Category: Wide Web

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?
Versioning and Variable Data in Flexible Packaging

According to Smithers Pira in its “Future of Global Flexible Packaging to 2020” report, “Flexible packaging has been one of the fastest growing packaging sectors over the past 10 years, thanks to increased consumer focus on convenience and sustainability, and this rapid development will continue to accelerate.” This growth, however, will depend on the industry’s ability to cope with market trends driving shorter run lengths.

Versioning and Variable Data Printing

Two of these trends driving shorter run lengths are versioning and variable data. Versioning is used to produce packages for different variations of a product (such as a line of flavors) while maintaining brand continuity. For the printer, a large print job is segmented into smaller lots that are customized based on each “version” of the product.

Variable data printing is mainly used in flexible packaging applications for product authentication and logistics in the distribution chain. Companies can add a unique identifying code to each package, allowing individual products to be “tracked and traced” through the supply chain. Bar codes and RFID codes are used to facilitate inventory and prevent counterfeiting.

Both versioning and variable data lend themselves well to digital printing, a process that can easily and cost-effectively produce small lots. In flexible packaging, however, long runs are required to achieve the economies necessary to be profitable. How can a flexible packaging printer be competitive?

1. Take Advantage of New Wide Web Technologies

As run lengths become shorter, changeover speeds become more critical than press speeds. The wide web industry has responded with equipment technologies that make faster set-ups possible such as gearless presses, anilox sleeves and automatic impression settings. Some printers are converting to fixed ink sets, such as extended gamut, to minimize the number of wash-ups, or eliminating manual cleaning altogether with automatic wash cycles.

2. Add Mid-Web Equipment

A number of large format printers are adopting mid-web press technology for economical production of medium-length jobs. By comparison, these presses not only cost less but are built for faster changeovers, lower tooling costs, and less consumption of ink, plates and other consumables. They require fewer operators to run and deliver easier reproduction of high-quality graphics.

3. Incorporate Digital

Finally, for some work, digital just makes more sense. Digital printing’s sweet spot is its ability to produce short runs economically. By adding this complementary technology, printers can take advantage of the flexibility offered by having both capabilities under one roof. Like narrow web, using digital for short run work also frees up wide-web presses for big jobs.

The flexible packaging industry is experiencing a reduction in run lengths driven by shifts in the way brand owners do business. Printers have to find ways to adapt to such changes as versioning and variable information printing by creating new technology and processes. By improving equipment to shorten changeover times and adopting additional printing capabilities, wide web printers will be able to claim its share of future growth in the package printing market.
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.
Polymer Doctor Blades are Safe Substitutes for Steel in Flexible Packaging

If you are using steel doctor blades, you are probably well aware of the risk of serious cuts from handling the blades. Pressroom injuries can be expensive in terms of morale and accident-related expenses. Today’s next generation polymer blades combine the best of traditional plastic and steel blades and provide safe substitutes for steel in flexible packaging applications.

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

Until recently, steel was the only material capable of producing the high quality print required in flexible packaging applications so printers had no choice but to accept these risks. While plastic blades were safer, they were not able to achieve a fine enough contact area with the high line screen rolls.

Today’s next generation polymer blades act as a hybrid between steel and plastic and offer a safe alternative to steel. The combination of an advanced polymer material and an innovative “MicroTip®” design allows these blades to perform in highly demanding applications where previously steel was the only option. Due to their material composition, the new polymer blades are safe to handle even when worn. Converting to these blades will reduce lost-time accidents and can save a printer a lot of money in terms of workman’s compensation insurance rates, medical bills, labor replacement expenses and press downtime.

