Category: Corrugated

Doctor Blade Quality through Tight Manufacturing Control
From the moment raw material enters our building, Flexo Concepts® measures, analyzes and controls every step of the process of turning the polymer stock into high-precision, performance doctor blades.

Our Doctor Blade Innovation Lab is where ideas are born and developed by our R&D department. But it is our manufacturing folks who are responsible for bringing the concepts to life on the production line.

Quality control is a core value of our manufacturing team. Being able to execute blade fabrication day after day with high precision and repeatability is critical to our customers’ success. Printers have to be able to trust that every shipment of our TruPoint® doctor blades will deliver consistent performance – every time, in every application.

Tight tolerances and high dimensional standards

We establish and strictly maintain tight tolerances on all our cutting, beveling and finishing machines and set high dimensional standards for our doctor blades. To make sure our products meet these requirements, Flexo Concepts’ quality assurance team uses certain measurement techniques and analytical tools. Among them is statistical process control, or SPC, a method for managing and monitoring a process using data analysis.

10-Point inspection

We also apply a 10-point inspection, where blade material and tip table dimensions are measured in real time at various points in the manufacturing cycle. We certify:
1. 1. Material thickness
    
    Material width
    
    Material cupping
    
    Material camber (deviation from a straight edge)
    
    Tip table height
    
    Tip table thickness
    
    Tip table width
    
    Tip table length
    
    Tip table depth
    
    RA value (surface roughness)
Our engineers plot their measurements on a graph to see if they fall within pre-set tolerance limits. If there is a variance, the process is tightened up, and any deficient product is thrown away. This rigorous inspection system cuts down on variability in the manufacturing process and protects against blade irregularities.

Track and trace

To bolster our quality program, we track and trace every aspect of production: from raw material, to operator, to machine, to boxed shipment. If there is an issue down the line, our staff is able to easily go back and pinpoint the problem and correct it right away.

Flexo Concepts wants to help its customers be the most efficient organizations in their industry, and that starts with delivering products that they can count on. It’s important to us that our doctor blades increase the performance, quality and output of the printing press, its operator and the company as a whole. By putting systems in place to guarantee the consistent production of superior doctor blades, we make sure that our customers get exactly what they expect so their customers get exactly what they expect.
The World’s Most Innovative Doctor Blade Company

Flexo Concepts® wants to be the world’s most innovative doctor blade company.

How are we going to do it? By creating products, services and a brand experience that inspire.

Products that inspire

We start by crafting superior products and designs.

Our salespeople “have their finger on the pulse” of the industry. They are well-versed in flexography and stay up on market trends. When they report back printers’ needs and challenges, our engineers get right to work.

We partner closely with the world’s most advanced material suppliers and perfect designs in our state-of-the-art doctor blade innovation lab. New blade concepts are subjected to rigorous internal benchmark analysis and then sent out for advanced third-party testing with customers, industry associates, material labs and OEMs before being released to the market. Our premium, solution-based portfolio of innovative products ensures that customers have blades that meet their exact needs. Combinations of materials and tips present a large range of options so that blades can be customized for specific applications.

But we don’t stop there. Our culture of “continuous improvement” compels us to keep moving forward. Whether it’s experimenting with an interesting new material or working tirelessly to perfect the geometry of a new tip, we never rest. The same goes for our manufacturing processes. We regularly invest in new (oftentimes custom) equipment so we can produce our blades swiftly and efficiently while maintaining high standards of quality.

Services that inspire

We make doing business with us easy for our customers so they can focus on their businesses. As trusted advisors, our highly-trained salespeople and customer experience reps help printers find the best solutions, even if it means sometimes recommending a competitor’s product. Wait, what?? It’s true.

Providing support before, during and after each sale is important to us. Our company understands that printers need flexibility from their partners; we pride ourselves on providing quick responses, short lead times, inventory management programs and expedited shipments (even second-day or overnight guaranteed deliveries for those times that receiving blades ASAP is critical!).

A brand experience that inspires

Flexo Concepts wants to be the professor that’s helpful, collaborative and innovative, as well as the uncle who’s friendly, unconventional, guiding and cool. We promise to build meaningful relationships through exceptional experiences. We want our customers to feel comfortable working with us and trust us to have their best interests in mind. Having always been “different” as a niche manufacturer in the industry, we’re comfortable blazing our own trail – trying new things and coming up with unique innovations that set us apart from other doctor blade manufacturers.

Flexo Concepts works hard to consistently deliver products, services and a brand experience that inspire. It’s not just our understanding of the market’s needs, highly-focused R&D efforts, ground-breaking blade technology, sales “consultants” and adaptive support services. It’s also a culture throughout our organization that makes us always try to be better. These are the things that will make us the world’s most innovative doctor blade company.
The 5 Ws of TruPoint Doctor Blade Tips
This infographic is a beginner’s guide to Doctor Blade Tips, providing a brief overview of the 3 main tips offered with TruPoint doctor blades. Viewers will uncover the following 5 Ws of TruPoint doctor blade tips:

Who – Who (which industry) predominantly uses this blade tip option?

What – What does this doctor blade tip look like?

Where – Where is this doctor blade found in a chambered ink system?

When – When a certain anilox line screen is used, which doctor blade tip is the best option?

Why – Why is this doctor blade tip used for all of the above?
New Polymer Doctor Blade for High-Graphics Box Makers

If you are a producer of simple corrugated graphics, you are probably very familiar with UHMW as the best solution to optimize doctor blade life and pressroom safety. However, if your customers expect higher print quality for brand consistency and marketing appeal, steel might be your blade material of choice.

