-operating) fingertips. Our marketing staff has gained tools to determine the information prospective customers are looking for and deliver it to them not only when they want it, but how. A central repository offers the entire international team access to all online marketing collateral, and a Kanban process enables them to request sales support materials digitally.

Today, we are proud to report that 100% of our business processes are in the cloud (except for a few processor-intensive applications and some local file storage). Our entire office staff company-wide has access to all job functionality via the web, facilitating remote operation on laptops, iPads, mobile phones and other devices. As a result, we now have maximum flexibility to maintain uninterrupted service to our customers despite unforeseen events that may impact our ability to operate from a central location.

Greg sees our company’s digital transformation as a logical extension of our continuous improvement mindset and believes that you can’t really do one without the other. “Our culture has always placed an emphasis on finding ways to work smarter and leverage technology to do it. Much like continuous improvement, meaningful digital transformation is an accumulation of very small improvements done over time that come together to create large, efficient and more capable systems.”

It began with the belief that if we could create a digital record of all our customer interactions, we could attain operational bliss and deliver amazing experiences for our customers. And we did. For now. Because, almost by definition, digital transformation is a never-ending process with infinite room for improvement. As our ways of conducting business keep evolving, our technology capabilities grow, and our customer focus remains steadfast, there’s no doubt we will continue to “transform.”
XL Blade Holder by TRESU Gives P-Line Users Access to TruPoint® Blades

As part of a program to expand doctor blade options for its chamber users, TRESU has introduced a modification to its P-Line Clamp System to fit TruPoint safer and longer-lasting doctor blades – the Series XL Blade Holder.

TRESU’s Chamber Doctor Blade Systems were originally created for use with steel doctor blades. However, to address the increasing demand for plastic doctor blades, TRESU worked closely with Flexo Concepts to develop the exclusive new Series XL Blade Holder. The interchangeable quick-change clamp apparatus can accept slightly thicker (up to .050” or 1.25mm) TruPoint doctor blades, giving printers access to a much wider variety of blade options. Those who prefer plastic blades over steel – whether to improve safety, extend blade life or solve problems – have the flexibility to switch back and forth between materials based on job requirements.

Like its E-Line system, which replaced screws with a more efficient eccentric locking mechanism, TRESU’s P-Line clamping system uses air instead of screws to lock the blade in place. The design allows for fast, tool-free blade replacement in corrugated applications where the ink delivery systems contain long chambers and blade changes are time-consuming.

Why use TruPoint Blades over Steel?

With growing pressure on box makers to produce packages that are both functional and appealing to consumers, corrugated printers are challenged with finding a doctor blade that can deliver predictable ink density and color control. Unfortunately, traditional UHMW blades cannot meter mid-level line screen anilox rolls required in these applications effectively. The contact area of the blade grows too quickly, and print quality rapidly deteriorates. Complicating the situation is UHMW’s poor creep, or its ability to maintain force under pressure without bending. Often, press operators try to correct the problem by increasing blade pressure but doing this leads to accelerated blade and anilox wear.

For printers who don’t want to switch to steel in these applications, TruPoint Orange and Green blades provide the perfect solution – effective metering, longer blade life and safe handling. The blades are highly abrasion-resistant and chemically compatible with all ink and coating formulas. As an added bonus, TruPoint blades are safer than steel on anilox rolls – there are no metal slivers that can cause scoring.

As it did for label printers using the E-Line Clamping System, the new Series XL Blade Holder gives P-Line users a quick and easy way to change blades along with the flexibility to choose steel or TruPoint blades based on the needs of their jobs. No modifications to the chamber are required to retrofit the new clamp system into existing flexo printing units.

Watch how easy it is to change a blade with the P-Line clamping system!

Learn how the E-Line clamping system gives narrow web printers access to TruPoint doctor blades.
Defeat Back Doctoring with Polyester Containment Blades

In flexographic printing, perfect print quality and efficiency are the ultimate goals for press operators. One pesky obstacle that often disrupts this quest is the notorious “back doctoring” or “trail doctoring.”

Understanding Back Doctoring

No press operator wants to deal with the hassle of frequent press stoppages for cleaning sessions. Back doctoring or trail doctoring, is not only a nuisance but also a costly problem, leading to lost press time, wasted ink, and substrate.