When it comes to the pressroom, safety is everyone’s concern. Flexible packaging printers no longer have to accept the danger that comes with using steel blades to get the print quality their customers demand. To greatly reduce the risk of injury and associated costs, try substituting next generation polymer blades for steel.
Request a Free TruPoint Doctor Blade Sample
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
5 Reasons to Switch to Polyester Containment Blades

Switching to polyester containment blades from steel can offer several benefits for printers. Here are the top 5 reasons to make the switch:

1. Elimination of Back Doctoring:

Some printers encounter back-doctoring issues at higher press speeds when using steel containment blades. Steel blades are too rigid to allow back-doctored ink to flow back into the chamber, leading to ink buildup and negatively affecting press uptime. Polyester blades, while effectively containing ink, are flexible enough to enable back-doctored ink to return into the chamber, preventing back-doctoring and maintaining print quality.

2. Cost Savings:

Polyester containment blades are significantly more cost-effective than steel blades. The price per inch for polyester blades is typically one-third to one-half that of steel, making them a cost-efficient choice for printers.

3. Enhanced Safety:

Replacing the steel containment blade in a chamber with polyester reduces the risk of doctor blade injuries by 50%. Polyester blades are safer to handle, as they don’t pose the same cutting hazard as steel blades during installation and removal from the press.

4. Prevention of Anilox Damage:

Polyester containment blades are gentle on anilox rolls. They won’t score or damage the rolls, and the material contains no sharp fragments that could break off and harm the engraving on the roll. This non-abrasive quality helps extend the life of anilox rolls, saving on the expense of re-engraving or replacement.

5. Reduced Environmental Impact:

Polyester containment blades emit a smaller amount of carbon dioxide during production compared to steel blades. Using polyester blades can help printers meet environmental requirements for reducing their carbon footprint, contributing to an eco-friendly printing process. Switching to polyester containment blades reduces downtime and provides a lower per-unit cost while delivering safety benefits, reducing back-doctoring, and lowering the environmental impact of the printing process. It’s a small change that can make a significant difference in efficiency and overall performance in the pressroom.

Request a Free Sample of TruPoint Polyester
New Doctor Blade Technology Is Worth a Look

As a consumables manufacturer introducing new doctor blade technology to a mature industry, we’re constantly hearing, “But I’ve done it this way forever.” Press men are busy and don’t’ have time to waste trying new products when their current ones are working fine. But changing times call for an ongoing evaluation of your print process to find ways to improve. Today’s printers are smart to run controlled tests of new products to make sure they are maximizing efficiency and profitability and “keeping up with the times.”

Anilox Roll Evolution

Chrome anilox rolls

Let’s use anilox rolls as an analogy. When chrome-plated anilox rolls came on the market almost 80 years ago, they were an improvement over the previous (and crude) methods of ink transfer. Steel rolls were covered with a chrome layer and mechanically engraved using a knurling tool. The dimples or “cells” filled with a precise volume of ink and carried them to the plate. This gave the printer more control over the ink application process and better print quality.

As the industry continued to evolve, however, the limitations of chrome-plated rolls became apparent. The chrome surfaces wore down quickly from the friction between the roll and the doctor blade. Due to their shape, the cells quickly lost volume capacity and print densities declined. Also, the maximum line screens that could be achieved with the knurling tool were 500 lpi which was only enough for basic and moderate graphics reproduction. As demands for higher quality printing increased, and there were advancements in presses, plates and inks, so did the need for better anilox roll technology.

Ceramic-coated rolls

To keep pace with the industry, anilox roll manufacturers began applying a ceramic coating to their rolls using a plasma spray device. These new surfaces had hardness of over 1400 Vickers compared to 850-900 Vickers for the chrome-plated surfaces. As the hardness of the roll determines its strength and durability, the new surfaces had better resistance to wear from the doctor blade. These rolls were too hard to engrave mechanically and lasers started being used to etch the rolls. The lasers produced a consistent engraving with cleaner cells and more distinct cell walls. Higher line screens could be achieved to expand a printer’s graphics capabilities. The ceramic surfaces not only lasted longer but the cells were also less sensitive to volume changes from wear. Printers gained more control over print quality and were now able to achieve target ink densities with thinner ink films.

New doctor blade technology

Like presses and other press components, doctor blades have evolved to adapt to the market. Blade manufacturers are continually experimenting with new materials and edge designs and introducing new doctor blade technology to keep up with their customers’ needs.