Many printers producing high graphics don’t want to accept the downside of steel – short blade life, potential for anilox scoring and risk of serious injury to press operators. To address this market need, Flexo Concepts has introduced the TruPoint Green® doctor blade for high graphics corrugated printers who prefer a plastic blade. Green can handle these metering requirements while delivering the added benefits that polymer materials are known for – long blade life and safety.

Corrugated Box Market Evolution

UHMW has always been the “standard” doctor blade used in corrugated applications. However, the function of the corrugated box has evolved from a simple “this side up” logistics package to eye-catching promotional packaging that also serves as a display vehicle. Today’s graphics requirements are exceptionally challenging, and more colors, finer plate screens, half-tones and higher anilox line counts are being used to produce attractive point of sale containers. Predictable ink density and color control are essential to ensure manufacturers’ brand consistency. In these demanding graphics applications, however, UHMW doesn’t perform well. Until recently, a steel blade was often necessary to achieve a precise wipe of the higher line screen anilox rolls required to produce this level of work.

Faced with this market evolution, some printers continue using their current blades and accept limitations on print quality or blade life. For example, as line screens increase, standard UHMW will produce dirty print due to its large contact area with the anilox roll. On the other hand, steel blades wear more quickly, damage the anilox roll, and can easily injure press operators.

Modified traditional blade products can offer a solution in this space up to a point. By placing a lamella, or stepped edge on standard UHMW, the blade can achieve a slightly smaller contact area with the roll and metering quality can be improved on line screens up to around 360 lpi or 142 l/cm. (Keep in mind that print quality will diminish as the blade wears and contact area grows.) Unfortunately, a lamella tip does not solve the problem of doctor blade mechanical creep (or bending). UHMW is notorious for its poor mechanical creep properties, meaning the material tends to bend and lose its shape under a consistently applied force. Over time, the blade angle decreases and the contact area increases. UHMW’s poor creep quality often results in reduced graphics quality, requires increased blade-to-anilox pressure to achieve a clean wipe and causes more press downtime for blade adjustments and changes.

In moderate graphics applications, graphite, polyacetal and Teflon-filled Delrin can be used to replace steel. These materials will deliver decent metering and longer blade life on line screens ranging up to 550-600 lpi or 217-236 l/cm. The blades are thinner and bevels ranging from 22°-45° can be applied to further improve contact area (which, again, grows as the blades wear). The problem with these blades, however, is their thickness in comparison to the blade holder. On press models where the chamber is designed to hold a .060”-.080” UHMW blade, these .020”-.040” thick blades require a shim or modification which can slow down changeovers.

A Blade Designed to Replace Steel in Moderate to High Graphics Applications

The need emerged for a doctor blade that was stiff like steel, resistant to bending, long-lasting, safe and compatible with current blade holders, sparking the development of the TruPoint Green doctor blade. TruPoint Green was created in Flexo Concept’s Doctor Blade Innovation Lab and tested and refined for over two years before entering the market in 2017.

TruPoint Green is a custom compounded next generation polymer material that is stiff, durable, and more than 4x more resistant to bending than UHMW. The construction allows for a fine contact area with the anilox roll and better print quality throughout the entire life of the blade. The rigid material and creep resistance allow the blade to maintain a fine area of contact with the anilox roll throughout the life of the blade. Green is capable of metering mid-to-high anilox line screens effectively, delivering better control over color as anilox line screens increase. The material is also safe to handle and has a much lower wear rate than steel.

For box makers struggling to achieve the high-quality graphics demanded from today’s consumers, there is finally an ideal blade solution. The next generation TruPoint Green doctor blade is designed to deliver the best of both steel and plastic in corrugated pressrooms by producing high level graphics effectively, efficiently economically and safely.

Request a Free Sample of TruPoint Green
TruPoint Green®: The New Kid on the ~~Block~~ Anilox

What is TruPoint Green?

TruPoint Green is a next generation polymer doctor blade for corrugated printers producing mid-level graphics.

Why was TruPoint Green created?

UHMW has always been the “standard” doctor blade used in corrugated applications. However, as graphics requirements grow, many printers are finding that UHMW can’t meter their mid-level line screen anilox rolls effectively. Corrugated printers are reluctantly turning to steel in these applications even though steel blades don’t last as long and can easily cut press operators.

TruPoint Green is a blade that can handle these metering requirements while delivering the added benefits that polymers are known for – longer blade life and a safer alternative to steel.

Why won’t UHMW work in these applications?

UHMW is fine for basic graphics, but it lacks the precision for the higher graphic requirements today’s brand owners expect. Why? Because of the contact area between the blade and the anilox roll. A general rule of thumb is the smaller the contact area, the better the metering (or, the larger the contact area, the lower the metering quality).

When it’s received from the manufacturer, a new UHMW blade touches the roll with a nice small contact area. But as the blade wears, the contact area gets very large, growing to as much as twice the blade’s thickness.

The large contact area is made worse by the poor mechanical creep characteristic of UHMW. “Creep,” or “spring memory,” is the ability of a material to maintain its shape under force. For doctor blades, it represents how well a blade is able to maintain its original shape after being flexed. (View the Doctor Blade Mechanical Creep infographic to learn more)

UHMW has poor creep; it relaxes under a constant load and doesn’t spring back very well. In fact, it loses 70% of its reaction force in the first 30 minutes of being used and 78% of its force over a 14-hour period. To maintain blade contact with the anilox roll, press operators have to increase pressure as the blade loses its elasticity. This increased pressure further increases the contact area and restarts the creep cycle (while accelerating blade wear). Ink film thickness grows, and printers end up with dirty print and ink waste.