Doctor Blade vs Containment Blade

The doctor blade and containment blade play different roles in transferring ink from the anilox roll to the substrate. Choose each blade carefully to ensure the doctor blade chamber works optimally.

Doctor blades ensure precise ink transfer to the printing plate and substrate. It meters ink from the anilox roll before the transfer takes place. The doctor blade needs to be stiff and rigid to prevent ink from passing underneath it, leading to excess ink on the anilox roll.

Conversely, the containment blade collects any excess ink post-transfer. The rotation of the anilox roll lifts the tip of the containment blade, allowing ink to flow underneath. The ink flows back into the chamber, reclaiming it for future use. Unlike the doctor blade, the containment blade should be thin and flexible to create a one-way “valve.”

Back Doctoring Explained

Back doctoring occurs when the containment blade meters or doctors the ink, preventing its return to the chamber. The primary culprit of back doctoring is a steel containment blade. Due to its stiffness, steel doctor blades prohibit ink from re-entering the ink chamber on the back side of the anilox roll. Back doctoring can also occur when operating at high speeds or with smaller anilox diameters. The centrifugal force of the roll as it turns is greater causing the containment blade to become ineffective.

Defeat Back Doctoring

The key to eliminating back doctoring is using the right containment blade.

The containment blade should be thin and flexible so the rotation of the anilox roll can lift it. This allows the containment blade to effectively remove excess ink and create a one-way path for it to return to its chamber. Unlike a doctor blade, a containment blade does not require a bevel to function correctly. Choosing a straight or radius blade edge will optimize performance and cost.

Polyester containment blades offer a winning combination of flexibility, stability, and solvent resistance. Not only are they more cost-effective than steel doctor blades, but they also enhance safety during the printing process. With no sharp fragments to worry about, polyester blades reduce anilox roll scoring and excessive wear.

Back doctoring is a common pressroom problem that, fortunately, has an easy fix: converting to a polyester containment blade. Choosing a plastic blade keeps unused ink in the chamber reducing downtime and increasing print efficiency – even at high press speeds.

Read our blog post, “5 Reasons to Switch to Polyester Containment Blades” to learn more about the benefits of using high-performance polyester containment blades.

Request a Free Sample of TruPoint Polyester
Flexo Concepts Joins Local “Scallop Roll”

Flexo Concepts recently joined 29 other area businesses participating in the latest Plymouth Area Chamber of Commerce street-side art project – “The Scallop Roll.” Part of a celebration to commemorate our country’s upcoming 400-year anniversary, the project features a collection of large, fiberglass scallop-shaped forms about 4 feet tall and 3 feet wide. Company sponsors worked with local artists to come up with design concepts and paint the structures – front and back. The shells have been installed at various locations around the downtown and waterfront areas for residents and visitors to admire, and maps are available to help people make a fun activity out of finding them as they explore the town.

According to the Plymouth Area Chamber of Commerce, “The scallop was selected for this year’s campaign because of its symbolism for pilgrimage. Artwork of the shell can even be found on local headstones dating back as early as 1681.”

For its design, Flexo Concepts chose a nautical theme radiating a message of acceptance and equality. The front of the shell depicts a seaside display with a rainbow-colored lighthouse at its center. The back features a quote by John Lennon, “It matters not who you love, where you love, why you love or how you love; it matters only that you love.”

Anyone visiting the area is encouraged to visit the Plymouth, Massachusetts downtown waterfront to see the shells.
TRESU and Flexo Concepts boost flexibility and efficiency in the pressroom

Industry partners TRESU and Flexo Concepts set their sights on boosting flexibility and efficiency in the pressroom. The result: a doctor blade clamping system that allows printers to quickly change between steel and plastic blades to optimize their ink and coating delivery system for effectiveness, efficiency and safety. Two amazing products – the E-Line Chamber Doctor Blade System by TRESU and Flexo Concepts’ TruPoint Orange® doctor blade – have been brought together to revolutionize the ink delivery system for today’s printers.

The E-Line Chamber Doctor Blade System

TRESU’s E-Line Chamber Doctor Blade System has been simplifying and speeding doctor blade changes for steel blade users since 2013. In its spirit of “innovating tomorrow’s printing,” TRESU designed a simple clamping apparatus that replaces screws with an eccentric rod that can be actuated from the end of the chamber. Printers using the E-Line system no longer have to loosen and tighten multiple screws across the clamp, and blade changes can be completed in a swift two minutes or less.

