Category: Doctor Blades

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.
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
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.
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.
In Safe Hands with Polymer Doctor Blades Blog Series Part 2 “Steel Doctor Blade Risk Management”

Workplace hazards are present in almost every industry, and the printing industry is no exception. A press operator faces many dangers at work every day. One of the greatest is the risk of serious lacerations to his hands if he’s using steel doctor blades. He is exposed to being cut anytime he’s handling them – installing or removing them from the press, cleaning them, disposing them and when changing end seals. The blades are especially dangerous when being replaced – their edges become honed through contact with the anilox roll as they wear, leaving razor-sharp tips that can cause serious cuts.

Fortunately, printers have a variety of options to reduce or eliminate the risk of injuries from steel doctor blades without sacrificing print quality.

Wear personal protective equipment

When worn correctly, cut-resistant gloves can prevent injuries to operators when using steel blades. However, the U.S. Bureau of Labor Statistics 2012 figures show that about 70% of lost-time hand injuries occur on workers who aren’t wearing gloves. The remaining 30% are wearing gloves at the time of the accident, but the gloves are inadequate, damaged or the wrong type for the job. It goes to show, the steel doctor blade risk of serious lacerations to a press operator’s hands doesn’t just go away with wearing protective gloves.

Establish occupational health and safety programs

Companies with safety and health management programs reduce their injury and illness costs by an estimated 20-40% according to the Occupational Safety and Health Administration (OSHA). In fact, an ASSE white paper by OSHA’s Office of Regulatory Analysis suggests that companies that implement effective safety and health programs can expect a return of $4 to $6 for every $1 invested. These programs lead to improved productivity and employee well-being in addition to reducing injury-related direct and indirect costs. Training employees and documenting handling procedures can also be beneficial in reducing the doctor blade risk of lacerations. In the pressroom, operators should be taught how to minimize their exposure to the risks from steel doctor blades by following standard protocols – for example by keeping blades in their protective packaging until they are ready to be installed and not changing blades on a machine while it’s running.

Switch to plastic doctor blades

The above options will certainly lower the risk of getting cut by steel blades but switching to plastic doctor blades will completely eliminate this doctor blade risk. Plastic materials are inherently softer and less sharp than steel. Even when plastic blades are worn, their edges are not sharp enough to cut a press operator.

Unlike in the past, a printer producing high-quality graphics now has the option of choosing a plastic blade for its safety benefits. Next generation polymer blades with MicroTip® technology can compete with the metering performance of steel in even the most demanding graphics applications while retaining the safety benefits of traditional plastic.

Next generation polymers with MicroTip®

Today’s advanced polymer material is stiffer than traditional plastic and can support a precisely engineered MicroTip edge. This tip design allows the blade to achieve and maintain a fine contact area with the anilox roll comparable to a steel blade. Next generation polymer blades are able to effectively meter line screens up to 2000 LPI or 785 L/cm and produce graphics of the highest quality. The MicroTip has a long and steady wear period which reduces the frequency of blade changes and delivers consistent ink film thickness for the duration of the print job.

Today’s printers have more options than ever to improve workplace safety. Protective gear and safety programs will no doubt reduce the risk of injuries from steel doctor blades. But if you want to completely eliminate these injuries, then completely eliminate steel blades from your pressroom. Switch to next generation polymer blades and get the best of both worlds – high performance metering and safety.

Look for part three of our In Safe Hands with Polymer Doctor Blades Blog Series – “Not the Sharpest Blade in the Pressroom.”

Part 1: “Numbers That Add Insults to Doctor Blade Injuries“ – Read about the frequency of hand injuries in the workplace and their impact on a company’s bottom line
Request a Free TruPoint Doctor Blade Sample
In Safe Hands with Polymer Doctor Blades Blog Series Part 1 “Numbers That Add Insults to Doctor Blade Injuries”

OSHA reports, “Businesses spend $170 billion a year on costs associated with occupational injuries and illnesses.” Also, “Employers pay almost $1 billion per week for direct workers’ compensation costs alone.” These statements by themselves are alarming. But even more concerning is the fact that these costs are “expenditures that come straight out of company profits.”

It’s not hard to imagine how traumatic it can be to experience (or even witness) an accident at work. But what not many people think about is the frequency that these injuries occur and the impact they can have on a company’s bottom line.

It’s true that government regulations have helped keep workers safer. But on-the-job accidents continue to be a big problem for many businesses – and the printing industry is no exception. In the pressroom, some of the most common accidents are cuts and lacerations that occur when operators are handling steel doctor blades. Their edges are incredibly sharp, and machinists need to be extremely careful when installing and removing them from the press to avoid seriously injuring their hands.