Steel

Today’s steel blade users have a choice of carbon, stainless, long life, coated and ceramic blades to fit their precise applications. Until now, steel was considered the only material capable of achieving a fine contact area with the roll and producing an effective wipe on high line screen engravings. Printers had to accept the downside of frequent blade changes, injuries and anilox roll scoring because there were no alternatives.

Plastics

Plastics, on the other hand, have always been known for their blade life and safety. The material has to be thicker to provide rigidity and these blades were suitable only for producing low-moderate graphics. The upside is that they don’t have to be changed as often, and the long and steady wear period allows for consistent ink film thickness for the duration of the print job. The material is also safer to handle and won’t score anilox rolls. Plastic doctor blade choices include a variety of acetals, UHMWs, and polyesters.

Next generation doctor blades

Flexo Concepts® recently introduced a new blade that acts as a hybrid between steel and plastic. A combination of an advanced polymer material and an innovative tip design called “MicroTip™” allows the blade to perform in high line screen applications where previous non-metallic materials were not an option. Printers using these advanced polymer products get blades that can produce the graphics quality of steel while remaining safe to operators and anilox rolls. The blade is now successfully being used in a range of narrow web and wide web applications.

As with anilox rolls and other press components, new doctor blade technology has gone hand in hand with the evolution of the flexo printing industry. The new polymer MicroTip blade is an example of a product that, once again, improves upon “what you were using before.” Why not try it?
Request a Free TruPoint Doctor Blade Sample
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.
Take Care of Your Doctor Blade Chamber and It Will Take Care of You!

Carbon fiber chamber system by Celmacch

The job of a doctor blade chamber is to help deliver a precise, consistent ink film thickness to the substrate.  Like other parts of the press, the doctor blade chamber needs to be maintained and inspected on a regular basis to ensure its peak performance. Taking the time to do this is a smart way to maximize press uptime and minimize costs.

What Can Go Wrong

1. The chamber needs cleaning – The doctor blade chamber requires regular cleaning to make sure it functions properly. Dried ink and coating particles can interfere with doctor blade seating in the blade holder and cause the chamber to go out of alignment.

2. The doctor blade chamber is not aligned properly – The doctor blade and anilox roll work best together when there is light, consistent contact between the two. If the blade does not have even contact with the roll due to chamber misalignment, it will not shear the ink cleanly and consistently from the anilox roll surface.

Doctor blade chamber corrosion

3. There is corrosion or pitting in the chamber components – Over time, regular exposure to harsh cleaning chemicals can cause corrosion and pitting in parts of the chamber. This can create recesses in the metal that prevent the blade from lying flat in the holder. Pitting also makes cleaning difficult, and particles from a corroded chamber can dislodge, settle into the ink and score anilox rolls.

4. The chamber is bowed or warped – Due to the length of the doctor blade chamber, it can bow and become warped from being mishandled. When bowing or warping occur, the blade will not lay flat along the full surface of the blade holder and contact the anilox roll uniformly when engaged.

Oftentimes, the press operator may try to correct some of these issues by increasing pressure to force contact between the anilox roll and doctor blade. While this may fix the problem temporarily, it often makes it worse. The added friction from excessive blade-anilox contact can cause chamber leaks and accelerated wear on the blade and roll.

What To Do

1. Clean the chamber – A cleaning routine involves wiping down the chamber with a cloth and flushing with approved cleaning solutions every day to remove ink deposits and particles from the doctor blade and blade clamp.  (This can take place when the press is shut down to clean the anilox roll which is also recommended on a daily basis.)

2. Verify chamber alignment – Operators should take the time to make sure the system is properly aligned and parallel on a regular basis. This will prevent early and excessive doctor blade and anilox wear and ink leaks.  If aligned properly, the system will remain stable even at increasing press speeds.