Growing Demand for Plastic Doctor Blades

Market developments have inspired the introduction of a variety of new ink and coating formulas – UV chemistries, specialty coatings and digital priming solutions to name a few – to enhance the look of packaging and gain press efficiencies. Steel blades are effective when applying water and solvent-based inks, but many printers have problems when using steel to apply these new formulas. Press operators are increasingly finding that plastic blades are superior in these applications.

The NEW TRESU Series XL Blade Holder

The E-Line Chamber Doctor Blade System was originally created for steel doctor blades, and its design limited its use to steel or very thin polyester blades. To address the increasing demand for plastic doctor blades, TRESU worked closely with Flexo Concepts to develop its exclusive Series XL Blade Holder. The interchangeable quick-change clamp apparatus, used with the E-Line System, can accept blades between .02″ or 0.5mm and .04″ or 1mm thick. E-Line users will now have access to a much wider variety of doctor blade options, and printers who prefer plastic blades – whether for safety, blade life or solving problems – can also enjoy its benefits.

Limitations of Steel Doctor Blades

When metering UV chemistries, a steel blade’s surface energy and flexibility can prevent a smooth transfer of ink or coating to the plate. The higher-viscosity formulas tend to build up behind the blade and spit onto the web, especially at high press speeds. Inks containing large particulates and specialty coatings such as grit, glitter, dull and satin, and the coarse anilox surfaces used to apply them are also extremely abrasive to steel doctor blades. Blades have to be changed frequently which impacts press running time and blade costs. Fast blade consumption also occurs when steel blades are used to apply digital priming solutions which are highly corrosive to metal. In all of these applications, slivers of a steel blade can break off and cause issues with print quality and anilox scoring.

TruPoint Orange Doctor Blade

Since its introduction in 2013, the TruPoint Orange doctor blade has been widely adopted as a replacement for steel in narrow web pressrooms due to its equivalent metering performance and safety benefits. But its ability to eliminate UV ink spitting and last longer in abrasive and corrosive environments is what has made it more popular than ever in digital and sheetfed offset pressrooms as well.

A product of Flexo Concepts’ doctor blade innovation lab, TruPoint Orange is constructed from a next-generation polymer material and finished with a precisely engineered MicroTip® edge. The combination of material and tip provides enough stiffness – at thinner gauges than traditional plastic blades – to maintain a strong blade contact area that not only delivers exceptional metering but also prevents ink and coating from slinging. TruPoint Orange blades are highly abrasion-resistant and chemically compatible with all specialty ink and coating formulas, producing better lay-down and outlasting steel. As an added bonus, TruPoint Orange is safer than steel for blade handlers and anilox rolls – no injuries or metal slivers that cause scoring.

A Perfect Match

As TRESU’s original E-Line Chamber Doctor Blade System improved efficiency in the pressroom, the latest enhancement adds flexibility. The company’s Series XL Blade Holder makes it quick and easy for a press operator to change out a blade and choose a steel or plastic blade based on the demands of the job. And by making the use of a TruPoint Orange blade possible, the new design gives printers access to a blade that can handle difficult chemistries and deliver what today’s customers are looking for – eye-catching, brand-differentiating, vibrant packages that sell products.

Current Models

TRESU’s new XL Blade Holder is available for the D1E, D2E and D3E versions of its E-Line Chamber Doctor Blade System. These models make up the majority of systems used in narrow web, digital priming and coating, offset coatings and some wide web applications. No modifications to the chamber are required to retrofit the new clamp system into existing flexo printing units.

Watch how easy it is to change a blade with the E-Line clamping system!

Learn how the P-Line clamping system gives corrugated printers access to truPoint blades.
TruPoint Orange®: A Versatile Multi-Tasker in the Pressroom

As the label and packaging markets evolve, printers need products that can keep up. TruPoint Orange offers a versatile doctor blade solution that delivers high-quality graphics, keeps presses running longer, reduces waste and solves common pressroom problems in a single doctor blade product.