Hand injuries in numbers

According to the U.S. Center for Disease Control and Prevention, hand injuries account for 1,080,000 emergency department visits by workers every year in the U.S. (Industrial Safety & Hygiene News, May 1, 2015). In fact, hand injuries ranked second in number after back strains, sprains and other work injuries to the torso in 2015, as reported by the U.S. Bureau of Labor Statistics (U.S. BLS), and close to 20% of all workplace injuries involved cuts and lacerations to the hand and fingers.

Some other statistics assign dollars to these injuries. The U.S. BLS informs us that hand and wrist accidents, the most expensive of all emergency department injuries, cost $740 million every year; the average hand injury claim now exceeds $6,000, with each lost-time workers’ compensation claim totaling just under $7,500.

Hidden costs of hand injuries

Equally significant are the indirect costs associated with work-related injuries. A study published in the Journal of Bone and Joint Surgery indicates that productivity costs due to absenteeism contributed more to the total costs of hand and wrist injuries (56%) than did directly related health-care costs. The U.S. BLS recorded 124,540 on-the-job hand injuries in 2015 that resulted in recordable missed work time of 5 days each. These and other secondary costs – machine downtime, equipment repairs, training of replacement employees, accident investigation, implementation of preventive measures, not to mention bad publicity – contribute to the already steep costs of workplace injuries.

Like many companies, printers pay a high price for on-the-job injuries. Some of these costs directly affect profits while others have an impact on operations and employee well-being that’s harder to quantify. One thing is certain though – as OSHA cautions, “In today’s business environment, these costs can be the difference between operating in the black and running in the red.”

Look for part two of our In Safe Hands with Polymer Doctor Blades Blog Series – “Steel Doctor Blade Risk Management” to learn about ways to reduce or eliminate these risks.
3 Ways to Conquer UV Ink Spitting in your Pressroom

Ever seen your perfect print job turn into a messy, chaotic artwork? If you’re a label printer, you’ve probably faced the nightmare of UV ink spitting. But don’t worry, we’ve got the solutions you need to reclaim your sanity!

1. Start with Some TLC

Ensure your equipment is in top shape. Clean the anilox roll, inspect the doctor blade holder or chamber, and lower the doctor blade pressure for a perfect wipe. Minor tweaks can work wonders.

2. Opt for New Anilox Roll Engravings

Traditional engravings can hinder UV ink flow. Because UV inks have a viscosity of 5-7 times greater than that of water-based or solvent-based formulations, different anilox configurations may be required. New elongated hexagonal cell engravings, or even newer channeled engravings, can improve ink transfer and reduce or eliminate ink spitting.

3. Try a Different Doctor Blade

Doctor blades are an easy variable to change when up against UV ink spitting. It’s a low-cost part with a big impact. TruPoint polymer doctor blades are a fantastic choice for handling UV inks. Why? Our unique MicroTip edge ensures consistent ink metering but more importantly, TruPoint polymer materials have a lower surface energy than steel.

This lower surface energy reduces the attraction of the UV ink to the doctor blade and allows for a cleaner ink transfer. Steel’s high surface energy attracts UV ink, causing it to accumulate on the backside of the blade and then release. This is UV ink spitting!

Taming UV ink spitting can be easier than you think. Regular maintenance and the right doctor blade can make all the difference. Don’t let ink-spitting drive you crazy; we’re here to help!

Request a Free TruPoint Doctor Blade Sample
Corrugated Converters at the Crossroads Blog Series Part 4 “The Digital Printing Revolution”

Our first post in the Corrugated Converters at the Crossroads blog series looked at changes in the corrugated printing market, the factors driving them and how big-box retailers and CPCs are increasing their requirements of packaging suppliers. The major areas of change range from graphics quality to flexibility to velocity, and pressroom versatility is the name of the game.

The final post in our series will explore how digital printing is becoming a key player in the corrugated evolution, with added insight from Paul Aliprando, VP of Digital Technologies at Sun Automation Group. Expanding with digital technology can help printers meet demands for short runs, fast turnarounds, stunning graphics and customization without sacrificing efficiency or, more importantly, profits.

Sun Automation CorrStream® Digital Printer

A new take on old news

Digital printing is already being used in corrugated plants to produce samples, prototypes and other one-off or small-batch jobs due to its relatively cheap cost to produce shortruns compared to flexo. But the use of digital technology is ramping up as a growing number of jobs creep into its sweet spot – high resolution graphics, smaller order sizes, short lead times, fast turnarounds, customization and personalization.

