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Improve Product knowledge -generally we think we know it is

simple & quite confident giving a convincing reply, but at times when a question thrown at us unexpectedly we tend to stutter... so I have gathered some useful tips for us to keep in store handy to avoid embarrassment.

Contents - Look for ( new)

* what is vignette...................................................................................................................................3 * What is CMYK......................................................................................................................................3 * What is PMS .......................................................................................................................................4 * Printing processes..............................................................................................................................5 *Iwasaki advantages ( NEW ) .............................................................................................................6 * What is DPI.......................................................................................................................................12 * Measuring Repeat Length .............................................................................................................12 * Convert LM to SQM......................................................................................................................14 * What is a Blanket.............................................................................................................................14 * What is Pre-Press.............................................................................................................................15 * What is UV curing............................................................................................................................16 * What is an Impression.....................................................................................................................16 * Definition of a Self Adhesive Product...........................................................................................16 * Various types of face stock materials ( NEW ).............................................................................17 * QC test methods..............................................................................................................................19 * Theory of Corona treatment..........................................................................................................22 * Positive & Negative plates.............................................................................................................23 * Offset Plates technology................................................................................................................23 * Flexography trouble shooting guide ...........................................................................................23 *Metallization (NEW ).......................................................................................................................28 * 25 simple ways to save money at work place ( NEW )...............................................................28

* to be continued.............................................................................................................29 onwards

What is Vignette in printing

Vignette can be used to artistic effect, as demonstrated in this panorama. In photography and optics, vignette (from French "vignette", pronounced /vnjt/) is a reduction of an image's brightness or saturation at the periphery compared to the image center. The word vignette, from the same root as vine, originally referred to a decorative border in a book. Later, the word came to be used for a photographic portrait which is clear in the center, and fades off at the edges. It is sometimes purposely introduced for creative effect, such as to draw attention to the center of the frame. What are Process colors

The CMYK color model (process color, four color) is a subtractive color model, used in color printing, and is also used to describe the printing process itself. CMYK refers to the four inks used in some color printing: cyan, magenta, yellow, and key (black). Though it varies by print house, press operator, press manufacturer and press run, ink is typically applied in the order of the abbreviation. The "K" in CMYK stands for key since in four-color printing cyan, magenta, and yellow printing plates are carefully keyed or aligned with the key of the black key plate. Some sources suggest that the "K" in CMYK comes from the last letter in "black" and was chosen because B already means blue. However, this explanation, though plausible and useful as a mnemonic, is incorrect. The CMYK model works by partially or entirely masking colors on a lighter, usually white, background. The ink reduces the light that

would otherwise be reflected. Such a model is called subtractive because inks "subtract" brightness from white. In additive color models such as RGB, white is the "additive" combination of all primary colored lights, while black is the absence of light. In the CMYK model, it is the opposite: white is the natural color of the paper or other background, while black results from a full combination of colored inks. To save money on ink, and to produce deeper black tones, unsaturated and dark colors are produced by using black ink instead of the combination of cyan, magenta and yellow. Original Pantone Color Matching System

The Pantone Color Matching System is largely a standardized color reproduction system. By standardizing the colors, different manufacturers in different locations can all refer to the Pantone system to make sure colors match without direct contact with one another. One such use is standardizing colors in the CMYK process. The CMYK process is a method of printing color by using four inkscyan, magenta, yellow, and black. A majority of the world's printed material is produced using the CMYK process, and there is a special subset of Pantone colors that can be reproduced using CMYK Those that are possible to simulate through the CMYK process are labeled as such within the company's guides. However, most of the Pantone system's 1,114 spot colors cannot be simulated with CMYK but with 13 base pigments (15 including white and black) mixed in specified amounts.[6] The Pantone system also allows for many 'special' colors to be produced such as metallic's and fluorescents. While most of the Pantone system colors are beyond the printed CMYK gamut, it was only in 2001 that Pantone began providing translations of their existing system with screen-based colors.

Types of Printing processes 1. Offset Lithography the most common printing process today the workhorse! It offsets ink from metal plates to a rubber blanket (cylinder) to the paper. Almost every commercial printer does offset printing. 2. Engraving think "fine stationery." Produces the sharpest image of all. Image feels indented (run your fingers over the back side of the sheet). Most law firms still use engraving. 3. Thermography raised printing, less expensive than engraving. Uses special powder thats adhered to any color ink. Mainly used for stationery products. 4. Reprographics general term covering copying and duplicating. Think in-house copying departments and copy or quick-printing shops. They take your originals and make duplicates of them. 5. Digital Printing the newest printing process and the least understood! Includes all processes that use digital imaging to create printed pieces. Doesnt use film. (Think desktop to the digital press.) For short-run, fast-turnaround jobs. Limitations include color, paper choices, and quality. But not for long -- the technology is exploding! 6. Letterpress the original process founded by Gutenberg in 1440. "Relief" printing (like rubber stamps, images on the plate are higher than the surface). Fine letterpress is being done by fewer and fewer printers. 7. Screen a.k.a. silk-screening. Ink is forced through a screen following a stencil pattern. Used for ring binders, t shirts, bumper stickers, billboards.

8. Flexography special type of printing for packaging products. The plates used are flexible. Products include cardboard boxes, grocery bags, gift wrap, and can and bottle labels. Frequently used for printing on plastic, foil, acetate film, brown paper, and other materials used in packaging, flexography uses flexible printing plates made of rubber or plastic. The inked plates with a slightly raised image are rotated on a cylinder which transfers the image to the substrate. Flexography uses fast-drying inks, is a high-speed print process, can print on many types of absorbent and non-absorbent materials, and can print continuous patterns (such as for gift-wrap and wallpaper).