Orange meters like a steel doctor blade

TruPoint Orange delivers the metering performance of a steel doctor blade in highly demanding graphics applications. The next-generation polymer material together with an advanced MicroTip® edge allows the blade to achieve a fine contact area with the anilox roll and deliver effective wiping on line screens up to 785 L/cm. Due to the tip design, the small contact area is maintained throughout the life of the blade, and metering is consistent for the duration of the print job.

Orange eliminates UV spitting

When used to apply UV inks and coatings, TruPoint Orange is strong enough to withstand the force of these higher-viscosity formulas without flexing – even at high press speeds. Its controlled metering keeps the ink from sliding underneath the blade and spraying or “spitting’ onto the web and surrounding area. The material also has a lower surface tension than steel, decreasing the attraction of the ink to the blade and allowing a smoother transfer to the plate.

Orange is a good option for white decks and specialty coatings

Applying inks and coatings that contain titanium dioxide, metallic, glitter, sand or other large particles requires a tough, durable doctor blade that can stand up to their harsh properties and the coarse anilox surfaces required to transport them. The TruPoint Orange blade not only effectively meters these formulas, but the blade material resists their abrasive and corrosive properties, so it also offers superior longevity in these environments.

Orange is safe and lasts longer

The next generation polymer material that TruPoint Orange is constructed from retains the blade life and safety benefits that distinguish plastic doctor blades from steel. The material is self-lubricating, with a low coefficient of friction to resist mechanical wear, so blade life is extended in every application and presses can run longer. Even the worn blades will not damage anilox rolls or cut operators when handling them.

Orange thickness and MicroTip can be customized

TruPoint Orange blades are available in thicknesses ranging from .7mm to 1.25mm to offer varying degrees of stiffness, rigidity and deflection. Add to this a variety of MicroTip profiles and these blades can be customized for a “perfect fit.”

With options that can be tailored to fit every application, TruPoint Orange with MicroTip edge technology at once presents a versatile, safe and “problem-solving” doctor blade option for the narrow web pressroom. Choosing Orange to reduce blade changes, waste, mess and injuries can not only simplify the job of the press operator but also significantly enhance the printer’s bottom line.
Engineering Manager John Ferris Talks about Sustainability and Going Green at Flexo Concepts

What do 850 solar panels, a giant vacuum collection system, new LED lighting fixtures and a bunch of blue receptacle bins at 100 Armstrong Road in Plymouth have in common?

They are all part of Flexo Concepts’ efforts to “go green.”

Today we will talk with the engineering manager, the man behind the curtain, John Ferris, to find out the story behind these changes and how he is leading the way at Flexo Concepts when it comes to sustainability.

John, tell us about some of the things Flexo Concepts has done to reduce its carbon footprint.

For starters, Flexo Concepts installed a solar renewable energy system last year that produces 100% of the energy used by our company and the other tenants in the building. The project, which included 850 panels on the roof, 40 power inverters and all materials required to connect the energy to the building and electric grid, was completed over five months. We are proud to say that our entire facility is now energy-independent!

Also, two years ago, we equipped our entire facility with more efficient LED lighting. The scope of the project consisted of all Flexo Concepts’ manufacturing and administrative space as well as the parking lot and other common areas of the building complex. Every bulb in the office areas was exchanged for an LED lamp and all lighting equipment in the shop and common areas was replaced with new fixtures that contain LED lamps.

Could you describe some of the less obvious ways Flexo Concepts is leading the way in the industry with its sustainability practices?

One of my primary responsibilities as the engineering manager is to look for ways to develop products using materials and processes that don’t have a negative impact on the environment. Our R&D team and material suppliers work closely together to create polymer doctor blade materials that not only deliver performance to printers but also offer eco-friendly options to help our customers meet their sustainability goals. One of the criteria we use to select new materials and material combinations for testing is the eco-friendliness of the polymerizing methods. For example, the main polymer used to make our TruPoint Green® doctor blade is created from carbon monoxide that’s recaptured from a steel mill. If this vapor were released into the atmosphere, it would break down into carbon dioxide which is a well-known greenhouse gas.