Aliprando says, “some users are applying digital to increase value to their customers which allows higher product margins. Other users apply digital as an alternative to current methods for lower total production costs. Either way, money is the motivator.”

Let’s take a look at the ways digital technology is having the biggest impact in the corrugated post-print sector:

High resolution graphics

High-definition visuals, desired by today’s brand owners to create product differentiation and appeal, require high-resolution printing. A flaw with Flexo is as the sheet moves through each color station in the press, it shifts slightly, making it impossible to overlap every ink color and produce the image exactly as it was designed. Bleeds and traps have to be incorporated into the design to hide the registration issues.

Aliprando states, “In general, Digital has a higher resolution than ‘standard’ Flexo for corrugated. Although there are excellent flexo machines capable for printing Process work direct to corrugated, the cost, maintenance and operation knowledge is specialized.“

With a digital printer, images are printed in one pass. There are no registration issues and minimal dot gain, making digital printing a better option for reducing waste and producing images with high graphic resolution – especially with gradients and very detailed print that requires fine lines or images.

Smaller order sizes

The digital process offers an economical way to produce low-volume and custom print jobs. With flexo presses, high setup costs are offset by their faster speeds and lower production costs over a high-volume, long run job.

But digital presses are much more agile and a smarter choice for small print lots. The image is transferred directly onto a substrate, with no print cylinders, die-cut tooling, plates, ink tanks, anilox rolls, doctor blades or complex set up processes.

Short lead times and fast turnarounds

The quick and easy set-up of a digital press also makes it conducive to short lead times and fast turnarounds. Remember flexo’s cumbersome and expensive setup process – creating plates, filling the ink tank, assembling the ink roll and print cylinder? Digital files can be easily created, changed or updated so customers can request new or custom packaging on short notice or make changes on the fly. The full CYMK spectrum is readily accessible and producing gradients and other detailed effects is easy. Less waste…

Brands need responsive suppliers that can meet their needs for speed and versatility.

The flexibility that digital printing brings to the corrugated pressroom can also turn the package printer into a value-added service provider. With short lead times and fast deliveries, CPGs and big-box retailers can keep inventory levels low to save on warehousing and prevent outdated stock. However, Aliprando urges printers to consider the additional converting process with digital printing, stating “an added requirement for the corrugated facility is converting the printed sheet into a box. The digital printer is just that, a printer.”

Customization and personalization

Although, “Digital has its own ‘specialization’… it is offset by the variability and versatility digital allows,” says Aliprando. With digital, versioning is simple to execute – brands can customize graphics for multiple adaptations of the same package based on the audience, season, geography, event, market or any other segmentation criteria. The full range of CMYK colors are readily accessible for quick changes. Variable data – personalization with customer names, product expiration dates or any varying data used to personalize packages – is a snap to produce on a digital press.

Things to Consider

The Rise of Digital is a hot topic in the industry, and like many others, you may be hesitant to incorporate digital printing in your pressroom. Aliprando advises to “stay hesitant and get knowledgeable. Take the time to increase your understanding and knowledge of the complete digital process. You need to be comfortable about the technology and, once comfortable, decide if it fits into your current market or a new market you may want to pursue.” Aliprando adds,

“Ask yourself if your current manufacturing operation – order receipt to shipping – can accommodate digital. Digital is not for the faint of heart.”

By adding digital printing capability to the corrugated pressroom, printers can optimize efficiency and profitability by using the “right man for the job” every time. And that is just the tip of the iceberg – Digital press manufacturers are continually improving the digital print process with new technologies.

In October 2018, Sun Automation will introduce the new CorrStream®, which will have a new Aqueous ink set, capable of printing on standard white top sheets and clay coat for more “pop” to the printing. The new system allows 600dpi printing without any pre or post coating of the sheets and boasts a modular design, equipped to accommodate future system upgrades. “Obsolescence is not in our design”, comments Aliprando.

All in all, Digital Printing gives Corrugated Converters a cost-effective way to meet the market’s demands for flexibility and responsiveness. At the same time, the flexo presses are freed up to do what they do best – crank out large volumes of standardized products at fast speeds and low cost.

To sum up our Corrugated Converters at the Crossroads blog series, the logic is simple: what the consumers want, the manufacturers have to produce, and what the manufacturers want, the suppliers have to provide. The corrugated converting industry has responded to this market evolution with advancements in ink delivery, equipment, substrates, and digital processes to name a few. By adopting these market innovations, converters can embrace the market evolution as a great opportunity for not only survival, but future growth and prosperity.