Who created TruPoint Green?

TruPoint Green was created by and is exclusive to Flexo Concepts. Being a doctor blade innovator, the company set out on a two-year journey to develop a product that could function as a drop-in replacement for UHMW with the right amount of creep to maintain contact area in these mid-level graphics applications.

How was TruPoint Green created?

Flexo Concepts started by developing a material that was stiffer than UHMW but with enough flexibility to achieve a good contact area with the roll, better mechanical creep and superior wear properties. After two years of testing and refining, the company found the solution it was looking for: a custom compounded material that combines two different polymers. In lab tests, our engineers were happy to find that the material demonstrated better stiffness and only half the creep of UHMW and a much lower wear rate than that of steel! As a result, press operators see better print quality and don’t have to stop their presses as often for blade adjustments and changes.

Where was TruPoint Green created?

The proprietary material was developed and extensively tested in Flexo Concepts’ state-of-the-art Doctor Blade Innovation Lab in Plymouth, Massachusetts. Our customers spent over a year conducting additional trials of TruPoint Green in their plants to help us refine the material.

Is TruPoint Green “green”?

In addition to providing an effective blade solution in mid-level graphics applications, Green also helps printers reduce their carbon footprint! The main polymer used to make Green is created from recaptured carbon monoxide from a steel mill. If this vapor were released into the atmosphere, it would break down into carbon dioxide, a well-known greenhouse gas.

To sum it up, TruPoint Green offers a blade option for corrugated printers looking for a drop-in replacement for UHMW that meters as well as steel. With better stiffness, creep resistance and blade life, Green is the best alternative to UHMW and steel in mid-level line screen applications.

So… When will TruPoint Green be available?

It’s available NOW! Visit www.flexoconcepts.com/green-doctor-blade to learn more.

Request a Free Sample of TruPoint Green
The Evolution of Corrugated Doctor Blades

Since the 1960s, corrugated printing requirements have evolved from simple logistics to eye-catching promotional packaging with SKUs and tracking information. Improvements in doctor blade materials and tip configurations have played a key role in this evolution.

1960s – Straight UHMW

In the 1960s, corrugated printers started using doctor blades as a replacement for rubber rolls to gain control over the amount of ink transferred to the plate. The dense molecular structure of UHMW made it a good solution for printing environments that combined long runs and coarse anilox engravings. This soft, thick material was safe to handle, didn’t score anilox rolls, and was highly resistant to stress cracks and chips. It was also abrasion-resistant which gave the blades extremely long life. UHMW products were engineered in thicknesses of 2.29mm and 2.54mm which were adequate to produce the type of work being done at that time (and still in many applications today) – simple solids and lines in one to three colors.

Late 1980s – Early 1990s – Introduction of Bevels

As packaging began to take on a marketing role in the 1980s, the demand for higher quality graphics grew. Doctor blade use expanded in corrugated applications, and new press technology, including ceramic anilox rolls and doctor blade chambers, came to market. Blade manufacturers focused on developing stronger, more durable materials that could be engineered into thinner products. Blade thicknesses decreased to 2.03mm and 1.52mm, and 30° and 45° bevels were introduced to allow the blades to achieve a smaller area of contact with the anilox roll and produce higher quality print.

Late 1990s – Early 2000s – Plastics and Composites with Finer Bevels

In the 1990s, suppliers continued to innovate anilox rolls and press components to meet growing packaging graphics requirements. Printers began using more advanced plastic doctor blade materials as stiffer, more durable alternatives to UHMW. Acetal blades were effective at metering moderate to high line screen rolls while providing great chemical resistance, good dimensional stability and a low coefficient of friction. These materials could be fortified with additives such as Teflon and manufactured into thicknesses of .51mm to 1.02mm. The material was able to accommodate finer bevels of 15° and 22° to produce difficult fine type and reverses. Tight weave fiberglass composites were also developed for screen and process work due to their extremely stiff and durable properties.

Mid 2000s – Next Generation UHMW

For printers using UHMW to produce low to moderate graphics looking for longer blade life, Flexo Concepts introduced an exclusive high-density formulation UHMW blade called DuraPoint™. Still widely used today, DuraPoint’s material properties allow it to maintain more consistent metering throughout the life of the blade. DuraPoint has been shown to last 25-30% longer than traditional UHMW and is a direct replacement as both a metering and a containment blade. DuraPoint is available in the same widths and thicknesses as Flexo Concepts’ UHMW blade and offers a drop-in replacement for standard UHMW. The blade fits in existing blade clamp configurations, requiring no shims or modifications to the holder.

Today – Next Generation Polymers

Today, box makers are asked to produce packages that serve as both shipping and display vehicles. Graphics requirements are exceptionally challenging, and more colors, finer plate screens, half-tones, and higher anilox line counts are being used to produce attractive point of sale containers. Predictable ink density and color control are essential to ensure manufacturers’ brand consistency.

As market demands increase, printers are finding that UHMW and traditional plastic products, even with bevels, can’t meter their mid-level line screen anilox rolls effectively. Some printers continue to use their existing blades and accept poor print quality or more frequent blade changes. Others are turning to steel, despite its downside – short blade life, potential for anilox scoring and risk of serious injury to press operators.

