Tag: High Quality Print

  • 3 Ways to Conquer UV Ink Spitting in your Pressroom

    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! Ink Spitting explained

     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 3 “This Is Not Your Father’s Pressroom”

    Corrugated Converters at the Crossroads Blog Series Part 3 “This Is Not Your Father’s Pressroom”

    blankThe third post in our Corrugated Converters at the Crossroads blog series will look at how some pressroom equipment and substrates have evolved to help printers keep up with the times.

    Antiquated Equipment

    Many of the corrugated post print presses running today were installed as long as a half century ago. How can box makers, running this equipment, possibly keep up with the graphics quality and turnaround times expected these days?

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    The answer is, they can’t. At least not without incorporating the latest machine technology in their pressroom. Advancements in the powertrain, sheet transfer systems, substrates, coating chemistries and drying methods have made a huge impact on the speed and efficiency of the printing process and the quality of the output.

    Direct Drive Servo Motors

    Conventional presses use mechanical gear systems to drive the anilox roll and plate cylinder in the ink delivery process. But as press speeds and the demand for higher quality print grows, these systems can’t hold sufficient registration and adjust for in-run variation. Wearing of the mechanical gears produce backlash in the system and cause deviations in the print registration. For this reason, corrugated OEMs have followed the lead of other flexo press manufacturers by substituting direct drive servo motors for gearing systems. These new direct drive configurations synchronize the transfer rolls with a much higher level of precision, removing the variability in the process, allowing for more repeatable registration and better control over in-run adjustments.

    Vacuum Transfer

    Similarly, new vacuum transfer technology removes the registration variation from the sheet transfer process. The original systems use a knurled pull roll to grip and pull blankthe sheet through the print area of the press and, over time, create the same registration challenges. As the substrate’s abrasiveness wears the knurling on the roll, the sheet slips and the printed image becomes blurred and fuzzy. New vacuum transfer technology eliminates the mechanical pull rolls, instead using suction to smoothly move the substrate through the press. The system holds the sheet firmly in place and allows for a consistent and superior level of print registration accuracy, even at high speeds. (The elimination of these wear parts also makes set-up times faster, prevents jams and takes up much less space in the machine to make room for IR dryers which we will get to later!)

    Coated Substrates

    But the advancements in ink delivery and sheet control are meaningless if the substrate can’t sustain the improved graphics and high press speeds. Printing on corrugated board is challenging. Its absorption and surface tension qualities affect print density, drying, trapping and dot gain. Today’s brand owners are demanding not only eye-catching, differentiated products, but also precise graphical representation of their brands and messaging. So, the market has introduced semi-coated and fully-coated papers on finer fluted board that can support these requirements.

    IR Dryers

    Along with the market’s introduction of new substrates comes the challenge of drying. blank The new coated papers are difficult to dry at high speed, so dryers must be added to optimize press output. IR dryers heat the ink using infrared energy to accelerate evaporation of the liquid bases, leaving only the pigmented ink solids on the substrate. The technology significantly reduces drying time and allows for drying at full speed with coated papers and high-quality inks. As we mentioned earlier, the adoption of vacuum sheet transfer systems has freed up space in the press to install IR dryers between stations. The overall improvement in color brilliance, gloss levels and processing speeds more than justify the investment in this technology.

    UV Curing

    The final step is to protect the high-quality graphics on a semi- or fully-coated sheet with UV curing capability. When a corrugated box is being used only for shipment and protection, there is little need to apply a UV coating.

    But as corrugated packaging is becoming more of a marketing tool, the coating delivers the same benefits as it does in other flexo markets – maximizing gloss, protecting the print, and improving water, scuff and rub-resistance at full speed. The same goes for UV-curable specialty coatings used to apply finishes such as soft touch, glitter and sand to create innovative, unique-looking packages.

    Like ink delivery system OEMs, corrugated equipment manufacturers and paper suppliers have responded with innovations to help converters thrive in the current market evolution. From direct drive motor systems to coated substrates, these new products help optimize pressroom efficiency and profits.

    In the next post in our Corrugated Converters at the Crossroads blog series, we will continue to look at how digital technology is expanding into the flexo pressroom and playing a key role in the converting industry. Watch for Part 4 – “The Digital Printing Revolution”

    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

  • New, Improved MicroTip®

    New, Improved MicroTip®

    blankSince 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.

    MicroTipFlexo 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

    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

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    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.

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    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
  • 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
  • Versioning and Variable Data in Flexible Packaging

    Versioning and Variable Data in Flexible Packaging

    versioning in flexible packagingAccording 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.

  • New Polymer Doctor Blades with MicroTip Are Best for Applying Special Effects Coating

    New Polymer Doctor Blades with MicroTip Are Best for Applying Special Effects Coating

    Anyone who uses doctor blades for printing knows the range of options available today.  From the thickness of the material to the tip configuration, a doctor blade’s design has a direct impact on the job it will do.  While traditional tip options have ranged from straight to rounded to lamella, the new kid on the block, “MicroTip,” offers printers a smart choice when applying special effects coating.