3. Inspect the chamber for defects – Chamber bodies should be flat and straight. This should be confirmed periodically (such as when other scheduled maintenance is taking place). To check, take a long straight edge and lay it along the full length of the doctor blade. Look for gaps which indicate that the chamber is bowed or warped. Also, examine the blade mounting surface and holder for corrosion and pitting. The chamber should be replaced if any of these conditions are evident.

4. Replace consumable parts – It is important to replace doctor blades and end seals when needed. Skimping on these inexpensive consumables is penny-wise and pound-foolish! Using new blades and seals to ensure a good contact area with the anilox roll and a tight chamber seal will prevent chamber leaks and anilox roll damage.

5. Standardize a cleaning and maintenance routine – Establish a recommended schedule of cleaning and maintenance for the doctor blade chamber. Make sure that procedures are documented and press operators are properly trained and evaluated.

Tresu’s carbon fiber E-Line chamber

6. Convert to a carbon fiber chamber system – In addition to other benefits, carbon fiber chamber constructions, such as the ones pictured here by Celmacch and Tresu, offer superior resistance to corrosion and pitting.

The doctor blade chamber is a precision tool that plays a vital role in producing a consistent product, and a regular routine of cleaning and maintenance will ensure its peak performance. A small investment here will go a long way to guarantee that this press component does its part in keeping your bottom line healthy and your customers happy!
New Polymers Meter Like Steel Doctor Blades

Steel doctor blades used to be a printer’s only option to produce high-end graphics. It wasn’t because he didn’t want longer blade life and the safety benefits that came with using plastic, steel was simply the only material that could sufficiently meter a high line screen roll. Not anymore! Today’s next generation polymers and advanced tip engineering have at last resulted in a non-metallic doctor blade with the metering quality of steel. This blade can replace steel doctor blades in a full range of flexo printing applications from solids and lines, to reverses and fine print, to screens and process work. Here’s why.

Steel Doctor Blades vs. Traditional Plastic

Due to its thinness and stiffness, steel has been the only blade material that could achieve a fine point of contact sufficient to execute a clean wipe on a high line screen anilox roll. By comparison, the characteristics of traditional plastic doctor blades require them to be thicker to provide the same rigidity. While they have other benefits in terms of safety and blade life, their thickness prevents them from maintaining a fine contact area with the anilox. As they wear and their contact area with the anilox roll grows, plastic blades produce changes in tonal value and dot gain when metering high line screens. For this reason, they have historically been limited to jobs with low to modest graphics requirements.

Next Generation Polymers

Now, specially formulated polymer doctor blades can compete with steel in the most demanding graphics applications. Unlike traditional plastic, the stiffness of the next generation material with a precisely engineered MicroTip™ edge allows the TruPoint Orange doctor blade to achieve and maintain a fine contact area with the anilox roll. Orange can deliver effective metering on line screens up to 2,000 lpi (785 L/cm) and produce graphics of the highest quality. The following diagrams compare the contact areas of traditional plastic, steel and next generation polymer blades:

Doctor Blade Contact Area Comparison

As shown, the contact area of a worn traditional plastic blade grows to .060″ (1.52mm) compared to a contact area of .016″ (.40mm), for a worn steel blade. The next generation polymer is able to maintain a contact area of .012″ (.305mm), equal to or smaller than that of most steel doctor blades, throughout the life of the blade due to the edge design. The engineered tip wears slowly and evenly and delivers consistent ink film thickness for the duration of the print job.

Today’s innovations in polymer doctor blades offer printers a viable alternative to steel. A combination of advanced materials and new tip technology has yielded a blade that meters as well as steel on the highest line screens yet retains the benefits of traditional plastic. Printers no longer have to compromise on anilox scoring, blade life, and safety to fulfill the most demanding graphics requirements!
Request a Free TruPoint Doctor Blade Sample
Cut-to-Length Doctor Blades Can Reduce Ink Chamber Leaks
Doctor blade chamber leaks are costly in terms of downtime and waste. While failed end seals are responsible for a large number of chamber leaks, ill-fitting doctor blades can also contribute to leaks. Ordering cut-to-length doctor blades from your supplier is a smart way to reduce leaks, maximize doctor blade and end seal performance and save a printer thousands of dollars every year.