8. Gravure prints directly from cylinder to paper. Used when printing for millions of impressions think magazines, newspapers, and direct mail catalogs. Iwasaki advantages Offset rotary intermittent press for label printers. This intermittent press fits exactly in the trend toward shorter runs and quick set-up demands. In fact it is the ideal modular alternative for the printers that consider going digital. This press can combine all used processes in line such as wet/ dry offset, letterpress, screen-print , hot foil stamping, embossing, flexo varnishing, laminating and die-cut. next to this backside printing in the same pass is possible. The advanced servo system of this press assures a high quality control and print quality. Objectives

Production for medium to long run Quality and speed of print Both Wet and Dry offset versions

Advantages

Robust Construction Simple set up Reduced waste High Print Quality High press performance Full servo control for registration and control Options include: Hot Foiling unit, flexo unit, Rotary diecutting, laminating etc... TR2 DH 330 DH 250 50 -310 mm 100 - 330 mm

Maximum repeath length Web width : mini-maxi Maximum print format

50 - 260 50 - 310 mm mm 100 100 - 330 330 mm mm

310 x 310 x 254 310 x 254 254 mm mm mm

Maximum diecutting format

310 x 310 x 310 310 x 310 254 mm mm mm (opt) 310 x 310 mm

Maximum foiling format Press Speed Number of colours

30 - 250 30 - 200 30 - 200 rpm ( 50 rpm rpm m/min) (40m/min) (40m/min) 1 to 7 colors 9 KW 3 Phase 200 V

26 KW + Electrical 5,6 KW 12 KW requirements (UV) Power source 3 phase 3 phase 200 V 200 V

IWASAKI (TR2) Contribution courtesy Mr. Sachin Arya - Baddi

Features New machine IWASAKI TR 2 got the printing features: 1. Waterless offset (Ajantas USP) which gives fantastic half tone quality. 2. Offset with water dampening. 3. Additional advantage over other Iwasaki is that, it has flexo unit. 4. Semi Rotary 5. Online varnish, stamping Die punch (Flatbed), slitting & rewinding. 6. Max Image Area- 320mm 7. Repeat Length- 250mm 8. Halftone -0 to 100% 9. Waterless printing has some advantages over conventional offset as colors are more vibrant and the printed image sharper; however, the overall cost is slightly higher.

Offset technology
Offset technology works on the principle that Image Area gets separated from Non Image Area on the same surface due to chemical applied to develop the silicone coated aluminum plate. Image area on the plate only catches the Ink & non image area does not take the ink. Then image area, which holds the required ink dispense the same onto the blanket. From the blanket ink is transferred onto the substrate. In Iwasaki TR2 , ink is cured through UV lamps.

Iwasaki TR 2 is semi rotary machine.

Flexo Technology

Ink Tray / pan

Through rubber roller Ink is picked Doctor Blade spreads the evenly. Anilox picks the evenly spread Ink Plate Cylinder holds the Nylo Plate

Nylo plate picks the Ink Apply on Substrate Impression cylinder gives pressure from backside.

Ink is cured through U.V lamps Types of plate 1. For Offset:- Pressure Sensitive Aluminum Plate- Has relatively short life. Waterless Ink is used. 1. For Flexo-Digital Nylo plates - Long Lasting ( It is similar which is used for Varnish) Flexo Ink is used. Water less Offset Ink Waterless Ink, Silicone Based. Very Thick, High Density Viscosity Check not applicable.

Preparation of Plate After graphic is approved. Negative is prepared at designing Studio. Aluminum Plate is exposed to 120 pulses with negative to prepare the positive. (100pulse=1min). Negative give printing plate with all the specifications of colors & job also depicts the feed amount. Plate is initially silicone coated and a film protects it from light. After exposing it is treated with PTS 2 & WH3. Plate should be placed very carefully & special attention has to be paid so that there is no scratch. Blanket is pasted on Chest with Lohman Tape. All set-up / environment should be dust free. Varnishing Varnish comes in two type (Gloss or matt) It is done to protect ink on label paper. UV Curing is done. Varnish Patch (Nylo Plate) is used to apply varnish evenly. For all the filmic labels , only varnish is done. Lamination Either varnish or lamination is done both cannot be done on same job. Lamination adds strength to the paper & withstand in wet area better than only varnished labels.

10 10-23 mic. (As per customer specs) BOPP film is used for laminating along with glue. It is not advisable to laminate on IWASAKI, it is better to use separate machine for better results. But to save time we are using self adhesive laminating film. We can die cut on IWASAKI after getting lamination done on separate machine that is called second pass.

Hot Stamping 10-12 mic hot stamping foil is used.

Stamping Block

Separate stamping block for each job (made of Copper or Zinc). Block is pasted with SR 998 adhesive.
apply heat & pressure on foil leaves foil color on specified area on substrate.

Block is pushed downwards

Embossing Its another kind of special effect that can be given to specified area on label. It is somehow opposite to hot foil stamping and embossing plate is fixed downside and pressure is applied from upside and particular alphabet or picture appears little above over the label.
NOTE: hot stamping & embossing can be done on same job as per requirement.