In 2017, Flexo Concepts introduced an alternative solution for printers with higher graphics requirements who don’t want to use steel. The company created TruPoint Green® – a new blade that can produce mid to high level graphics effectively, efficiently and safely. Green’s custom compounded next generation polymer material is stiff, durable, and resistant to bending, allowing for a fine contact area with the anilox roll and better print quality throughout the entire life of the blade. The material is also safe to handle and has a much lower wear rate than steel.

Along with press builders and anilox roll manufacturers, corrugated doctor blade suppliers have done their job of “keeping up with the times.” Blade materials, formulations and technology have advanced over the past half-century in pace with the demands of the packaging industry. Today’s corrugated printers have a full range of TruPoint non-metallic doctor blade options available to meet these demands. While standard UHMW, traditional plastics and composites are still the best choices in many low-moderate graphics applications, printers with high graphics requirements who want to avoid the risks associated with using steel now have a next generation polymer blade to produce quality work required in today’s market.

Request a Free Sample of TruPoint Green
Doctor Blade Fatigue: What It Is, Why It Matters & What You Can Do About It

UHMW has always been the “standard” doctor blade used in corrugated applications. However, the function of the corrugated box has evolved from a simple “this side up” logistics package to eye-catching promotional packaging and displays. As corrugated graphics requirements continue to grow, many printers are finding that UHMW blades can’t meter their mid-level line screen anilox rolls effectively, due to what we call “Fatigue”.

In this infographic, you will learn the basics of what doctor blade mechanical creep is and how it affects your pressroom.

Fill out the form to download the Infographic PDF.
Consultative Selling: What It Is and Why It Works

Today, successful sellers act as trusted advisers to their buyers to help them find the best solutions. By adopting a consultative selling strategy, salespeople create value in the selling process and benefit from better sales results, stronger customer bases and referrals.

What is consultative selling?

Consultative selling is defined as “personal selling in which a salesperson plays the role of a consultant” by www.businessdictionary.com. It’s a sales method where the salesperson gains a solid understanding of the buyer’s challenges before recommending a solution. An important distinction from other methods is that the main objective is helping the prospect find the right solution, not just getting him to “sign on the dotted line.” The key elements of consultative selling fall into four categories: research, relationship, resolution and reward.

Research

Today’s customer is much savvier than in the past and is doing his homework before buying. The explosion of digital media has made it easy for people to access information online and share experiences with each other. The buyer has already explored solutions, competitors, and prices and is well educated by the time a vendor comes calling. The salesperson has to do his research, too, and can take advantage of “lead intelligence” to learn about his prospects and home in on the most qualified leads.

Relationship

The consultative salesperson is an industry expert who “gets it” and wants to help. He continues to learn more about his prospect’s challenges and obstacles by asking open-ended questions to uncover his real motivation for buying. He builds trust by sharing his knowledge without asking for anything in return.

Resolution

If the seller’s products are determined to be a good fit for the buyer, the salesperson presents the customer-specific benefits of his products, figures out the next steps in the purchasing process and establishes a timeline for closing the sale. If it is clear that he can’t meet the buyer’s needs, it is completely acceptable for him to recommend an alternative solution, even if it’s a competitor!

Reward

No matter the outcome, consultative selling results in a valuable experience for both sides. The buyer is able to get advice from an industry expert who helps him understand his obstacles and navigate a solution. By investing time to provide tailored, customized solutions, salespeople will enjoy better closing rates, higher value sales, increased customer retention and referrals.

In the end, consultative selling is about helping prospects find solutions. Salespeople who take the time to fully understand their buyers’ needs and challenges are in the best position to recommend the right solutions. They will be rewarded with satisfied, loyal supporters.
How to Prevent Anilox Roll Scoring
Anilox roll scoring poses a challenge for many printers, evident when a shiny line encircles the roll, indicating a groove or “scoring” of the anilox roll. If you are a printer this means dark lines in your print – especially when printing solids. If you are applying a coating, it’s even more important to reduce scoring since most coatings are clear, and heavy coating lines are hard to detect.

Once scored, an anilox roll can often be used selectively, working around the score lines. But at some point, the roll needs to be reengraved and depending on size and finish, comes with a significant cost.

Scoring often arises from debris trapped between the doctor blade and the anilox roll. Common sources include particles from steel doctor blades, dried ink build-up, or coating particles in the fluid delivery system. To minimize or eliminate anilox scoring, consider the following practices:

1. Maintain Good Housekeeping:

Prevent dried ink or coating from accumulating on the anilox rolls and related components within the ink delivery system

Use filtration in the fluid delivery system to remove dried, hard debris during prolonged production runs.

2. Implement Magnets:

If using metal doctor blades, add high-strength magnets to the fluid delivery system to capture steel particulates.

Maintain minimal pressure between the doctor blade & anilox roll when using steel blades to avoid entrapment of dried particulates.

3. Optimize Mechanical Setup:

Ensure level and parallel alignment of the doctor blade chamber or single blade holder with the anilox roll.

Misalignment can lead to excessive pressure needed to engage the doctor blade, this will bend the blade and increase chances for particle entrapment.

4. Use Plastic Containment Blades:

Consider using a plastic (polyester) doctor blade for the containment blade on enclosed chambers.

This change cuts steel doctor blade usage (and particulate) in half, reducing the chances for scoring to occur.