Another example is the procedures we have in place to reduce, reuse and recycle waste throughout the company. Flexo Concepts recycles 100% of its manufacturing cardboard waste and has placed blue recycling bins at every desk and in common areas to collect office waste and food packaging. But, in addition to these more “typical” recycling practices, we have installed a central trim collection system in the manufacturing area to consolidate blade material waste. The system consists of a network of pipes from each point of plastic chip generation connected to a centralized suction machine. (As an added benefit, we found the system significantly reduced electricity usage by replacing the use of higher-amperage and landfill-disposable shop vacs at individual workstations.) The waste is then made available to be reused as filler by other industries.

John, explain how this program could be adopted by other companies in the industry.

Any company can install a solar system, LED lighting and recycling bins in their facilities. But our efforts reach beyond the bricks and mortar of our facility to the printing industry as a whole. Our customers choose plastic doctor blades in part because they help reduce their carbon footprint. Producing steel is a highly energy-intensive process that uses up large quantities of fossil fuels and releases a significant amount of greenhouse gases into the atmosphere. Producing plastic uses much less energy, emits smaller volumes of greenhouse gases, and has lower transportation requirements due to local sourcing of raw materials and its relatively lighter weight. Plastic blades, such as our TruPoint Orange® doctor blade for the tag and label market, also lasts longer than steel in the press, which results in less start-up waste and fewer order deliveries. We believe, by setting this example, we can inspire other organizations in the industry to turn to their supply chains to source more eco-friendly components.

What is unique about your approach?

Our desire is to not only pursue environmental responsibility for our company but also help our customers achieve their sustainability goals is what makes our approach different. To our knowledge, we are the only global doctor blade manufacturer that uses 100% solar carbon-free energy to power its entire facility and the only blade manufacturer that uses recaptured carbon monoxide as a feedstock in our products.

While every company wants to be able to call itself “green,” we feel we have gone above and beyond to reduce energy dependence, improve efficiency, and recycle and reuse waste across our entire organization. Plastic, as a material, has developed a negative image in society due to a culture of “throwaway living,” its limited recycling and its inability to break down in the environment. As a manufacturer of plastic doctor blades in an industry that primarily uses steel (sometimes referred to as the “most recycled material on the planet”), we are working hard to change this negative image by promoting the “green” benefits of our operations and products.

Thank you, John!

[Read how we were awarded the “Calvin Frost Environmental Leadership Award” by the Tag and Label Manufacturers Institute in October 2018!]

To learn about the environment impact of plastic vs. steel doctor blades:

[Download our infographic, “The Environmental Impact of Doctor Blades”]

[Read our white paper, “Reduce Your Carbon Footprint with Plastic Doctor Blades”]
Flexo Concepts®: Distinguished Exporter of TruPoint® Doctor Blades

If a time period in a company’s history can be characterized by a single phrase, 2018 could be called the “year of the export” for Flexo Concepts.

On the verge of wrapping up its 3^rd decade of selling overseas, doing business globally is nothing new for our doctor blade manufacturing company. But 2018 has been a year to celebrate. Flexo Concepts received two high profile export awards, won its fifth export grant, and is about to onboard its third international business development manager.

First, Flexo Concepts was named, “2018 Exporter of the Year” for Massachusetts by the U.S. Small Business Administration in April. The very next month, Flexo Concepts was recognized at the national level, receiving the President’s E Award – considered the highest recognition any U.S. entity can receive for making what Secretary of Commerce Wilbur Ross calls “a significant contribution to the expansion of exports.”

In November, Flexo Concepts received notification that it was awarded funding for the fifth time through the Massachusetts State Trade Expansion Program (STEP) to facilitate long-term export growth. When allocating the grant, the Massachusetts Export Center chooses companies based on their demonstrated commitment to boost exports, create jobs and impact the economy.

And now, the company is adding to its team of overseas sales representatives fully dedicated to international business development and service.

Flexo Concepts understands the importance of having salespeople in the field who understand the regional markets, speak the native languages and are intimately familiar with local cultures and business practices. Soon Arnoud de Jong will join Bernat Ferrete (based in Spain) and Steve Kao (based in Taiwan) in promoting the TruPoint line of doctor blades globally. Arnoud will be based in his home country, the Netherlands, and brings a wide range of strategic capabilities to his new role – a good sense for the European flexo industry, strong marketing background and proficient language skills in his native Dutch, English and German.