Problems arising from Chamber Leaks:

Ink waste

Substrate waste

Excessive solvent consumption for clean-ups

Downtime for change-overs

Reduced doctor blade life

Scored anilox rolls

Increased end seal consumption

Chamber leaks are a nuisance in the pressroom that cause frustration and reduce press efficiency. When faced with a leaking chamber, a press operator has to stop the press and clean up the mess. Often, he will try to fix the problem by increasing the load pressure instead of looking for the basic cause of the leak. While this may work as a temporary solution, it can lead to other problems such as accelerated doctor blade and anilox wear. The increased pressure may also force ink out of the ends of the chamber, making the situation worse. Paying a little extra attention when installing doctor blades and ends seals can prevent many leaks from occurring in the first place.

Causes of Chamber Leaks:

Improper seal material

Bad seal design

Lack of proper seal lubrication

No dead bands on anilox rolls

Anilox roll chips

Incorrect doctor blade length

Failed end seals account for many chamber leaks. Using an end seal material that is not compatible with the type of ink being used, the length of the run or the press speed will allow ink to escape from the ends of the chamber.  Ink build-ups can result from not using the appropriate lubrication to reduce friction between the anilox roll and end seal. If the seals are not a proper fit, they will not do their job at containing ink within the confines of the chamber. Working with your end seal supplier is a good way to work through these issues and ensure that you are using the correct end seals for your application. (View End Seal Brochure)

The condition of the anilox roll can also play a role in chamber leaks. If the roll lacks a dead band (an unengraved area) at each end, ink will build up there and cause the seals to fail. Chips on the ends of the anilox rolls can also create ink buildup and compromise the integrity of the end seals.

Incorrect Doctor Blade Length can cause Chamber Leaks

In addition to failed end seals and defects in the anilox roll, doctor blades that are too short or too long

Doctor blade is the correct length for the chamber

can be another source of leaks.  When changing a doctor blade, it’s important to make sure that the new blade is the right size for the chamber and installed correctly. If it’s not a perfect fit, the doctor blade provides a gap through which ink can leak out of the chamber.

When properly installed, the doctor blade should have some upward pressure from the end seals to ensure a sufficient seal. A very slight rise in the blade is okay, however, extra loading pressure should not be necessary to get the blade to wipe the center of the anilox roll.

When a blade is too short or too long for the chamber, it prevents the end seals from doing their job. The blade should come to about halfway across the tops of the end seals when placed in the chamber. If the blade does not reach the seals, then the seals can actually prevent contact between the doctor blade and the anilox roll.

Doctor blades are too long for the chamber

On the other hand, if the blade extends beyond the outer edge of the end seal, it may create a small opening between the underside of the blade and the end seal which creates a path for ink to flow out of the chamber. If it’s too long, the blade may also become wavy and not lie flush with the roll, causing uneven metering and leaking.

Installing doctor blades that are a perfect fit for the chamber will eliminate this source of leaks. When ordering doctor blade material by the roll, it is important to confirm the proper blade specifications with your chamber OEM to make sure that press operators are cutting blades to the correct length.  An easier way to ensure the proper size is to order cut-to-length doctor blades from your supplier that are ready to install right out of the box.

Cut-to-length Doctor Blades can Reduce Chamber Leaks

Doctor blades that are the incorrect size for the chamber can be a frustrating source of chamber leaks, downtime and waste. Installing blades correctly and making sure that they are the precise length according to OEM specifications is one way to prevent this problem. Ordering cut-to-length doctor blades from your supplier will not only speed up blade changes but also ensure a perfect fit to maximize blade performance and minimize leaks.
Request a Free TruPoint Doctor Blade Sample
Plastic Doctor Blades – Advanced Polymers Compete with Steel

While steel doctor blades used to be the only option to produce high-end graphics, a printer had to deal with the shorter blade life and pressroom injuries that came along with using the material. No more! Recent innovations in materials technology and tip engineering have at last resulted in polymer doctor blades that can compete with steel and also resolve a number of common problems in the pressroom.