5. Switch to Polymer Doctor Blades:

Explore transitioning to plastic or polymer doctor blades to eliminate steel from your system.

Polymer doctor blades have advanced dramatically in terms of stiffness, edge smoothness, blade life, and durability for long production runs and offer metering quality that meets or exceeds steel.

In conclusion, anilox scoring is permanent damage commonly caused by debris between the doctor blade and the anilox roll, resulting in a defective product. Minimize anilox scoring and save unnecessary engraving costs by filtering inks or coatings and using magnets with metal doctor blades. Alternatively, you can switch to plastic doctor blades to potentially eliminate the problem altogether.

Request a Free TruPoint Doctor Blade Sample
Kanban 101
In today’s competitive marketplace, manufacturers are looking for ways to improve efficiency and wring costs out of the production process. By adopting lean manufacturing concepts, companies can eliminate waste and operate more efficiently. One way to do this is to implement kanban, a Japanese inventory scheduling system that promotes just-in-time production by delivering parts on an as-needed basis.

In a kanban system, the production process is seen as a “chain,” where each “process” becomes the supplier for the next (“downstream”) process in the sequence and a customer to the previous (“upstream”) process. This approach extends all the way to a company’s external suppliers and customers. It optimizes production flow and minimizes inventory levels by directing the supply of parts and components to workers exactly when and where they need them.

The advantages of using a kanban system include:
- Lower inventory costs
- Quicker response to changes in demand
- Increased productivity and efficiency
- Reduced waste
Kanban Origins

Kanban originated in Japan in the mid-20^th century by Toyota looking to increase the efficiency of its factories. Its engineers were inspired by the inventory replenishment process used by supermarkets. They observed that customers purchase only the items and quantities they need, and store employees restock their shelves with only as much product as they expect to sell. This began an important distinction between a “push” system of manufacturing and a demand-based or “pull” system.

Push vs. Pull Inventory Control Systems

With traditional push manufacturing systems, companies produce what they think their customers will order and make items to stock in batches. While there are economies of scale, the downside is that inventory costs are high and companies can end up overproducing if sales forecasts are incorrect. Excess inventory ties up working capital, increases storage costs and exposes the company to the risk of parts becoming obsolete.

A pull strategy, on the other hand, ties production directly to actual customer demand so there is little risk of overproduction and little excess inventory. Tasks in the production process are completed when requested by the next process down the line so parts or components are “pulled” into production only when needed. With a pull system of inventory management, a company may find itself slow to respond to a sudden increase in demand but very little capital is tied up in excess parts and storage.

Kanban Cards

In order to facilitate its just-in-time manufacturing system, Toyota instituted a method using cards in its factories called “kanban” (a Japanese word combining “kan” for card and “ban” for signal). The cards, called “kanbans,” contain information about how to replenish each component used in production. By moving a kanban, an employee can signal when more parts are needed by an upstream process, prompting the production or purchase of these additional parts. Each kanban conveys all information required to replace the item such as the part name, number and description as well as the quantity to be produced and any other information about how the replenishment should take place. When delivering a kanban, the employee will write the date the order is initiated or “dropped” and when the parts are needed. The card is placed in a kanban rack to be retrieved along with the container by the appropriate person in the upstream process. Once replenished, the bin containing the new parts and kanban card are returned to their original location.

Six Elements of Kanban

The following principles are fundamental to a kanban system:
1. Downstream processes always pull from upstream processes
2. Upstream processes produce only when instructed
3. Defects are never passed on to the next station
4. Kanban cards are attached to part containers and no item is moved without a kanban
5. Production is leveled throughout the system to prevent bottlenecks
6. There is continuous fine-tuning of the kanbans in the production process
The success of kanban as an inventory control system depends on its execution. Adopting this system requires well-defined, documented procedures and training so employees are clear about every step, because a disruption in the process may lead to out-of-stocks and delays in filling customer orders. If executed properly, this is an excellent tool used to facilitate just-in-time manufacturing by eliminating waste and inefficiency from the production process.
What the Automakers Have Taught Us About Manufacturing Efficiency
We’ve learned a lot from the automakers when it comes to manufacturing efficiency. Our car-making forefathers took a long look at their production methods and figured out ways to increase value by making improvements in their processes. Today, printers, along with countless other industries, are realizing the benefits of implementing these concepts to improve their bottom lines.

It started with Henry Ford. He revolutionized the production process by using interchangeable parts, standardization, and what he’s best known for, the assembly line. By streamlining production, he was able to mass produce the Model T and make cars available to middle class families across America for the first time in 1908. By 1927, Ford had shipped 15 million cars, and the Model T came to symbolize a new method of manufacturing.

In the mid-21^st century, Toyota engineers expanded on Ford’s ideas to become more market-focused. Their inspiration came from a supermarket model of inventory management where stores restock their shelves as products are purchased by shoppers. Applied to manufacturing, the concept of just-in-time inventory replenishment recognizes that more efficient inventory management results when customers “pull” products through the supply chain.

According to Toyota’s website, the objective of its “Toyota Production System,” or TPS, is to serve its customers and employees while aligning with the company’s business goals. Central to the TPS are the principles of “Kaizen,” “Just in Time Manufacturing” and “Jidoka.” These values attempt to maximize efficiency and quality by using methods that simplify production flow and speed up response times. Production is driven by customer demand, and the way resources are allocated within the plant is known as “kanban.” All employees throughout the organization strive for continuous improvement in every aspect of the process.