Die Cutting All the labels need to be cut according to their specified shape (punch to shape). Flatbed Die is pasted upwards and pushed downwards onto substrate to cut along the boundaries of each label. Downside there is a acrylic sheet (make ready sheet) to adjust the proper half cut & also to protect 8mm steel plate of machine. Precautions & Maintenance While printing temperature has to be maintained at 19 - 21C as to avoid Motelling or scump. o Motelling- If temp. is low Ink becomes tight and diminishes the effect. o Scump If temp. is high Ink tends to spread while printing. If there is any Minor spot on label apparent while printing, the Blanket has to be cleaned with UV wash If there is any scratch, either that area has to be removed from Blanket or new plate has to be prepared/ mounted. Ink has to be regularly checked and has to be spread with help of spatula as it will leave some oily substance if contaminated for some while. It can affect the inks effect. While changing the job, if color sequence has to be changed than Ink tray has to be cleaned with UV wash. While printing if there is adhesive on roller than, labelstock will stick resulting breakage of roll. In that case Toluene has to be used to clean the rollers properly.

Preparation of Flexo Plate

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According to job, Flexo / Nylo plate comes from repro house / studio Flexo /Nylo Plate is pasted on cylinder with Tessa tape. In Iwasaki, flexo plate is mounted at first unit. It can be used to print high opacity on clear labelstock before image is printed.

Quality Checks
1. Scuff Test ( Standard: 50 rounds on 2lbs) It is a test to check that label does not get affected by rubbing against each other. 2. Tape Test Ink should not come out with tape from the printed label surface. 3. Fade test / Sun Test Sun light should not affect / damage the label print. Label is pasted in a area exposed to sunlight test the effect of the same. 4. Oven Test Labels adhesive on actual bottle / container is checked. Also Lamination on label is tested. 5. GSM testing GSM of RM is tested as per the specifications. 6. Dynes Treatment- ( 40+ important) Mainly it is to be done on films as it is difficult to determine the substrate. Red color solution is applied on substrate, if bubbles appear immediately then it is wrong, bubbles should appear after 2-3 seconds

Other Important Terms

1. 2. 3. 4. Misregister-When printing gets missed and Ink falls on other than specified area. Micro setting- Plate is set through the photocell to ensure proper registration of image. Feed Amount- Amount of paper that is required for single time impression/printing. No. of Ups- No of labels that can be printed at single Impression.

Important Calculation
1. 2. 3. 4. 5. No of Impression= Total Quantity/ No. of Ups Running meter required for one job= Impressions X Feed amount (mm) / 1000 Sq.mtrs = Rmtrs X Paper width mm /1000 Label size (Sq.inch) = {width (mm) X height (mm)} / 645. GSM= weight(gm) / Area(Sqm)

Width

Height

12 What is DPI

DPI stands for dots per inch. DPI is a measurement of printer resolution that defines how many dots of ink are placed on the page when the image is printed. The higher a printer's DPI, the smoother your printed image will appear. Today's photo-quality ink jet printers have DPI resolution in the thousands (1200 to 4800 dpi). They will give you acceptable quality photo prints of images with 140-200 ppi resolution, and high quality prints of images with 200-300 ppi resolution.

A close-up of the dots produced by an inkjet printer. Actual size is approximately 0.25 inches square (0.635 centimeters square). Individual colored droplets of ink are visible; this sample is about 150 DPI. The term DPI is often used interchangeably with PPI, causing a lot of confusion, however, DPI refers to the resolution of the printing device, where PPI refers to the resolution of the image itself.

Monitoring Repeat Length Have you ever had the problem of repeat length varying through a printed roll? You measure the repeat when you stop the press, and its correct, but when the roll is being converted, unacceptable variations or shifts in repeat length are encountered throughout the roll. Perhaps the repeat measures 12 near the core, but measures 13 towards the outside of the roll. Sound familiar? This is not an uncommon problem. Repeat length can vary when printing on substrates that are stretchy, or have properties that push the limits of our equipments ability to control web tension or web speed relative to plate surface speed. With a stretchy or elastic substrate, we often print on the material while its slightly stretched by excessive tension and end up with a short repeat when the substrate contracts after printing. With a rigid or stiff substrate, we may rewind so tightly that we pull the material past the plate at a speed slightly faster than that of the plates surface and end up with a repeat length thats too long. Or, we may not be able to pull the material through the press fast enough and end up with a

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short repeat length. The tension control demands we face when working with touchy substrates can pose problems with respect to repeat length. Variation in repeat length is often associated with poor tension control. However, even under the best of tension control conditions, the simultaneously and inversely changing diameters of the unwinding and rewinding rolls almost certainly guarantee tension variation throughout the printed roll. With many substrates, this is not a major problem. But printing on a light gauge low-density polyethylene web with old, cranky equipment, or pulling heavy gauge material through our presses, for example, can test the limits of our ability to control repeat length. Most of us lack the technology to monitor repeat length while the press is running. However, imagine being able to tell while the press is running that your repeat might be long or short, simply by analyzing the print with the unaided eye or an average video inspection device. It could mean a reduction in difficulties and waste associated with repeat variation. What follows is a way to do just that. One of the trademark properties of flexographic printing is the appearance of a halo around the printed image. This halo is mainly caused by slight over-impression of the plate to the substrate. Keeping this halo to a minimum is a basic goal of quality flexographic printing, but often we cannot avoid at least some degree of visible halo. Lets define the leading edge of a printed image as the edge closest to the rewinder, and the trailing edge as the edge furthest away from it. At times the halo is more pronounced at either the leading or trailing edge of the printed image. This can result from a difference in plate surface speed and substrate speed, and can be present whether or not our plate is over-impressed. Fortunately, its sometimes possible to interpret the relationship of the substrate speed to the plate surface speed by close observation of this type of halo, and judge from its asymmetry the likelihood of a discrepancy in repeat length. It is found that if the halo is more pronounced at the leading edge of the image, the substrate is traveling faster than the plate surface and the repeat length is longer than what it should be. If the halo is more pronounced at the trailing edge of the image, the substrate is traveling slower that the plate surface and the repeat is short. Therefore, our goal is to try to avoid halos or keep them equally distributed between the leading and trailing edges of the images, by making the appropriate adjustments in tension.

