Printing Technologies –Flexo Printing –Gravure Printing
Printing TechnologyPrinting Technologies–Flexo Printing–Gravure PrintingMunich 1.3 Million inhabitants Industrial and high-tech hub:BMW, MAN, Linde, Siemenset al. Top location forbiotechnology & lifesciences, media Germany‘s safest city(ranked #1 / 50; source: Cologne Institute forEconomic Research Consult survey 2009) Most livable city(ranked #7 / 221;source: Mercer Quality of Living Survey 2010) Booming tourism destination Cultural center Capital of BavariaProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 21
Printing TechnologyGeneral Information about Munich University of Applied Sciences Founded in 1971 about 15.000 Students– 489 faculty members– approx. 750 part timelecturers– 500 staffCampus Lothstraßeapprox. 9.000 studentsCampus Karlstraßeapprox. 3.000 students Second largest University ofApplied Sciences inGermanyCampus Pasingapprox. 3.000 studentsProf. Dr. Ulrich MoosheimerSeite 3General Information about Munich University of Applied Sciences14 Departments Engineering Business / Tourism Social Sciences DesignAppliedSocialSciences;10%More than 60 studyprograms: 29 Bachelor‘s 33 Master‘s 2 DiplomaBusinessTourism;18%Design ; 3%Engineering;69%Prof. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 42
Printing TechnologyBachelor of Engineering: Print and Media Technologygeneral modulesindividual modules7Bachelor thesispreferred in cooperation with industry6laboratory workproblem based strial semesterin-depth knowledge inpre-media technology, prepress technology,printing methods and machine technology,print finishing,technical and business processmanagement,print media markets, financial accountingbasics inmathematics, physics, chemistry,information technology, mediaprogramming and media designoptional:preindustrial semesteradmission procedureProf. Dr. Ulrich MoosheimerSeite 5Master of Engineering: Printmedia, Technology and Managementstart summer term 2011general modules3Master thesispreferred in cooperation with industryandbasic knowledge – methodsproduct developmentprocess developmentbusiness methodscommunicationbasic research and development methods1project work in managementproject work in technologies2individual modulesmanagementtechnologymarketsprint and media processesand technologiesbusiness processesrelevant future technologiesproductsstrategyadvanced research anddevelopment methodsleadershipAccess requirements bachelor’s degree from a German university diploma (FH) equivalent in print and media engineering equivalent from a foreign universityProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 63
Printing TechnologyPrint and Media TechnologiesProf. Dr. Ulrich MoosheimerSeite 7Where I studied:University Regensburg– Applied PhysicsProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerUniversity of Colorado, Boulder– Exchange student– DAAD scholarshipSeite 84
Printing TechnologyFraunhofer-Institute for ProcessSchreiner GroupEngineering and Packaging– Products and Processes– Development and optimization– Surface modification of polymer films– vacuum web coating– lacquering– lamination– Main research activities– Permeation and polymer films– Adhesion mechanism– Management– Printing technologies– conventional and digital– Dye cutting– Patent managementdefect in a SiOx layer coated on PETProf. Dr. Ulrich MoosheimerSeite 9Printed Electronics - Added Value in a BookDisplaysOLEDElectroluminescent displaysElectrochromic displaysConductive ElementsMagnetic switchSwitch plateConductive linesEnergy SupplyRFID battery chargerSolar cellPrinted batteriesThin interactive-book.comProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich Moosheimer105
Printing TechnologyWhat was thelargestprinting jobworldwide?Seite 11General Terms in the Field of Printing TechnologyThe process of information reproduction by printing is divided in the sectionsplate makingcylinder preparationprintingfinishingProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 126
Printing TechnologyTeamwork: Gravur and Flexo PrintingVernissageProf. Dr. Ulrich MoosheimerSeite 13Gravure printingPrinting Technology using the lower parts of the printing block for ink transfer.Types of gravure printing block– plate– cylindersubstratematerialimpression cylinderdoctor bladeprinting cylinderinkProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 147