Modern lean manufacturing is derived from the TPS and strives to eliminate all excess from a manufacturing system by focusing only on the things that add value. By removing the causes of “muri”,” or overburdening of people or equipment, and “mura,” or unevenness, the overall “muda,” or waste in the manufacturing process is reduced. (These terms were originally used in Japanese martial arts to protect the fighter by eliminating unnecessary movements!) In relation to manufacturing, seven deadly wastes (or mudas) have been identified:
1. Transportation
2. Inventory
3. Motion
4. Waiting
5. Over-processing
6. Over-production
7. Defects
These activities take up time, resources and space and add no value in the eyes of the customer. The more these wastes can be minimized, the more dollars a manufacturer can wring out of the production process.

For several years, press builder Gallus has seen lean manufacturing concepts in the print industry “as a means of ensuring perfect job processing without sacrificing profit margins.” Through its “Smart Production Concept” program, Gallus helps its customers evaluate their print quality, production sequences and production environment to find opportunities to improve pressroom efficiency. The press manufacturer compares lean manufacturing to Formula 1 racing, where “a single second more or less at a pit stop can make the difference between winning and losing.”

We can learn a lot from our predecessors when it comes to many things, and manufacturing methods are no exception. Through the years, companies have continued to improve upon the basic concepts of production efficiency introduced by Henry Ford and Toyota. Today, printers and businesses across many industry sectors strive to adopt the principles of lean manufacturing in order to achieve the ultimate goal of maximizing value to customers and optimizing profits.
Our Visit to SinoCorrugated 2015 – Shanghai, China

Kevin McLaughlin

April was a highlight of our corrugated marketing efforts in the Far East as Flexo Concepts® supported its Asian distributors at SinoCorrugated 2015. Taking place every two years, the event is known for showcasing a plethora of the latest in corrugated machinery and equipment among a lively atmosphere of partnering, relationship building and business transacting.

Our Asian Key Account Manager, Steve Kao, and I took advantage of our four days at the show to make our way around the 67,000 square meters of exhibition area filled with more than 600 exhibitors. We were two of over 40,000 local and international attendees who had come to see some 1,400 pieces of corrugated manufacturing equipment and check out some 1,000 consumable products.

A large part of the reason for our visit was to support our Asian distributors who were exhibiting at the show: GrandCorp Group, Guangzhou Ming Yang and Guangzhou Ruijian, a doctor blade chamber OEM that also featured our blades on their equipment. We are grateful for their continued promotion of the benefits of our doctor blade products. We would like to thank two additional chamber manufacturers, Baoqi and Corupak, who also featured our TruPoint™ blades on their equipment.

As China’s economic development continues to outpace the rest of the world and the country maintains its status as the largest corrugated market, we believe that Flexo Concepts is well-positioned to enjoy sustained growth in the region. Our company has been actively selling its non-metallic doctor blades in China for over 14 years and is currently a major supplier to the local corrugated OEMs. As a result, TruPoint has become the leading doctor blade brand. At SinoCorrugated this year, we took the opportunity to introduce our newest blade, TruPoint Orange®, to the corrugated market. This product has been very successful in narrow web flexo applications as a safe and longer-lasting substitute for steel. Early testing has shown that these benefits also transfer to corrugated high-end graphics applications.

Again this year, SinoCorrugated lived up to its reputation as “the largest business platform for the global corrugated manufacturing industry.” Having shown steady growth since 2001 in terms of the number of visitors and exhibitors, machines on display and show area, I think all would agree that the show is worthy undertaking. I know the event was a big success for Flexo Concepts, and we look forward to returning in 2017!
Anilox Roll Cleaning is Essential to Effective Ink Delivery
You spend a lot of time selecting the correct anilox roll for a job. Careful consideration goes into line screen, cell geometry and cell volume in order to guarantee that a precise amount of ink or coating is delivered to the substrate. Aniox roll cleaning is essential to maintain this precision. If you neglect to clean your rolls on a regular basis, you will not get the most out of your anilox investment. Plugged cells will affect print quality and cause you frustration, waste and downtime. An anilox roll cleaning program consisting of daily, weekly and deep cleaning will preserve the integrity of the anilox engraving and ensure quality, press efficiency and longer anilox life.

When a newly engraved anilox roll arrives from the manufacturer, volume is even across and around the surface of the roll. As the roll is used, however, a residual amount of ink or coating material is left behind in the cells after the transfer has taken place. The residue dries and creates build-up in the cells. Over time, these deposits decrease the capacity of the cells and reduce their ability to carry and release the volume of liquid for which they were designed. This residue also raises the surface tension, or dyne level, of the roll and increases the tendency of the coating to “cling” to the surface. When this occurs, the roll will not release the proper volume or ink or coating to the plate.

Benefits of regular anilox roll cleaning:
- The repeated transfer of a precise volume of ink or coating
- Consistent coverage
- Reduced labor and less downtime
- Fewer job rejections and waste
- Longer anilox life and lower re-working costs
Flexo Concepts recommends a 3-step anilox roll cleaning program:

1. Daily wiping to prevent ink or coating build-up

Applying a liquid cleaning agent by hand and wiping down the roll with a clean, lint-free cloth on a daily basis is the simplest and most effective way to keep ink and coating from drying and building up in the cells. As a basic rule of thumb, the best time to clean a roll is as soon as it is removed from the press. The longer inks, resins, adhesives, etc. have been allowed to sit in the engraving, the harder these materials are to remove. To maximize cleaning performance, choose a cleaner specifically formulated to remove water-based, UV or solvent-based chemistries based on your application.