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Conversion of LM to SQM The conversion goes like this: Area(sq mtr) = L(m) X W(m) .
Area is Length * Width, so just divide area by the Width and you will end up with the linear meters. All the units need to match so convert millimeters to meters first. 185 / 0.085 = 2176.47 linear meters of paper

What is a Blanket
Printing surface / Fabric ply / Close cell compressible layer / Cord ply / bottom fabric
BLANKET BASICS 1. During unpacking and handling, take particular care not to scuff rubber surface or make sharp bends or creases that might create surface impressions. Check entire blanket for visual defects or blemishes. 2. Make sure blanket is cut square and properly punched, or where required, bars are parallel and securely fastened. 3. Check caliper/gauge of each blanket using a deep throat bench micrometer (Cady gauge), NOT a machinists micrometer or paper micrometer. 4. Establish and maintain usage records for each blanket. 5. New blankets should be washed before use to remove any dust or protective coating applied during manufacture. Use clean sponge or soft, lint-free cloth wet with water or water-miscible blanket wash. 6. Striping on fabric side of blanket must run around cylinder. Striping running across cylinder identifies a blanket that has been cut in the wrong direction.

Sealed

15 MOUNTING DIRECTIONS 1. Thoroughly clean blanket cylinder and bearers. 2. Mounting a blanket is not the same as mounting a plate ... blankets are elastic. Mounting procedures and tension are critical to proper performance. 3. Securely lock leading edge of blanket into cylinder. Slowly turn cylinder while pulling blanket over cylinder. Lock trailing edge in place. Tighten initially only to take up slack. 4. Make final check of printing surface to ensure nothing has been trapped under blanket or packing. Allow setting by running cylinder on impression, Pre-Press

What is Pre-Press
All activities before commencement of bulk production like preparation of design, correction / improvement / changes in existing design to initial proofing are carried out in the Pre-Press department. It is further divided into sections;

Computerized Designing Section comprising of Macintosh and advanced PCs with up to date commercial designing software is manned by experienced personnel. Here the Final CD is prepared to make layouts for production plates / Cylinders. Plate Making Section is equipped with computerized plate exposing units and automatic plate developing machines. Facility to bake the plates for extra long run life is also available.

What is UV Curing?

Ultraviolet curing (commonly known as UV curing) is a photochemical process in which high-intensity ultraviolet light is used to instantly cure or dry inks, coatings or adhesives. Offering many advantages over traditional drying

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methods., UV curing has been shown to increase production speed, reduce reject rates, improve scratch and solvent resistance, and facilitate superior bonding. Look What UV Curing Can Do For You UV curing offers manufacturers many benefits. Below youll find additional information on some of the most significant ones.

Inks, coatings, and adhesives with dramatically improved physical properties. Faster production speeds and capacity Reduction of Work-in-process Dramatically reduced set-up/clean-up labor Environmentally Friendly Energy savings, no emissions controls Less floor space needed Increase yield and reduce scrap

print impressions
Number of images (individual copies) produced in a print run.

Definition of a Self Adhesive Product

Self Adhesive paper is a complex made up of three component parts 1. The Face Stock - this is the part that will finish up as the label. A wide variety of face stock materials can be chosen depending on quality required. The face stock used in white, colored, fluorescent, laminated, metalized, thermal and carbonless, film. 2. The Adhesive - it's function it's to keep face material joined to the release liner. When these two elements are separated, the adhesive stays attached to the face material forming label.

The quantity of adhesive which is applied to the release liner varies between 1025gsm depending on the final use to be made of the product.
Depending on the composition, adhesives can be found in 3 main types

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1. Water based Emulsion ( or Acrylic ) adhesives - These are made up polymers dissolved in water. Most widely used types are acryl ate dispersions ( water based acrylic adhesive ) 2. Solvent Based Adhesive - These are made up of solutions in a organic dissolvent with different components ( rubber , resin etc. ) 3. Hot melt adhesive - These are made up of rubber with resins, plasticizers and other additives which, when producing the self adhesive complex in melted form are applied by means of heat ( with temperatures of higher than 120c ) neither dissolvent nor water are used. 3. The Silicon coated Release Liner - This is the part which is eliminated after the label has been attached to the appropriate surface. The coating of silicon ensures that the adhesive will only be attached to the material. The Silicon coating that is applied to

the release liner usually around the 1.2 gsm range depending on the type of release liner and final product.

* ( contribution courtesy Mr.Manoj Kumar - Daman 12/12/2011 )

Various types of Self Adhesive Stock materials used in Printing

Description Substrate Adhesive Liner / Release paper Silicone coated Release liner Application Used where Paper label is required with UV / Lamination

Fascoat (Avery)

Chromo

Hot melt

18 80 GSM Clear on Clear PP Transparent 60 micron Opaque Polyethylene 85 micron Transparent Polyethylene 85 micron Biaxially Oriented Polypropylene White 50 micron Biaxially Oriented Polypropylene transparent 60 micron Biaxially Oriented Poly Ethylene White 50 micron Biaxially Oriented Poly Ethylene Transparent 50 micron Biaxially Oriented Polypropylene metallic 50 micron Ultra Destructive Surface Paper is made out of Egg Cell 18 (+-2) Acrylic 19 GSM 62 GSM PET transparent 36 mic Silicone coated Release liner 62 GSM Silicone coated Release liner 62 GSM where absolute transparency is required Used for squeezable containers / bottles / tubes Used for squeezable containers / bottles / tubes Used where Opaque Filmic Label Required ( but not suitable for squeezable Bottle) Used where Opaque Filmic Label Required ( but not suitable for squeezable Bottle) Used where Opaque Filmic Label Required ( Suitable for Oil Product)