Printing TechnologyGravure Printings - Schematicfilling of the cellsdoctor bladingtransfer to the substrateProf. Dr. Ulrich MoosheimerSeite 15Gravure Printing- manually, art techniques- copperplate engraving- copperplate etching- industrial technology- gravure printing- pad printingProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 168
Printing TechnologyGravure printing: ComponentsPrinting block with engraved printing- screen ruling 40 to 200 lines/cm- cell wall between the cells 0,003 – 0,005mm- cell depth 0,01 – max. 0,05 mm- cell width 0,03 – 0,230 mm- cell volume and density determine thefinal ink thicknessdoctor blade- removes ink from non-printing partsSoft impression cylinder- ink transferred from printing block tosubstrate material- electrostatic support- pressure 1,5 – 5 MPa- small diameter for small contact zoneProf. Dr. Ulrich MoosheimerSeite 17Prepress Gravure printing– engraving and polishing– testing and corrections–REACH: Use of Cr(III): cancerogen, poissening, acid, No alternative process without drastically increasing the prodction costs/1//1/Seite 18 Professor Dr. Ulrich Moosheimer9
Printing TechnologyTypes of Cellsdifferences- depth variable cells- constant cell area- variable cell depthhighlightmiddledark- area variable cells(autotypic)- variable cell area- constant cell depth- depth and area variable cells(semi-autotypic)- variable cell area- variable cell depthProf. Dr. Ulrich MoosheimerSeite 19Engraving TechnologyDirect engravingProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 2010
Printing TechnologyGravure Printing Cylinder for PackagingSetup from steel cylinder toprinting layer– steel base cylinderwidth up– copper base layerabout 2 mm thickpolishing for high truerunning accuracy– copper engraving layerabout 0.1 mm thick– chromium layerfor high abrasionresistanceabout 0.006 mm thickProf. Dr. Ulrich MoosheimerSeite 21Printing Block Production: Gravure Printing– electro-mechanical gravuresemi-autotypic/1/Prof. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 2211
Printing TechnologyPrinting Block Production: Gravure Printing– electro-mechanical gravurevariation of the penetration depth of the gravure headfrequency about 11.000 dots / sProf. Dr. Ulrich MoosheimerSeite 23Engraving TechnologyDirect laser engravingCopper or zinc cylinderProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 2412
Printing TechnologyVibration GravureSeite 25Extreme GravureSeite 26 Professor Dr. Ulrich Moosheimer13
Printing TechnologyDirect engravingScreen ruled cellshalf cellssmooth linesvariable cell depthScreen lines:1.000 l/cm / 2.540 dpiProf. Dr. Ulrich MoosheimerSeite 27Comparison: Direct Laser to Electromechanical EngravingDirect Laser to Electromechanical EngravingDirect Laser EngravingElectromechanical Laser EngravingProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 2814
Printing TechnologyComparison: Direct Laser to Electromechanical EngravingProf. Dr. Ulrich MoosheimerSeite 29Comparison: Direct Laser to Electromechanical EngravingVibration GravureLaser Gravurescreening lines70 L/cm80 - 140 L/cmgravure speed11.000 dots / s70.000 dot / sabrasiongravure headnonedot formgiven by gravure head andvariable in sizevariable in form and sizeProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 3015
Printing TechnologyEngraving Technology: Non-direct LaserSeite 31Engraving Technology: Non-direct LaserThink-Laser– Imaging into polymer layerby laser– Variability of cell areas aswell as cell depths– High resolution of 1 – 2 µm– Small-sized fonts possible– Saw tooth free outline ofletters– Very deep cells for highlayer thicknessesSeite 32 Professor Dr. Ulrich Moosheimer16
Printing TechnologyEngraving TechnologiesDirect engraving– packaging– decor– illustrationDirect laser engraving– packaging– decor– illustration– security elementsNon-direct laserengraving– packaging– high resolution printing– security elementsSeite 33Cost development of gravure cylinders (Average Values)Quelle: Wessendorf, Ansgar. „Im Fokus der DRUPA 2012: Der Flexodruck“ Flexo Tief-Druck 3-2012Prof. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 3417