2. Weekly scrubbing with a paste-like cleaner and an anilox cleaning brush

Manually scrubbing the roll once or twice a week with a brush and a paste or cream chemical cleaner will mechanically loosen and remove any ink or coating residue that remain in cells despite daily cleaning. The cleaner is applied to the roll, vigorously scrubbed in a circular motion with an anilox cleaning brush and flushed with water while the roll remains in the press. It is important to remember that stainless steel brushes are suitable only for ceramic anilox surfaces and brass bristles should be used for chrome surfaces to prevent damage to the engraving.

3. Monthly deep cleaning to remove tough ink or coating deposits

Over time a residual amount of ink or coating material is left behind in the cells and the roll requires a deep cleaning to remove these tough deposits. The most common methods of deep cleaning are chemical wash and ultrasonic. With these methods, the roll is removed from the press and placed into a chemical bath where it soaks in a powerful cleaning solution before being subjected to a high pressure rinse or ultrasonic vibrations to loosen and dissolve the deposits. These methods vary in cleaning effectiveness, risk of damage to the roll, and water and chemical consumption.

There are also particle-blasting methods of mechanically removing the dried cell contents. These methods are especially effective for removing chemistries that may be resistant to chemical cleaners. Soda blasting technology uses small granules of sodium carbonate to go in and “pick out” the ink or coating. The roll is then rinsed with water and wiped to remove any remaining soda residue. A more eco-friendly method to deep cleaning anilox rolls that uses no water or chemicals is the MicroClean™ System: an off-press, completely dry media cleaning machine that uses recyclable plastic media pellets. The system gently but thoroughly removes all types of dried inks and coatings, virtually restoring cell volume to full capacity with each cleaning.

Laser cleaning is another anilox deep-cleaning method that’s growing in popularity and effective at removing chemical-resistant ink and coating deposits. The technology uses a pulsed laser beam to heat and evaporate the tough residue in the anilox cells. This method requires no consumable and produces no waste stream, although the capital investment is high.

Like on other parts of the press, a maintenance program for anilox rolls keeps the ink delivery system running at its peak. Regular anilox roll cleaning will prevent anilox cells from plugging with residue and stop build-up before it dries. Maintaining anilox rolls through a regular cleaning program can pay off tremendously in terms of maximizing print quality, press efficiency and cost control. Click here for more information on our anilox roll cleaning brushes
The Right End Seals Will Prevent Leaks in Your Doctor Blade Chamber System
In an enclosed doctor blade chamber system, the job of the end seals is to keep the coating or ink from leaking out of the ends of the chamber. Selecting the right end seals for your application is critical to achieve proper doctor blade seating and prevent leaks. If used correctly, these inexpensive consumables will ensure graphic quality and save a printer thousands of dollars in waste, downtime and replacement of other press parts due to premature wear.

Problems That Result from Failed End Seals
- Chamber leaks and mess
- Poor graphic quality and ink/coating waste
- Excessive doctor blade wear
- Premature anilox roller wear and scoring
- Press downtime
Why Chamber Leaks Occur

While there are other causes of chamber leaks, failed end seals are responsible for the lion’s share. It is important to use an end seal material that is compatible with the type of ink or coating being used, the length of the run and the press speed. Good seal design for a proper fit is also critical to ensure that end seals contain the liquid within the confines of the chamber. Incorrect end seal size and shape will leave gaps for fluid to leak out of the ends. If the seals aren’t sufficiently lubricated, the increased friction against the anilox roller will cause buildup and leaking. Enlist the help of your end seal supplier to work through these issues and make sure that you are using the correct end seals for your application.

When a chamber is leaking, a press operator will often try to fix the problem by increasing the load pressure instead of looking for the cause of the leak. End seal leaks should never be resolved by increasing chamber pressure. The additional pressure increases friction between the doctor blade and the anilox roll and causes both to wear prematurely. Paying a little extra attention when installing doctor blades and end seals can prevent many leaks from occurring in the first place. After installing new end seals, a press operator should evaluate the chamber and confirm that there is a snug end seal fit with no gaps or distortion. The doctor blade should have some upward pressure to form an adequate seal, but not so much that it requires extra loading pressure to make contact with the anilox roller in the middle of the blade.

End Seal Materials for Chamber Systems

There are various end seal materials which range in abrasion resistance, durability and solvent resistance. Again, your end seal supplier is a good resource to help you determine the best material for your application:
1. 1. Foam seals are the most common and the least expensive type of end seals. This material generally does not perform as well as other materials and may not be a good choice for long runs, higher press speeds and certain fluid chemistries. There can also be a lot of variation in the density of the material which can range from super firm to more malleable.
1. 1. Neoprene or rubber seals offer longer life compared to foam seals. They are compatible with aqueous and UV coatings & inks so they don’t have to be changed out between jobs. However, these seals do not seat well due to the coefficient of friction between the material and the anilox roller surface.
1. Pre-soaked felt end seals are a superior solution for resolving leaks. These end seals are oversized for a snug fit and pre-soaked in petroleum to reduce friction and prevent buildup. Felt end seals are compatible with all ink and coating types, provide a tighter seal and typically last longer than rubber and foam seals. Keeping felt seals lubricated with seal grease is key to their superior performance and longer life. Felt end seals tend to dry out after the anilox system is flushed with detergents and water. Applying seal grease to the radius portion of the seals after flushing the system will ensure a tight fit and extend the life of the seals by reducing friction.
Choosing the right seal material and design for your application and replacing end seals when necessary will help ensure that they do their job of keeping inks and coatings from leaking out of the chamber. Better yet, the right seals will allow for proper doctor blade seating and a predictable and even transfer of fluid from the anilox roller to the blanket. Despite their small cost, end seals have the power to save thousands of dollars in waste and downtime.
Corrugated Ink Delivery Systems: Two-Roll or Doctor Blade?
The flexographic ink delivery process has come a long way since the days when “Fragile – Do Not Drop” and “This End Up” were the only requirements of box printers. New press designs are able to achieve the quality of work that has traditionally been done by litho lamination, and corrugated printers have to produce a consistently high level of quality to compete. The evolution of the ink delivery process from a two-roll ink metering system to the enclosed doctor blade chamber has made this possible.