PE 85 White

Acrylic 19 GSM

PE 85 Transparent

Acrylic 19 GSM

PP White

Hot melt 15.5 Gsm

Silicone coated Release liner 62 GSM

PP transparent

Hot melt 15.5 Gsm

Silicone coated Release liner 62 GSM Silicone coated Release liner 62 GSM

PET White

Hot melt 15.5 Gsm

PET Clear

Hot melt 15.5 Gsm

Silicone coated Release liner 62 GSM

Used where Transparent Filmic Label Required ( Suitable for Oil Product)

PP metallic

Hotmelt 15.5 Gsm

Silicone coated Release liner 62 GSM Silicone coated Release liner 62 GSM

Used where metallic Effect Filmic Label Required

Hot melt 18 GSM

Used where Tamper Evident Label Required

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Direct Thermal Thermal Transfer

Silicone coated Release liner 62 GSM Silicone coated Release liner 62 GSM

Used where Thermal Ptg on Label Required Used where Thermal Ptg on Label Required

Quality Control carried out on adhesive complex

1. Peel or Adhesive Capacity Test - according to the adhesive capacity, adhesives are commonly classified of ; Removable - adhesive that can be taken off after they have been stuck on.

Permanent - adhesive that cannot be taken off after they have been stuck.

Super Permanent - these are used when there are problems with the adhesive capacity of the release liner which the label is attached. The peeling or adhesive capacity test is a way of measuring the products adhesive capacity. According to the result the adhesive will be defined as Super permanent, Permanent, Removable.

Characteristics of Peeling test - The force required to remove at 180 and 300mm/min a sticker 25mm wide attached to the pressure exercised by a roller weighing 2kg on a plate of various different materials after specific periods of attachment ( 20 min, 24 hours, 1 week ) (Ref/Std:FINAT FTM-1)

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2. Quick Stick Test ; This test measures the tack ( or stickiness ) of the adhesive. Tack is very important for automatic application. A high level of tack means that the adhesive will be attached as soon as it touches the release liner. For manual application tack is less important since the person who stick on the label can subsequently apply the pressure for it to remain attached. For example, for stickers it is better to have a low tack which makes it possible to un-stuck if stuck in the wrong place. Logically this will always be for a short space of time, since the adhesive will increase their adhesive capacity over time.

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Characteristics of Quick Stick test - The force required to remove immediately at 300mm/ min a 190c25mm strip of adhesive face material attached to a plate of stainless steel measuring 25x25mm (Ref/Std:FINAT FTM-9) 3. Rolling Ball Test: This test also designed test Tack. Characteristics of Rolling Ball test - The distance ( in CM) covered by a stainless steel ball 11.1mm in diameter that falls onto a flat surface inclined at an angle of 30 and which rolls on to a sample, it's movement then being restrained by the sample's adhesive film. The slower the rolling ball move the greater the tack.(Ref/Std: PSTC 6M ) 4. Cohesion Test: Cohesion of a adhesive gives us an idea of it's resistance to fluidity. This is classic problem when we try to guillotine self adhesive sheets or die cut stickers. Since if the adhesive does not have sufficient cohesion it can flow over the edges and the sheets / labels will stick to one another. Characteristics of Cohesion test - Interconnecting or fragmentation force of an adhesive film in two parts when two different forces are applied. This test is based on the time required for a 1kg weight to produce an internal fracture in the adhesive film of a sample strip stuck to a plate of glass at an inclination of 2 from the vertical. (Ref/Std: FINAT FTM8 ) 5. Release Test : Release is the force that separates the face material and the release liner, and is a very important factor in the printing process and process of matrix stripping ( reels) and also for the automatic application of labels. release test carried out at two different speeds. Low speed - 300mm/ min. High speed - 150mtr/min. Characteristics of Release test - The force required to un-stick adhesive applied face stock material from the silicon coated release liner to which it is attached as part of a single adhesive complex. Low speed - sample 5cm width x 19cm long / High speed sample 3cm width x 70cm long. (Ref/Std: low speed - FINAT FTM3 / high speed FINAT FTM4 )

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Theory of Corona Treatment:

The surface tension of plastic films is not sufficiently high to permit good adhesion of print ink with plastic film . In case of lamination , it prevents better bonding between two or more materials. Hence, for better quality of printing, lamination and coating processes , surface tension of the plastic films should be increased. The Corona Treatment method is widely used nowadays to increase the surface tension of the films. The Corona Treatment of plastic film is done by passing the film through the corona discharge created between electrode and dielectric covered ( usually Silicone Rubber Sleeve) earthed roller as shown in Fig. 1. The air gap between electrode & roller is 2-3 mm. The electrode is connected to electrical supply having high voltage & high frequency. As film passes through the corona discharge, molecules of surface gets oxidizes which has more surface tension. The corona discharge between electrode and roller is visible by violet color flame between them.

Positive & Negative Plates Positive working plates are more expensive than their negative-working counterparts. These types of plates are used more by European printers. As the name implies, film positives are used to image this type of plate. The photopolymer used to produce a positive working plate is different from the polymer used in the negative working plate as it is hardened before exposure. The photopolymer used here becomes unstable when exposed to ultraviolet light and remains hard where no light strikes the polymer. Plate processing is similar to the negative plate except that the processor removes the exposed photopolymer from the plate and applies a thin layer of gum to protect the non-image areas from ink.