For more information on Sun Automation and the new Corrstream Digital Printer, contact Paul Aliprando at [email protected].

We hope you enjoyed our Corrugated Converters at the Crossroads blog series. Click on the links below to view previous posts in the series:

Part 1: “The Consumer Is King” – Read about the forces behind the corrugated package printing renaissance

Part 2: “Necessity Is the Mother of Ink Delivery Innovation” – Read about ink delivery system innovations

Part 3: “This Is Not Your Father’s Pressroom” – Read about innovations in equipment and substrates
The Environmental Impact of Doctor Blades

Generally, printers choose plastic or steel doctor blades according to their graphic requirements (or maybe blade life or safety). But, all else being equal, choosing the eco-friendlier material can help you reduce your facility’s carbon footprint.

This infographic compares the environmental impact of the two most common doctor blade materials: steel and plastic. For printers looking for innovative ways to reduce their carbon footprint, this infographic may help you better understand the impact your choice in doctor blade could have on the planet. Take a look and complete the form to download the PDF.
Doctor Blade Installation

Back to the basics with this doctor blade installation and best practice infographic, created by Flexo Concepts. This infographic is a simple 3-step guide to proper TruPoint doctor blade installation in a chambered ink system. We also offer helpful insight on the ideal blade orientation and blade pressure to prolong doctor blade life and ensure effective ink metering.

Complete the form to download this infographic – with this download, you will also have an option at the bottom of the graphic to print the installation guide on standard letter size or poster size paper. This graphic is a great resource to print and post by your press operators to facilitate accurate doctor blade installations.
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.
New, Improved MicroTip®

Since Flexo Concepts launched TruPoint Orange® with a MicroTip four years ago, it has been an overwhelming success in tag and label plants. Printers around the world have embraced the blade’s capabilities with enthusiasm. OEMs have endorsed Orange and are shipping the blade with new press installations, and industry co-suppliers have co-marketed the blade at trade events to demonstrate its unique benefits.

But despite the success, we haven’t stopped working to improve our revolutionary blade innovation.

By keeping our “finger on the pulse” of the industry, we continue to learn what issues today’s printers are facing. Using advanced equipment, our R&D folks experiment with blade materials and tips in our Doctor Blade Innovation Lab to come up with solutions, and our engineers deliver concepts that simplify life in the pressroom.

Flexo Concepts has expanded its range of blade thickness and MicroTip combinations on its Orange blade so printers can customize blades for their specific applications. Options range from material and tip duos that extend blade life in most process work to more robust alternatives for white decks and coarse anilox rolls.

Recently, our engineers modified the MicroTip design to further improve metering and blade life. A minor enhancement to the geometry of the tip doubles its stiffness at the contact point with the anilox roll. This refinement fortifies the strength of the blade and bolsters its impact resistance. The “new and improved” MicroTip delivers a cleaner wipe and lasts longer.

Our culture of continuous improvement also extends to manufacturing. Investing in advanced equipment allows us to achieve better precision and tighter tolerances in our blade production. In response to the industry’s struggle with start-up issues, we have improved finishing techniques to produce a smoother finish on the MicroTip. As a result, the blade requires no wear-in period and eliminates start-up lines.

At Flexo Concepts, we like to go above and beyond in what we do. Therefore, even after perfecting a new blade technology, we keep working to make it better. The latest design update to the MicroTip edge and improved “polishing” do just that. TruPoint Orange not only has the ability to replace steel in high line screen applications, but now meters even better and eliminates start-up lines. What was once used mostly as a “fix-it” blade (to prevent UV ink spitting for example) has proven that it can compete for best “all-around” blade in the narrow web pressroom.
Request a Free TruPoint Doctor Blade Sample
Hybrid Printing Technology Combines the Best of Both Worlds
The TeaToaster. An appliance that makes tea and toast? How nice would it be to have the option of preparing your breakfast and morning beverage at the same time??! (It doesn’t actually make toast, but a good idea, right?)

There are also innovations in the printing industry that combine functionalities to make life a little easier for press operators.

Today’s brand owners are more demanding than ever, looking for variable data and versioned graphics, short lead times, fast turnarounds and, of course, competitive prices. These forces are driving industry innovation, and Mark Andy and Flexo Concepts® have led with hybrid technologies that bring flexibility and efficiency to the modern-day pressroom.