Printing TechnologyVirtual Walk through a Gravure Printing StationProf. Dr. Ulrich MoosheimerSeite 35Beispiel: Kinder Schoko Bons60-fach10-fach200-fachSeite 36 Professor Dr. Ulrich Moosheimer18
Printing TechnologyIdentification- Saw tooth at letters and lines- High printing quality- Semi-autotypic- Halftone dots in different sizes and color densities- Spreading of the color- Light dots with open center/1/Seite 37IdentificationExample/1/Seite 38 Professor Dr. Ulrich Moosheimer19
Printing TechnologyIllustration Printer10 printing units (face and reverse printing)Folding unitPrinting width up to 4320 mm/1/Seite 39Packaging Printing- Flexible films- Multilayer films of metals, polymers and papers- Carrier bags- Paper- Folded boxes (cigarettes, laundry detergent)- Soft drinks- Gift wrap paper- High variations in- Formats- Substrates- Printing width about ca. 1400 mm- Limits due to the stability of the substrates- PET-films (thickness 0,012 mm)- PE-films (thickness 0,040 mm)- OPP-films (thickness 0,016 mm)Seite 40 Professor Dr. Ulrich Moosheimer20
Printing TechnologyGravure printing machine for packaging- post press units often integrated as- flexo printing units- lacquering units- coating units- lamination unitsSeite 41Comparison of illustration and packaging printingIllustration PrintingPackaging PrintingMarket segments90 %10 %Product variationssmallvery highSubstratesPaperPaper, metals and polymersFormatsStandard cylindersVariable cylindersSolventTolueneAlcohol, ester, waterPrinting widthmax.4320 mmmax.1500 mmPrinting speedmax. 900 m/minmax. 600 m/minPrinting units2 times 4 or 56 to 12Integrated post printingFolding unitsFlexo printing unitsLacquering unitsCoating unitsLamination unitsSeite 42 Professor Dr. Ulrich Moosheimer21
Printing TechnologyGravure printing: other application areas-Decor printBanknotesSecurity elementsStampsArt printSeite 43Pros and Cons of Gravure PrintingPros-Easy printing process – simple setup of printing unitConstant high printing quality at high volumesEnlarged color spaceReproducible printing qualityVariability in report lengthHigh printing speed up to 900 m/minColors containing high amount of solvent printableColors containing metallic pigments for mirror like layersCons- Quality of letters compared to offset printing- Costs of printing cylinders- (Proof of printing cylinders)- Set-up costs- Economic printing starting at volumes higher then 200.000 - 500.000- Storage costs of printing cylindersSeite 44 Professor Dr. Ulrich Moosheimer22
Printing TechnologyWhat was the largest printing job worldwide?IKEA catalogue 2008200 Millionen (1 km tour on a Tennis court)– 27 languages– 52 Ausgaben– 38 contriesReading by 200 Millionen peopleAdvantageLow costs per cataloguetUse of cheap papersStable printing processLargest cost blocks55% paper25 % color7 % postpress3 % reproK.A. print ?Seite 46LetterpressPrinting technology using the higher parts of the printing block for ink transfer.Example:– potato printing– flexo printing/1/Prof. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 4723
Printing TechnologyComponents of a Flexo Printing UnitGravure roll with doctor blade– 100 to 600 lines/cm screen ruling– ceramic or hard chrome coating– printing thickness depends on cellvolumePrinting cylinder– (elastic) printing block– plate– cylinder– sleeveprinting cylinderwith plateimpressioncylinderImpression steel cylinder– kiss printingCuring– thermal curing– UV curinganilox rollerink reservoirwith doctor bladeProf. Dr. Ulrich MoosheimerSeite 48Flexo Printing Plate Production - livepotato printingMethod MurmelgruppePrepare a printing plate containing the elements– quadrate as large as possible– 3 dots as small as possible discussion of the printing quality Proposal for improving the printing qualityProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 4924
Printing TechnologyFlexo Printing Plate Production: CtP (Computer-to-Plate) – Schematicback side curingUVAdigital engravingfront side curingUVAdevelopment solvent based plus drying thermal (Cyrel Fast)post curing UVA andUVCProf. Dr. Ulrich MoosheimerSeite 50Flexo Printing Plate Production: CtP (Computer-to-Plate)Best practice results:- minimum dot size 0,030 – 0,05 mm- separation of printing plates according to- areas and- small dots or fonts/1/Prof. Dr. Ulrich Moosheimer Professor Dr. Ulrich Moosheimer/1/Seite 5125