Steel doctor blades are thin and rigid which allows them to achieve a fine contact area with the anilox roll. A fine contact area is required for the blade to achieve an effective wipe on high line screen rolls used in more demanding graphics applications. Traditional plastic doctor blades, on the other hand, have long been preferred for their longer life in less demanding graphics applications. Plastic blades had to be engineered thicker in order to provide enough rigidity to maintain good contact with the anilox roll and achieve a sufficient wipe. The thickness and larger contact area prevented these blades from being effective when used to meter mid to high line screen rolls. While they lasted significantly longer and were safer to handle than steel blades, they tended to leave more ink on the surface of the roll; this produced dot gain and poor image quality in the printed piece.

Steel Blade Disadvantages

Despite its reputation for being the superior metering material, steel has many disadvantages. The blades wear quickly and need to be replaced frequently. Operators are also exposed to cut hazards when removing the worn blades from the press, and the metal fragments can come loose and score anilox rolls. The environmental impact of using steel can also be significant. There are huge energy costs associated with the manufacture of steel blades as well as anilox resurfacing, and additional station clean-ups generate a lot of contaminated waste. Despite these drawbacks, steel was believed to be the only doctor blade option to execute a clean wipe on a high line screen anilox roll, leaving printers no choice.

New polymer doctor blade contact area is smaller than steel

New Polymer Doctor Blades

Today, specially formulated polymer doctor blades offer the best of both steel and plastic. Unlike traditional plastic doctor blades, the next generation material allows for a precisely engineered micro-tip which wears slowly and evenly throughout the life of the blade. The micro-tip edge allows the blade to achieve a fine contact area with the anilox roll and deliver effective metering on line screens up to 2000 lpi or 785 L/cm. The long and steady wear period of the next generation polymer doctor blade maximizes press uptime and allows for consistent ink film thickness for the duration of the print job.

Compared to steel, the polymer material does not develop a dangerous cutting edge after use, and the worn blades are safe to handle. Also, the material will not separate, splinter or crack and produces no metal fragments that can lodge between the doctor blade and the anilox roll. A reduction in anilox scoring means better image quality, less downtime, less waste and lower roll replacement costs.

Polymer doctor blades have come a long way in recent years. A combination of advanced materials and a micro-tip edge has produced revolutionary new doctor blade option for printers: a blade that can compete with steel in the most demanding graphics applications while retaining the safety and blade life benefits of traditional plastic.
Request a Free TruPoint Doctor Blade Sample

Category: Wide Web

Products that inspire

Services that inspire

A brand experience that inspires

Versioning and Variable Data Printing

1. Take Advantage of New Wide Web Technologies

2. Add Mid-Web Equipment

3. Incorporate Digital

What is consultative selling?

Research

Relationship

Resolution

Reward

Kanban Origins

Push vs. Pull Inventory Control Systems

Kanban Cards

Six Elements of Kanban

Flexo Concepts recommends a 3-step anilox roll cleaning program:

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

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

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

Switching to polyester containment blades from steel can offer several benefits for printers. Here are the top 5 reasons to make the switch:

Anilox Roll Evolution

Chrome anilox rolls

Ceramic-coated rolls

New doctor blade technology

Steel

Plastics

Next generation doctor blades

Problems That Result from Failed End Seals

Why Chamber Leaks Occur

End Seal Materials for Chamber Systems

What Can Go Wrong

What To Do

Steel Doctor Blades vs. Traditional Plastic

Next Generation Polymers

Problems arising from Chamber Leaks:

Causes of Chamber Leaks:

Incorrect Doctor Blade Length can cause Chamber Leaks

Cut-to-length Doctor Blades can Reduce Chamber Leaks

Steel Blade Disadvantages

New Polymer Doctor Blades