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Plates are generally made from aluminum. Other base materials can be used such as paper, polyester and multi-metal. Multi-metal plates are used for long extensive press runs due to their durability. Paper type plates are used in small offset presses known as duplicators for very short runs (1,000 - 10,000 impressions). Polyester plates may be used in small press or in larger sheet fed presses. Like paper plates, these are intended for short runs. In general, the polyester and paper plates are much less expensive than the aluminum or multi-metal plates. Cost, run length, type of press and the type of job dictate the type of plate used by a printer.

Offset Plate Technology The aluminum-based plate contains the light-sensitive coating applied or coated over the aluminum. Paper and polyester plates are treated very similarly. The multi-metal plate, however, is similar but the structure of the base plate is slightly different from that of the aluminum, paper, etc. Multi-Metal Plates were developed to extend press run life. In general, multi-metal plates are presensitized polymer plates consisting of a metal base with one or more metals plated to it. Today, there are two basic types of "bi" or multi-metal plates:

Copper plated onto stainless steel or aluminum Chromium plated on copper

( * contribution courtesy Mr. Prashant Kulkarni - Daman 13/12/2011 )

Flexography Troubleshooting Guide Adhesion

Problem: Ink flakes off substrate, comes off when crinkled, or is removed easily in tape test. Cause: 1. Viscosity too high

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2. Viscosity too low 3. Ink surface tension too high 4. Incorrect ink system for substrate 5. Poor film treatment 6. Ink drying too slow 7. Substrate surface contamination 8. Insufficient web temperature Solution: 1. Reduce viscosity consistent with acceptable printability 2. Add virgin ink to fountain 3. Consult your technical sales representative 4. Ensure that the correct ink for the substrate is being used 5. Check surface of film for adequate treatment; treat in-line, if possible 6. Check driers for heat and airflow; consult your ink manufacturer Solvent Flexo: Reduce with faster solvent blend 7. Check with film supplier as to advisability of applying a primer before printing, use in-line treater 8. Increase temperature settings of driers, check drier balance

Bleed
Problem: Color spreads into subsequently applied coating or adhesive Cause: 1. Improper pigment use in ink formulation 2. Coating or adhesive may be rewetting the dried ink Solution: 1. Consult your ink manufacturer to reformulate using resistant pigment 2. Consult your ink manufacturer to reformulate using resistant pigment

Blushing (Hazing, Fogging)

Problem: Milky, foggy or matte appearance in an ink or coating.
Cause: 1. Solvent Flexo: High humidity causing excess moisture build-up in ink 2. Solvent Flexo: Moisture condensation on surface of drying ink Solution: 1. Solvent Flexo: Consult your ink manufacturer for properly balanced solvent blend for specific ink and printing conditions 2. Solvent Flexo: Use less hygroscopic solvent blend for ink reduction; coordinate with your ink manufacturer

Color Too Strong

Problem: Visual color different from standard.
Cause: 1. Solvent Flexo: Ink viscosity too high Water Flexo: Ink pH too high 2. Ink pigmentation too high 3. Inappropriate anilox roll; cell volume too great or cell count too low 4. Inadequate pressure setting on impression roll 5. Plate and/or ink metering roll durometer too low 6. Inadequate impression on doctor blade Solution: 1. Solvent Flexo: Reduce viscosity to proper level with recommended solvent blend Water Flexo: Check and adjust pH then reduce viscosity to proper level 2. Reduce ink colorant strength with balanced extender 3. Replace anilox roller with one of higher line. Adjust impression for optimum printability 5. Consult plate and/or roller manufacturer 6. Adjust doctor blade to recommended pressure

Color Variations Among Same Color Jobs

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Being Run in a Plant

Cause: 1. Poor viscosity control Water Flexo: Lack of pH control 2. Variation in substrate porosity or surface treatment 3. Previously used ink 4. Inadequate amount of ink in fountain or doctor blade chamber 5. Different suppliers of same color 6. Variation in ink batches 7. Non-standard process design Solution: 1. Establish set procedures for viscosity control Water Flexo: Maintain proper pH 2. Consult with ink and substrate manufacturers for proper measures to be taken 3. Replace or add virgin ink 4. Add ink to fountain or ensure adequate ink pressure into enclosed doctor blade assembly 5. Run only one suppliers ink on a given color 6. Consult your ink manufacturer 7. Inks must be modified to matched print station; recommend match visual standard on-site

Dirty Printing
Problem: Fuzzy extensions of image into non-image area. Impression increase or change in plate durometer during run. Recovers when taken off press; sometimes results in cracks in plate during storage.
Cause: 1. Excess ink being applied to plate 2. Excess impression between plate and substrate 3. Ink viscosity too high 4. Accumulation of paper dust (lint) 5. Ink drying too fast 6. Water Flexo: Ink pH too low 7. Excessive anilox volume 8. Excess anilox impression 9. Plate swell caused by use of materials not compatible with printing plates Solution: 1. Adjust anilox/fountain roller impression; adjust doctor blade pressure 2. Reduce to kiss impression for type and minimize impression consistent with acceptable printability for reverses 3. Adjust to lowest viscosity consistent with acceptable printability 4. Improve housekeeping, vacuum paper dust and filter ink 5. Check air flow at between-deck driers; consult your technical service representative Solvent Flexo: Use slower solvent blend to reduce ink 6. Water Flexo: Raise pH as instructed to by ink manufacturer 7. Use lower volume anilox 8. Back off impression of anilox to plate 9. Confer with plate and ink suppliers

Excessive Ink Consumption

Problem: Too few impressions per pound of ink.
Cause: 1. Ink viscosity too high 2. Ink color acceptable, but stronger than standard 3. Weak ink 4. Excessive anilox volume 5. 2 Roll: Soft metering roller 6. Excess loss on start up or shutdown Solution: 1. Reduce ink to lowest viscosity consistent with acceptable printability 2. Use balanced extender to weaken range