Printing TechnologyHD-Flexo 2.0 (Esko-Graphics)4.000 dpi (8000 dpi opt.) with spec. screen pattern 70 l/cm at 256 gray levels(otherwise: Standard 2540 dpi – 62,5 L/cm at 256 gray levels)New printing screening technology– highlights – supporting dots– higher stability of highlights– expanded tonal range (about 30 %)down to almost 1 %– midtones – defined dot contact– homogenous printing gradient– solids – MicroCells– homogenous high solid coverage– higher solids larger gamutEnhanced printing quality and reducedquality gap towards gravure and offsetProf. Dr. Ulrich MoosheimerSeite 52HD-Flexo 2.0 (Esko-Graphics)defined dot contactBrilliantHighlightsProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich Moosheimerhomogenous high solid coveragehigher solids larger gamutSeite 5326
Printing TechnologyHD-Flexo 2.0 (Esko-Graphics)Prof. Dr. Ulrich MoosheimerSeite 54Comparsion of Solid Tone coverage CTP and Mikro ScreeningQuelle: Klein, Thomas: Dokumentation zur 61. DFTA Fachtagung, S. 23Prof. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 5527
Printing TechnologyFlexel-NX Flexographic System (Kodak)Printing quality (Flexo-Tief-Druck 1-2011, S. 4-5)– flexible packaging – qualitative alternative to gravure printing– Corrugated board – quality equal to Offset– Tonal range: 0,4 – 99,6 % at 90 L/cmProduction processSquareSpotImagingIR-Laser (830 nm)10.000 dpiLamination(self adhesive) onflexo platte; oxygeninhibationProf. Dr. Ulrich MoosheimerUVA reverseside andMainCuringDevelopmentSeite 56Flexel-NX Flexographic System (Kodak)(Flexo-Tief-Druck 1-2011, S. 5)Halftone dots with flat plateau– sharp bordered plateau– stabile connected to plate– higher stability (high volumes)Prof. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 5728
Printing TechnologyFlexel-NX Flexographic System (Kodak)Digi Cap NX-ScreeningImproved ink transfer– homogenous high solidcoverage– higher solids largergamut0,4 for magenta, cyan, key0,2 for yellow more opaque layersDigi Cap NX Screening(Flexo-Tief-Druck 1-2011, S. 4)LAMS plateProf. Dr. Ulrich MoosheimerSeite 58Laser Engraving of Flexo Cylinders– Base Material– rubber on fiber-reinforced plastic sleeve– stone polishing of the sleeves– true running accuracy of 0,02 mm– circumference tolerance of /-0,05 mm– CO2 high speed laser– 1000 Watt– dot frequency of 7000 Hertz– Direct engraving into the rubber– Screen ruling– 54 lines / cm– 80 lines / cmProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 5929
Printing TechnologyPrinting Blocks for Flexo of. Dr. Ulrich MoosheimerSeite 60Flexo Printing BlocksPlates (thickness 0,76 – 6,35 mm)- mounting on printing cylinder by pressure sensitivetapesSleeves- rubber coated sleeves plus direct engraving- photopolymer-sleeve with base rollCylinder- gravure into the cylinderPlatesStorage volumeCostsSleeves -Cylinders-- ---Print quality Mounting-- Accuracy ofprint length- Prof. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 6130
Printing TechnologyFlexo PrintingIdentification- dot fringe- dot structure of the anilox roll- missing dots at highlight areasProf. Dr. Ulrich MoosheimerSeite 62Substrates for Flexo PrintingPrinting materials- absorbend (paper)- non-absorbend (polymer films, metall plates)- rough surface (cardboard, corrugated board)Printing inks- solvent based- solvent free (water based)- UV curable inks- no thermal heat load on the materials- improved printing quality- reduced dot growth- off ordoe reduced by inert gas curing (nitrogen atmosphere)- higher costsProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 6331
Printing TechnologyComparison: Gravure to Flexo Printing and UV-Flexo PrintingGravure printing- fine dots- saw-tooth effectProf. Dr. Ulrich MoosheimerSeite 64Comparison: Gravure to Flexo Printing and UV-Flexo PrintingFlexo printing- dot fringesProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 6532