The activities of the international business development managers are fortified by support from back home – Flexo Concepts’ headquarters in Plymouth, Massachusetts. The company actively participates in foreign trade associations and regularly exhibits at key trade events around the world. To localize its selling, the company’s marketing department provides translated versions of its sales tools and promotional materials – brochures, installation guides, email campaigns, blogs, white papers, infographics, ads, training documents, etc. – and recently launched Spanish and Chinese versions of its website (with French and German to follow in 2019).

Behind the scenes, developing and executing a successful international business model is a whole-company team effort. From navigating the intricacies of international accounting, to mastering the complexities of shipping and logistics and maintaining compliance with foreign regulations, every department is involved.

But, while “internationalizing” the business has been (and will continue to be) one of our biggest challenges, it will surely also remain one of our biggest rewards. Exports have grown from 17% of revenues in 1991 to over 40% today. We maintain OEM relationships and distribution on every (habitable) continent, and our current customer base spans 50+ countries worldwide. The recognition we have received in 2018 celebrates our efforts over the past 30 years to advance the global flexo printing industry.

And we’re pretty darn proud of it.
Manufacturing Manager Adam Yock Talks about Plant Safety at Flexo Concepts

One of Flexo Concepts’ most important cultural values relates to its people and keeping them safe is one of its highest priorities. For this reason, the company has established a “Safety Team” and protocols throughout the building to create and maintain a safe environment for its employees.

Today we will talk with Manufacturing Manager Adam Yock to learn more about what Flexo Concepts does to keep workers safe.

Adam, can you tell us about the Safety Team and their responsibilities?

The Safety Team consists of five members from the production staff who meet on a regular basis to review the overall safety of the premises and address any areas of concern. As the manufacturing manager, I perform random safety audits to identify risks and make suggestion tickets available for employees to communicate any safety concerns they may have. The tickets are posted on a master board in the shop, tracked through our CRM system and attended to by the Safety Team. Safety tickets receive immediate attention and take priority over ideas for needed repairs or continuous improvement posted on the board.

What are some of the safety measures you have in place in the manufacturing area?

On the manufacturing floor, there is a wide variety of safety equipment available to protect workers from injuries. All our machines are guarded at the cutters to keep operators from being hurt and prevent loose pieces of blade scrap from flying into the air. Ear plugs or muffs are worn by employees running the blade cutting equipment to protect from the loud machine noise. There are anti-slip mats throughout the shop and anti-fatigue mats in all blade fabrication areas. Bench heights are kept at a comfortable height that allows the operators to work without being hunched over, and windows have been installed in doors entering/exiting the shop to prevent someone from being hit by a door being opened from the opposite side.

The company purchased flow racks for the storage of raw material to reduce the need for workers to bend when picking material, and an automated conveyor system makes it easy to move heavy boxes from the production lines to the shipping area. Flexo Concepts also installed a Dura-Vac central trim collection system to gather and dispose of manufacturing waste, eliminating the need to physically remove blade scrap from the workstations.

We also use 5S practices which not only drive efficiency but also a continuously tidy and safer shop environment. The company has structured, documented procedures and shop floor workforce training programs in place to ensure that blade fabrication, order fulfillment and scrap removal are done properly and safely. All manufacturing employees are formally trained and certified in the proper use of forklift equipment.

How do you communicate safety procedures with your employees?

Safety procedures are communicated through monthly team meetings, quarterly company meetings, building-wide notices and training events. Evacuation procedures and instructions specific to each department are posted throughout the facility. Also, the Safety Team sends out safety tip sheets to all employees before each major holiday to help protect them and their families from accidents at home.

Do guidelines change and evolve over time, and if so, how?

Flexo Concepts takes pride in being proactive when it comes to safety. Our company stays in compliance with Osha guidelines and has outsourced the management of some of our safety initiatives to vendors. Through contracts with providers such as CINTAS and Yankee Sprinkler, our equipment specifications and instructions are continuously monitored and kept up to date. For example, Cintas has installed a first aid station in our shop, including AED technology with on-site monthly service to maintain the device. Yankee Sprinkler is under an annual contract with Flexo Concepts to maintain our fire protection system. Both companies provide regular training for our staff on the proper use of this equipment.

How successful has your company been with plant safety?