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3. Check ink for strength vs. original standard 4. Finer/shallower anilox 5. Check durometer; extend or reduce ink 6. Additional care in ink handling; can be due to large amount of ink required for inking station

Foaming
Problem: Voids in printing, foam visible in sumps, or ink overflowing sump.
Cause: 1. Too much air being introduced into ink 2. Ink level in fountain below pump intake level 3. Ink falls excessive distance when recycled into reservoir 4. Ink viscosity too high 5. Improperly formulated ink 6. Water Flexo: Poor cleanup procedures Solution: 1. Check for leaks in hoses and pumps. Adjust pump speed to reduce agitation 2. Fill fountain with ink well above intake level 3. Use hose or pipe to eliminate long ink falls into pan 4. Reduce viscosity to allow any bubbles to rise and break at surface 5. Consult your ink manufacturer 6. Water Flexo: Ensure that no detergent from clean-up has contaminated ink

Ghosting
Problem: Part of image not printing; resembles an offset of same image. (See also Tracking)
Cause: 1. Ink dries too fast for anilox volume, does not adequately replenish anilox Solution: 1. Slow ink down Add extender Use coarser anilox Reduce press speed

Mottle
Problem: Random light and dark spots. May cause color to appear dirty.
Cause: 1. Substrate has non-uniform caliper or absorption characteristics 2. Ink viscosity too low 3. Improper impression. Can be caused by uneven plates, surface dirt on plates or dirty impression cylinder 4. Non-optimal plate selection 5. Contaminated plates 6. Transparent color Solution: 1. Try lower durometer plate; try opaque ink 2. Add fresh ink and maintain proper viscosity 3. Clean plates and impression cylinder; adjust impression; check and adjust plate cushion or mounting materials; remake plates 4. Consult plate manufacturer 5. Wash plates with appropriate solvent or replace plate if cannot be cleaned 6. Transparent color does not cause problem, but increasing opacity of the color match may mask the problem

Set-off and/or Blocking

Problem: Ink transfers from image side to back side of substrate when unrolled; inability to separate printed sheets or to unroll web.
Cause: 1. Drying too slow

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2. Excess pressure in re-wound roll 3. Film substrate treated on both sides 4. Film substrate heavily plasticized 5. Web too warm when rewound 6. Web rewound with too much surface moisture 7. Solvent Flexo: Trapped solvent in printed ink film 8. Water Flexo: Trapped amine in printed ink film Solution: 1. Check driers for heat and air flow; reduce ink viscosity consistent with acceptable printability; consult your ink manufacturer 2. Reduce rewind tension 3. Avoid excessive pressure in rewind; apply offset powder o web prior to rewind; overprint with non-blocking clear varnish, if necessary 4. Avoid excessive pressure in rewind; apply offset powder to web prior to rewind; overprint with non-blocking clear varnish; consult your ink manufacturer for different ink 5. Reduce web temperature by chilling within 10 F of ambient temperature 6. Avoid over chilling which allows condensation to form on film surface 7. Solvent Flexo: Check driers for heat and airflow; consult your ink manufacturer 8. Water Flexo: Check driers for heat and airflow; consult your ink manufacturer

Tracking
Problem: Ink appears in area where there is no print. (See Ghosting)
Cause: 1. Ink film too heavy 2. Ink drying too slow 3. Mechanical problems 4. Difficult design due to extreme color coverage, degree of trapping and/or die cut positioning Solution: 1. Reduce viscosity consistent with acceptable color and printability; have ink reformulated for stronger color to permit thinner film; adjust to proper pressure at all roller nips 2. Solvent Flexo: Adjust ink drying speed with supplier-recommended solvent blend Water Flexo: Adjust ink drying speed based on instructions from supplier 3. Adjust and clean all belt and idler roller surfaces that are in contact with the printed substrate 4. Change layout of design and/or consult your ink manufacturer

Trapping
Problem: Cannot achieve good coverage in areas where more than one color is applied.
Cause: 1. First-down color drying too slow 2. Subsequent colors drying too fast 3. Improper pressure setting on Impression cylinder 4. Water Flexo: Improper viscosity 5. Incorrect plate or backing Solution: 1. Consult your ink manufacturer; check drier capacity; Solvent Flexo: Use faster-drying reducing solvent 2. Check air flow in between-color driers. Consult your ink manufacturer; Solvent Flexo: Use slower drying reducing solvent 3. Adjust impression on first- and second down inks 4. Water Flexo: In general, each succeeding color requires slightly higher viscosity; adjust accordingly 5. Use optimal plate, firmer backing

Weak Color
Problem: Visual color different from standard.
Cause:

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1. Ink viscosity too low Solvent/Water Flexo: a. Too much solvent added to cut ink b. Excess clean-up solvent in system Water Flexo: pH too low 2. Worn anilox roller 3. Plugged anilox roller 4. Plate durometer too high 5. Improper pressure setting on impression and/or anilox roller 6. Ink too weak for anilox roller volume 7. Inadequate ink in fountain or in doctor blade chamber 8. Solvent Flexo: Dirty plates 9. Water Flexo: Glazed or dirty plates 10.Water Flexo: Glazed metering roll Solution: 1. Replace ink totally or add virgin ink to fountain 2. Consult anilox roller manufacturer to verify; replace if necessary 3. Use brass bristled brush for chrome rollers; stainless steel bristled brush for ceramic rollers Solvent Flexo: Clean with recommended solvent to remove dry ink from cells Water Flexo: Clean with brush, hot water (140 F) and detergent to remove dry ink from cells 4. Remake plates to proper specifications and replace 5. Re-adjust impression for optimum printability 6. Consult your ink manufacturer to strengthen ink if at all possible. If this is not possible, replace anilox roller with one having a deeper etch 7. Add ink to fountain or ensure adequate ink pressure into enclosed doctor blade assembly 8. Solvent Flexo: Wash plates with recommended solvent and, if necessary, a moderately stiff non-metallic brush 9. Water Flexo: Wash plates with warm water, a mild detergent and a moderately stiff nonmetallic brush 10.Water Flexo: Wash with warm water, a mild detergent and a moderately stiff non-metallic brush