Printing TechnologyComparison: Gravure to Flexo Printing and UV-Flexo PrintingGravure printing- fine dots- saw-tooth effectFlexo printing- dot fringesUV-Flexo printing- homogenous printinggradient- smooth edgesProf. Dr. Ulrich MoosheimerSeite 66Comparison: Gravure to Flexo Printing and UV-Flexo PrintingGravure printing- fine dots- saw-tooth effectFlexo printing- dot fringesUV-Flexo printing- homogenous printinggradient- smooth edgesProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 6733
Printing TechnologyDecor PrintingPilot Printing Unit for SamplingProf. Dr. Ulrich MoosheimerSeite 68Flexo Printing Machine NOVOFLEX CM (Windmöller & Hölscher)8 /10Quelle: Windmöller & Hölscher KGPrinting UnitsPrinting Width 1300 – 1650 mmPrintingLengthWeb Seep.max. 1250 mm400 / 600 m/minQuelle: Windmöller & Hölscher KGtension sensitive filmsPE-filmsshrink filmsSeite 69 Professor Dr. Ulrich Moosheimer34
Printing TechnologyFlexo Printing Machines- central cylinder a)- unit construction b)- compact construction c)/1//1//1/Prof. Dr. Ulrich MoosheimerSeite 70Pros and Cons of Flexo PrintingPros-Easy printing process – simple setup of printing platesEnlarged color spaceVariability in report lengthHigh printing speed up to 600 m/minHigh number of printable substrates, including rough surfacesCons- Lower quality compared to gravure and offset printing- Min. dot size reduced tonal range- Dot fringes- Set-up of plates on cylinders- Set-up of colors – also at rerunsSeite 71 Professor Dr. Ulrich Moosheimer35
Printing TechnologyComparison: Gravure to Flexo Printing(Methode geteilte Murmelgruppe)Strength of Gravure PrintingStrength of Flexo printingsProf. Dr. Ulrich MoosheimerSeite 72SummeryPrinting processplate making and cylinder preparationprintingfinishingGravure printinghigh printing qualityFlexo printingcost advantageSummabstimmungProf. Dr. Ulrich Moosheimer Professor Dr. Ulrich MoosheimerSeite 7336
Soft impression cylinder - ink transferred from printing block to substrate material - electrostatic support - pressure 1,5 – 5 MPa - small diameter for small contact zone Gravure printing: Components Prof. Dr. Ulrich Moosheimer Seite 17 /1
Flexo Cotton Top Wide Web Flexo Narrow Web Flexo Flexo uncoated Corrungated Coated Flexo New Plate Coldset Improved News UN SCA Publication Sheetfed Digital. Brand Equity: Tying this all together Flexo Narrow Web CRPC6 Wide Web Flexo CRPC5/6 .
, a 40 contact angle between the blade and gravure cylinder, and pyramidal engraved cell structures on the gravure cylinder (10–35μm in depth and 55–130 μm in width as illustrated in Supplementary Fig. S1). The engraved cell structures are selected based on our previous results from R2R gravure-printed SWCNT-TFTs on a 150m PET roll17 .
Packaging Gravure Printing Problems and their Solutions On the following pages, you will find the information on the most common packaging gravure pressroom problems, how to recognize them, their ca
1 Ian Hole VP Market Development Flexo FPPA Seminar March -2014 HD Flexo Technologies -the printing issues -technical solutions &am
UVivid Flexo JD is a high gloss UV flexo ink system that incorporates a wide range of colours, process inks, metallic shades and specialist products. . from formulation through to production and supply. Research and development team, work to
Learning about Pad Printing APPLICATIONS OF PAD PRINTING Transfer pad printing or tampo printing, commonly known as pad printing, is an "indirect offset gravure" printing process. It was originally used in the watch making industry in Switzerland to decorate watch faces. Pad printing has now developed to a point where it is one of the
Indirect gravure printing is a printing process in which a pad transfers the ink from an engraved printing form (cliché) to a substrate. In some literature, it is called pad printing (Hahne, 2001; Kipphan, 2001). The indirect gra-vure printing method has an acceptable accuracy and a resolution of 20 μm to print, e.g., high accuracy elec-
Rough paths, invariance principles in the rough path topology, additive functionals of Markov pro-cesses, Kipnis–Varadhan theory, homogenization, random conductance model, random walks with random conductances. We gratefully acknowledge financial support by the DFG via Research Unit FOR2402 — Rough paths, SPDEs and related topics. The main part of the work of T.O. was carried out while he .