Flexo Concepts continues to be very successful with its safety protocol as indicated by our low injury rates and minimal lost-time accidents. Since establishing a Safety Team dedicated to this important aspect of our business, the number of accidents that occur in our building has been reduced to almost zero. We are proud of our great track record and feel confident that the safety systems and procedures we have in place will keep it that way!

To learn about how using plastic doctor blades can improve safety and reduce costs in your pressroom:

[Read our white paper, “The [Hidden] Costs of Using Steel Doctor Blades”]
Safety First: Discover Why Plastic Doctor Blades Are Preferred over Steel

Everyone agrees that plastic doctor blades are safer than steel. But why exactly is this true? The answer lies in the fundamental differences between the two materials: steel blades are harder and sharper than plastic blades. While this is commonly understood, the reason becomes clear when we examine the molecular structures of these materials.

What Does It Mean to Be Sharp?

Steel and plastic materials (and all matter) are comprised of small particles. As a doctor blade wears, the material is removed in clusters of particulate which can be no smaller than the basic particle size of the material. So, the finest tip on a blade can only be as wide as one particle. And since plastic particles are larger than steel particles, a plastic blade worn to its finest point will be wider than steel. This combined with the fact that plastic is inherently softer than steel, results in a plastic blade edge that is less “sharp” than steel and safer to handle.

Ink Metering with Plastic Blades

Given this information, one might wonder if plastic blades can wipe as effectively as a steel blade. The answer is some can, and some can’t. UHMW plastic for example is perfect for applying ink or coating in applications where graphic difficulty is limited. But it is too soft for applications involving high screen anilox rolls or precise metering requirements where a fine contact area is required.

Thanks to next-generation polymers like Delrin, Polyether Ether Ketone (PEEK), or glass/Kevlar reinforced materials, there are compositions that are rigid enough to support a fine contact area similar to that of steel. The bonus is these blades are plastic, so they are inherently softer and do not develop a dangerous cutting edge risking injury to press operators.

Making the Switch

Next-generation polymer doctor blades offer the performance of steel blades while providing the safety of plastic blades. The combination of advanced materials and innovative profile (MicroTip, bevel, etc.) design enables these safe doctor blades to perform in demanding applications previously dominated by steel. Substituting a next-generation polymer doctor blade for steel is a great way to produce a high-quality product while maintaining a safe work environment.

Glitter	Iridescent	Crackle
Soft-touch	Gloss	Scratch-off
Pearlescent	Matte	Grit
Sand	Frost	Scent
Metallic	Glow-in-the-dark	Satin
Texture	Thermochromic	Dull

Category: Blogs

Flexo printing

Digital printing

Applying digital printing technology to packaging

Primers, varnishes and special effects coatings

Primers

Varnishes (protective coatings)

Special effects coatings

Coating formulas

Selecting a coating formula

Coating application

TruPoint Orange® doctor blade with MicroTip®

Doctor blade optimization

OEMs supporting TruPoint Orange

Summary

Safety

Performance

Durability

Cost-Effectiveness

Sustainability

Principles of proper doctor blade installation

1. Protecting the blade edge

2. Correct blade orientation

3. Minimal blade pressure

Why use TruPoint Blades over Steel?

Understanding Back Doctoring

Doctor Blade vs Containment Blade

Back Doctoring Explained

Defeat Back Doctoring

The E-Line Chamber Doctor Blade System

Growing Demand for Plastic Doctor Blades

The NEW TRESU Series XL Blade Holder

Limitations of Steel Doctor Blades

TruPoint Orange Doctor Blade

A Perfect Match

Current Models

Orange meters like a steel doctor blade

Orange eliminates UV spitting

Orange is a good option for white decks and specialty coatings

Orange is safe and lasts longer

Orange thickness and MicroTip can be customized

John, tell us about some of the things Flexo Concepts has done to reduce its carbon footprint.

Could you describe some of the less obvious ways Flexo Concepts is leading the way in the industry with its sustainability practices?

John, explain how this program could be adopted by other companies in the industry.

What is unique about your approach?

Thank you, John!

Adam, can you tell us about the Safety Team and their responsibilities?

What are some of the safety measures you have in place in the manufacturing area?

How do you communicate safety procedures with your employees?

Do guidelines change and evolve over time, and if so, how?

How successful has your company been with plant safety?

**The NEW TRESU Series XL Blade Holder**