Tag: Fill the Gap

  • Corrugated Converters at the Crossroads Blog Series Part 1 “The Consumer is King”

    Corrugated Converters at the Crossroads Blog Series Part 1 “The Consumer is King”

    Corrugated package printing is evolving. Lead times are shortening, order sizes are decreasing and pressure to reduce turnaround times is growing. At the same time, brand owners and big-box retailers are demanding high quality graphics, customization and flexibility – all with an eye toward sustainability and, of course, keeping costs down.

    The savviest corrugated converters will use the tools at their disposal to meet these changes head-on. Our 4-post blog series, Corrugated Converters at the Crossroads, will not only examine the forces behind this evolution but also describe some of the “tools” that can help corrugated converters acclimate to these market changes.

    Who is today’s consumer?

    Demographics and lifestyles are changing – the population is aging, household sizes are decreasing and fewer families are eating together at the dinner table. Consumers are busy, finicky and impatient – they want convenience, quick satisfaction and competitive prices – and want to purchase in ways that fit into their fast-paced schedules.

    People access information at their fingertips (or palms) so products are researched, reviewed, recommended, rebuked and requisitioned – all outside the scope (and power) of the brand owner. Manufacturers must make their products stand out on-line and on retail shelves to catch the consumer’s eye and “win” sales.

    Let’s explore how these changes are affecting the job of corrugated converters.

    High quality graphics

    blankFor years, corrugated converters were asked only to produce durable containers and packages with few embellishments and uninspired graphics. Now, in addition to protecting the products, secondary packaging is being used as a strategic marketing tool. Products must stand out from the pack and “speak” to the customer, and the way they are “dressed” is paramount. Box makers are expected to create enticing shelf-ready packaging and shipping containers that double-down as POP displays. The package design plays the important role of effectively and consistently conveying the manufacturer’s messages, differentiating the products from those of competitors and enticing the shopper to buy. The use of expanded gamut, finer plate screens, half-tones and higher anilox line counts is creeping into the corrugated pressroom, and predictable ink density and color control are essential for brand image and consistency.

    Short Runs

    As retail strategies take direct aim at the individual consumer, what used to be large jobs are being broken into smaller lots based on each “version” of the product. Globalization of brands requires that product packages be produced in multiple languages and “localized.” Variable data, where companies add a unique image or message to each package, has been found to improve the effectiveness of marketing and allows individual product skus to be “tracked and traced” through the supply chain. Customization and personalization are effective marketing tools that, by their nature, dictate shorter runs.

    Faster Turnarounds

    Everything in the marketplace is speeding up –today’s consumers are bombarded with messages, their attention spans are short, they get bored easily and they want products ASAP. Brand owners have to keep packaging fresh, interesting and relevant. They want to optimize their time-to-market and be able to test prototypes and make updates as fast as possible. The corrugated converter’s agility is key to his survival.

    E-Commerce

    Today’s consumers want to shop online from the comfort of their couch, desk, coffee shop (you name it!) in addition to conventional retail outlets. And shoppers expect not only convenient ordering but also quick and low-cost deliveries. Shipping boxes must still protect the contents but do so in the most efficient and economical way. People are also demanding environmental responsibility and “green” packaging from manufacturers and retailers which brings us to…

    Sustainability

    Even though corrugated waste is considered the most-recycled packaging material on the planet, eco-conscious consumers are demanding more from their manufacturers and retailers. The industry is undergoing pressure to not only reduce paper weights and streamline product packaging but also revamp its energy and water conservation programs and optimize logistics and transportation to reduce its carbon footprint.

    There is no question that new consumer on-the-go lifestyles and buying practices are fueling the changes taking place in today’s corrugated package printing industry. To market to these “new” buyers, brand manufacturers and big-box stores need their suppliers to deliver high quality graphics, customization and fast response times in packaging that can serve on-line as well as brick-and-mortar demand in sustainable ways. That is a tall order.

    In the next few posts in our Corrugated Converters at the Crossroads blog series, we will look at how the industry is responding to these market changes with new technologies. Watch for Part 2 – “Necessity is the Mother of Ink Delivery Innovation.”

  • New Polymer Doctor Blade for High-Graphics Box Makers

    New Polymer Doctor Blade for High-Graphics Box Makers

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

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

    Corrugated Box Market Evolution

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

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

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

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

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

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

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

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

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

    TruPoint Green®: The New Kid on the Block Anilox

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    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).

    blankWhen 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

    The Evolution of Corrugated Doctor Blades

    corrugated doctor blades - UHMW, DuraPoint and Green

    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

    UHMWIn 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.

    doctor blade innovation and technologyLate 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

    blankFor 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.

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

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

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

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

    Doctor Blade Fatigue: What It Is, Why It Matters & What You Can Do About It

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

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

    Fill out the form to download the Infographic PDF.

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