There are currently three types of ink metering systems used in corrugated printing applications: the two-roll system, the single blade system and the enclosed doctor blade chamber system. All three systems rely on an anilox roll to transfer ink to the plate. The difference lies in how the ink is applied to the anilox roll.

Two roll corrugated inking system

The Two-Roll Ink Delivery System

In the original two-roll ink metering system, a fountain roll rotates partially submerged in an open ink pan, picking up ink and applying it to the anilox roll. The anilox roll transfers the ink to the plate cylinder which then lays it down on the sheet. Though still widely used in the industry, there is a lot of variability in the two-roll system which results in a lack of control over the amount of ink transferred to the plate:

Imprecise wipe of the anilox roll leads to inconsistent volume of ink delivered to the sheet.

Color strength fluctuation and ink slinging can occur at higher press speeds due to the hydraulic force between the rubber roll and the anilox roll.

Transfer characteristics vary according to the hardness or “durometer” of the rubber roll.

Ink viscosity is subject to evaporation, dust and surface skimming due to the open tray design.

Single blade corrugated inking system

Single Doctor Blade Ink Delivery System

The addition of a reverse angle doctor blade added precision to the ink metering process. In the single blade ink metering system, a doctor blade made from steel, plastic or a composite material is used to replace the rubber roll. The blade is installed just beyond the ink metering nip to shear ink from the anilox roll surface. Doctor blade ink metering systems give the printer better control over the volume of ink being delivered to the plate. Where a rubber roll often leaves an additional ink film on the surface, a doctor blade shears ink cleanly from the roll. The inks perform better on press and a printer can achieve a more consistent ink film thickness. Ink consumption is reduced, and color application is consistent across the sheet even at higher press speeds.

Chamber doctor blade corrugated ink delivery system

Enclosed Chamber Doctor Blade System

The most recent development in the flexographic inking process is the enclosed chamber doctor blade system. In this system, two doctor blades are used along with an enclosed 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. 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 ink is delivered through a closed loop from the ink pump to the doctor blade system and then back to the pump.

With this method, a printer can maintain ink viscosity because the enclosed design provides protection from evaporation of solvents or amines from the ink, depending on whether the ink is solvent or water-based. Also, dust, slinging and skimming 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 not as much leftover ink at the end of a press run and ink can be removed and stored for future use.

Due to a more efficient cleaning process, a smaller amount of cleaning solution is needed to clean up a chamber so cleaning solution waste and disposal costs are also reduced. Color changes are quick, speeding up changeover and setup time on a run. The enclosed chamber system is more eco-friendly because of reduced ink consumption and disposal of waste ink as well as a lower volume of cleaning solution and water required to wash-up the station for a color change.

After years of being relegated to jobs with low graphics requirements, flexography now rivals other printing methods for quality. Today’s corrugated printers are able to produce products that are highly attractive and eye-catching to the consumer due to advances in the ink delivery process. Whether they opt for a single doctor blade system or see the benefits in investing in a dual blade enclosed chamber, printers gain clear advantages by using doctor blades in terms of controlling ink film thickness and maintaining color consistency.

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Optimizing Your Doctor Blade Trialing Process

Testing a new doctor blade in your printing operation should be a collaboration with your suppler that boosts performance while avoiding costly guesswork. Instead of randomly ordering samples, follow a systematic, data-driven approach.

Collaborate
Start by sharing key details about your press—dimensions, machine model, blade holder type, ink specifics, and any pain points you are experiencing. This information lets your supplier recommend tailored doctor blades rather than generic samples. There are a lot of options in terms of material type, thickness, and edge configuration.

Run Your Trial
Your supplier will likely send you one or more blades based on your provided data. Appreciate what these are and take care when testing them. They’re designed for your specific needs and should be used in a controlled production run.

Crawl, Walk, Run

Install and test the blades under normal operating conditions. Consider starting on a single print/coating station if the blade is new to you. Contact your supplier with any questions related to setup or installation and alignment. Clean the blade holder or chamber, using minimal blade pressure.

Provide Feedback

Complete any surveys your supplier has seeking feedback on the sample performance. Record important details and observations made during the testing related to blade longevity, metering quality, and any anomalies. Feedback is especially important if the blade fails as this can help your supplier make alternative recommendations by changing blade material, thickness, or edge configuration.

The Takeaway
An iterative, collaborative testing process is more efficient than random sampling. By working closely with your supplier—starting with detailed information, running controlled trials, carefully documenting results, and refining based on feedback—you achieve optimal performance and a long-term printing solution. Embrace this method to streamline your doctor blade selection and keep your press running at peak efficiency.

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