Hybrid press technology

In his 2016 article, Hybrid Presses – Combining digital and conventional printing offers converters the best of both worlds, Associate Editor of Label & Narrow Web Greg Hrinya compares hybrid press technology in the label printing market to that in other industries – a hybrid car which relies on multiple power sources or hybrid golf club that features the qualities of an iron and a fairway wood. Similarly, new hybrid presses combine the benefits of digital with the power of flexo in one piece of equipment. For printers, according to Hrinya, “The goal is to meet demand for large run flexo orders on the same press that is capable of handling a 500-label order from a local winery.”

Mark Andy’s Digital Series – best of flexo and digital

Mark Andy’s Digital Series, a 2017 technical innovation award winner, does just that. Built upon the industry-leading Performance Series architecture, these presses leverage the advantages of digital technology with the proven capabilities of flexo. The optimized hybrid platform is an efficiently designed, end-to-end workflow offering digital printing with in-line converting, decoration and finishing. This happens all in a single pass and any size converter or job can be accommodated. The machines run at printing speeds up to 240 fpm (73 mpm) and feature an intuitive user interface and consistent controls. Operators can customize and enhance their production process to:

Increase throughput

Minimize cost of operation

Optimize process for short to medium runs

Maximize versatility

Create a superior user experience

Obtain reliability of proven P-Series platform

Flexo Concepts’ TruPoint Orange® – best of steel and plastic

Just as Mark Andy’s Digital Series brings together the best of digital and flexo in one press, Flexo Concepts’ TruPoint Orange combines the advantages of both steel and plastic materials in a single blade product.

At one time, steel doctor blades were the only option capable of providing the fine, consistent contact area with the anilox roll necessary to produce high-end graphics. However, printers had to accept the risks of using steel – dangerous injuries and anilox scoring.

Although plastic is safer to handle and doesn’t produce metal fragments that can cause scoring, traditional plastic doctor blades must be engineered thicker to provide enough rigidity to meter the anilox. This thicker contact area can’t meter high line screens effectively, so plastic blades were ruled out as an option for narrow web printers.

That is, until the hybrid doctor blade came along.

A product of Flexo Concepts’ Doctor Blade Innovation Lab, TruPoint Orange is constructed from a next generation polymer material and engineered with MicroTip® technology in a combination that is capable of achieving a fine, consistent contact area with the roll. The blade can effectively produce high quality graphics as well as steel while retaining the benefits of traditional plastic – no dangerous cutting edge or metal fragments that will damage the anilox roll. Orange doctor blades are able to:

Effectively meter line screens up to 2,000 lpi (785 L/cm)

Reduce pressroom injuries

Eliminate anilox scoring

Prevent UV ink spitting even at high press speeds

Handle specialty coating chemistries

As the label and packaging market evolves, printers need products that can keep up. With their hybrid technologies, Mark Andy and Flexo Concepts are at the forefront in developing innovative solutions that combine the best of known technology to help printers operate efficiently and competitively. What the TeaToaster did for breakfast (in theory), the Digital Series and TruPoint Orange have done for printers: combine two technologies in one to bring maximum success to the narrow web pressroom.
Learn More about the Mark Andy Digital Series
Request a Free TruPoint Doctor Blade Sample
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

Category: Doctor Blades

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

Wear personal protective equipment

Establish occupational health and safety programs

Switch to plastic doctor blades

Next generation polymers with MicroTip®

Hand injuries in numbers

Hidden costs of hand injuries

Ever seen your perfect print job turn into a messy, chaotic artwork? If you’re a label printer, you’ve probably faced the nightmare of UV ink spitting. But don’t worry, we’ve got the solutions you need to reclaim your sanity!

Taming UV ink spitting can be easier than you think. Regular maintenance and the right doctor blade can make all the difference. Don’t let ink-spitting drive you crazy; we’re here to help!

A new take on old news

High resolution graphics

Smaller order sizes

Short lead times and fast turnarounds

Customization and personalization

Things to Consider

Tight tolerances and high dimensional standards

10-Point inspection

Track and trace

Hybrid press technology

Mark Andy’s Digital Series – best of flexo and digital

Flexo Concepts’ TruPoint Orange® – best of steel and plastic

What is TruPoint Green?

Why was TruPoint Green created?

Why won’t UHMW work in these applications?

Who created TruPoint Green?

How was TruPoint Green created?

Where was TruPoint Green created?

Is TruPoint Green “green”?

So… When will TruPoint Green be available?

**The NEW TRESU Series XL Blade Holder**