    Special effects coatings are challenging

    More and more, packaging companies are using specialty coatings to differentiate their brands and create a tactile and visual experience for consumers.  However, special coatings such as glitter, grit, soft-touch, metallics and pearlescents present particular challenges for the printer.  These coatings have high viscosities and contain larger particles which make it difficult to accurately control the amount of coating

     

    being applied. (UV chemistries, common in specialty coating applications, have a viscosity of 5-7 times that of water and solvent-based formulas.)  This higher viscosity applies extra pressure to the metering blade, resulting in hydroplaning or “spitting” (especially at high line speeds), and increases coating consumption and waste.  In these cases, a customized blade solution is often necessary to control the lay-down of coating.

    New Polymer Doctor Blades with MicroTips can help

    Doctor blade manufacturers have found a way to make new polymer doctor blade materials that can overcome the limitations of steel in specialty coating applications.  By engineering a modified lamella tip, known as a “MicroTip”, on these materials, they have introduced a doctor blade product that offers the best of traditional plastic and steel.

    Why do they work?

    When used to apply special effects coating, steel blades are subject to accelerated blade wear from the coarse anilox engravings and corrosion from the harsh coating chemistries.  Today’s new polymer materials are compatible with all coating formulas and do what plastic blades are known to do best: last longer.

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

    Doctor blade optimization for special effects coating

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

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    If you’re a printer struggling with special effects coating, consider switching to a next generation polymer doctor blade with a MicroTip.  A magical combination of advanced material and tip might be just what you need to achieve a perfect lay-down of coating with longer blade life to boot.

    Request a Free TruPoint Doctor Blade Sample
  • Anilox Roll Cleaning is Essential to Effective Ink Delivery

    Anilox Roll Cleaning is Essential to Effective Ink Delivery

    Anilox Roll CleaningYou 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

    Anilox Cleaning BrushManually 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.

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    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

  • New Doctor Blade Technology Is Worth a Look

    new doctor blade technology innovationAs 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.

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    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

    blankLike 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

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    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

    The Right End Seals Will Prevent Leaks in Your Doctor Blade Chamber System

    End SealsIn 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. 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. 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.

  • New Polymers Meter Like Steel Doctor Blades

    blankSteel 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
    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

  • UV Ink Spitting is a Dirty Habit

    blankAs competition for shelf space heats up, brand owners are looking to create more compelling-looking products. That means prettier graphics, more vivid colors and unique packaging. Today’s narrow web printers, also facing intense competition, are turning to UV inks and specialty coating formulas to produce higher print quality, speed up turnaround times, increase throughput and reduce downtime. Unfortunately, using a steel doctor blade to meter these chemistries often result in the UV ink spitting onto your print job, causing a speckled appearance. Where steel falls short, the TruPoint Orange® next generation doctor blade may be the solution in these applications.

    Eliminate UV Ink Spitting with TruPoint Orange

    The surface energy and flexibility of a steel blade can impede a smooth transfer of ink to the plate. The dyne level of a steel blade is higher than that of TruPoint Orange, causing the ink to have a greater tendency to adhere to the blade. With Orange, the characteristics of the material give the blade a significantly lower dyne level than steel, decreasing the attraction between the doctor blade and ink and facilitating a more fluid movement of ink to the plate.

    ink spitting steel doctor blades vs plastic doctor bladesAlso, UV ink has a normal viscosity of 5-7 times that of water and solvent-based inks, and its thixotropic properties (ability to thin out when agitated) make it transfer differently on press. This thicker consistency applies excessive pressure to a steel metering blade, often causing the ink to sling off, or “spit,” especially at high press speeds. The TruPoint Orange doctor blade prevents UV ink spitting. The blade’s tip provides enough stiffness to maintain a strong contact area with the anilox roll and prevent ink from sliding under the blade.

    Specialty Inks and Coatings Are Abrasive

    Specialty coatings and tactile finishes such as glitter, pearlescent, textures and soft touch, are being used to enhance the look of product packages, but the same challenging properties of UV inks also exist in these formulations. They have high viscosities and contain large particles, making it difficult to accurately control the volume being applied. These chemistries, and coarse anilox surfaces used to apply them, are extremely abrasive to steel doctor blades – printers consume blades faster which increases downtime and costs. TruPoint Orange next generation polymer blades are highly abrasion-resistant and chemically compatible with all ink and specialty coating formulas; they last longer and minimize press downtime for blade changes. Click Here to Read “5 Ways to Conquer UV Ink Spitting”

    As the industry evolves to keep up with the demands of the market, printers are faced with new challenges. The ink and coating formulas being used to make products stand out on the retail shelf and improve pressroom efficiency are difficult to meter with steel doctor blades. Due to its material properties and tip design, TruPoint Orange can help by reducing downtime and costs associated with UV ink spitting and accelerated blade wear.

    Request a Free TruPoint Doctor Blade Sample
  • Plastic Doctor Blades – Advanced Polymers Compete with Steel

    Plastic Doctor Blades – Advanced Polymers Compete with Steel

    blankWhile 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.

    blankSteel 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.

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    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