Metallization
Metallization is performed using a physical vapor deposition process. Aluminum is the most common metal used for deposition, but other metals such as nickel or chromium are also used. The metal is heated and evaporated under vacuum. This condenses on the cold polymer film, which is unwound near the metal vapor source. This coating is much thinner than a metal foil could be made, in the range of 0.5 micrometres [1]. This coating will not fade or discolor over time. While oriented polypropylene and PET are the most common films used for metallization, nylon, polyethylene and cast polypropylene are also used.[2]

25 simple ways to save money in the workplace and reduce climate change
The rate at which the climate is changing is directly attributable to the activities of humans. The burning of fossil fuels, such as coal and gas, for our electricity, heating and transport requirements emits potent greenhouse gases, in particular carbon dioxide. This warms the Earth by trapping heat from the sun within the atmosphere, a process known as the greenhouse effect. In Torbay, the average annual temperature will be up to 4C higher by 2080 than it was in 1990. This will lead to a 50% reduction in summer rainfall and a 20% increase in winter rainfall as well as an increase in sea level of up to 90cm. Storm events will also become more common and intense.

29 Changes to our climate on this scale will have wide ranging impacts upon food supplies, water resources, coastal defenses, transport and communication networks, public health, wildlife, landscape, and the make-up of Torbays economy. Forty percent of Torbays carbon emissions come from the energy needed to power our businesses. If we all make changes in our workplaces to reduce carbon emissions by saving energy we will make a difference. Whether its an office, a workshop or a retail outlet, there are many ways you can reduce the amount of energy used in your workplace. Most of these are easy and will not cost you a penny in fact theyll save you money on your energy bills! Saving energy means extra profit or more money which can be reinvested in staff, training or improved facilities.

Lighting
1. Switch off lights when theyre not required and when daylight is adequate. Consider fitting light switches that work through sensing movement, which can prevent lights being left on for longer than is necessary. 2. Save 125 per year by switching off lights at night and weekends. 3. Replace halogen and incandescent lighting with energy saving fluorescent types. They will reduce energy use by up to 80% and can pay for themselves in less than a year.

Appliances
4. Dont leave PCs on overnight. Switching off one PC and flat panel monitor when not in use can save 100 each year and the same amount of carbon each year that is emitted from driving a car 3,000 miles. Thats 1000 for every 10 PCs in your office! 5. Switch off printers, photocopiers and suitable water coolers and vending machines at night and weekends using time switches to save up to 500 a year. 6. Set your printers and photocopiers to use double sided printing to halve your paper costs, reduce waste and save energy. 7. Enable automatic power saving features on IT equipment. Screen Savers dont save energy. Instead, set your PC to automatically put the monitor into standby when youre unexpectedly away from your desk. 8. Label equipment and switches so that it is clear how to switch something on when it is needed 9. Only fill the kettle with the amount of water you need. The kettle will boil faster and youll be saving about 45 of electricity each year. 10. When replacing appliances try and buy the most energy efficient models. An energy efficient PC and printer will use 200 less electricity each year than an inefficient model. Look for the A rating on kitchen appliances, the Energy Star logo on IT equipment and the Energy Saving Recommended logo - visit www.eu-energystar.org to view approved products. 11. Use electricity-powered tools in preference to compressed air versions as they use one tenth of the energy. Check for leaks in any hoses and repair them immediately.

Heating, Cooling and Ventilation

30 12. Air conditioning typically accounts for 30% of the energy used in an office. Only use it when necessary and keep doors and windows closed. 13. Reduce the need for air conditioning and lighting by using window blinds to reduce the amount of heat entering the building and to direct strong sunlight up towards the ceiling. 14. Turn off extraction, compression ventilation units whenever theres nobody in the workplace to benefit from their use. 15. Install insulation where possible. Loft, cavity wall and draught proofing can reduce your heating and air conditioning bills by up to 15%. 16. Installing a timer to turn off heating overnight and at weekends could save up to 350 each year. 17. Ensure the heating thermostat is set no higher than 21C and avoid positioning your thermostat in draughts, in direct sunlight or near to equipment or machinery that gives off heat as this can result in over or under heated areas. 18. How hot do you need your water? You only need to heat water to 60C to avoid the risk of Legionnaires Disease. Any higher might be a waste of energy.

Transport
19. Use sustainable transport (walking, cycling, or public transport) one day per week and encourage your colleagues to do the same. 20. If you need to use your car to commute to work, why not car share? find people who make the same journey as you and are willing to share the costs 21. Organize meetings at venues that allow all participants to arrive by sustainable transport. 22. Use telephone or web conferencing as often as possible to avoid travelling to unnecessary meetings. 23. Consider working from home occasionally. This removes the need to travel to work completely. Make sure youre saving energy whilst at home

Organisational
24. Monitor your workplace energy use by reading your utility meters at regular intervals and place Energy as an agenda item for team meetings. 25. Assign somebody to be responsible for switching off lights and appliances at the end of the day - rotate this responsibility between colleagues. Show your commitment to tackling climate change