CHAPTER - 2

OFFSET PRINTING
PROCESS
 CHAPTER - 2

OFFSET PRINTING PROCESS

2.1 INTRODUCTION

After taking review of earlier research work on performance of offset printing process in
chapter 1, it was found that to ensure the better quality of print, the surface temperature of roller
needs to be maintained. In this chapter the details of offset printing process along with print quality
parameters are described.

2.2 PRINCIPLE OF OFFSET PRINTING

Offset lithography is a planographic printing process which requires an image carrier in the
form of a plate on which photo chemically produced image and non image areas are receptive to ink
and water respectively. The image on the plate must be right reading i.e. it is oriented the same way
that the printed image to be printed [7].

The basic principle used in offset process is that ink and water never mix each other.

Following are the basic steps involved in printing by offset lithography

• Plate with photo chemically produced image and non image areas is mounted on a cylinder.

• Plate is dampened with a mixture of Chemical concentrates in a water based solution which

adheres to the non image areas of the plate.

• Plate surface is contacted by inked rollers which apply ink to only image areas of properly

dampened printing plate.

• Right reading inked image on the printing plate is transferred under pressure to a rubber like

blanket on which it becomes reversed i.e. mirror image.

• Inked image on the blanket is transferred under pressure to a sheet of paper or other printing

substrate producing an impression of the inked image on paper.

2.2.1 Components of Sheetfed Offset Machine

• Plate Cylinder - A cylinder that carries the printing plate, a flexible image carrier with

oliophilic image areas and hydrophilic non-image areas.

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 Blanket cylinder - A cylinder that carries offset blanket, a fabric coated with synthetic

rubber that transfers the image from printing plate to the substrate.

Impression Cylinder -A cylinder running in contact with the blanket cylinder that transports

the paper or other substrate.

Dampening System - a series of rollers that dampen the printing plate with water based

dampening solution which contains additives such as orthophosphoric acid, gum arabic and

isopropyl alcohol.

Inking System - A series of rollers that apply a metered film of ink to a printing plate as

shown in the Fig.2.1

Printing plate -the Inking unit

humid areas repel
Non-printing areas
the oil-containing
are water-receptive
printing ink
Printing areas are
Only the printing water-repellent
areas are inked

Dampening unit

Paper

Blanket

Fig. 2.1 Configuration of Offset Machine

2.3 VARIABLES AFFECTING PRINT QUALITY

A final printed copy has three components: paper, ink and fountain solution emulsified in the

ink. These key components are complex in composition and the process of bringing them together to

satisfy a broad range of print quality is extremely challenging. This section describes most of the

variables that affect the print quality.

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Followings are some variables affecting print quality:-

Ink - Tack and viscosity

Ink / Water balance

Pigment strength

Temperature( affecting the viscosity of ink)

Ink film thickness and Trapping

Paper - Brightness, whiteness, and opacity

Porosity/Holdout and Smoothness

Fountain solution - pH, conductivity and hardness of incoming water

Plate - Exposure time and vacuum

- Processing

Speed - Low or High

2.3.1 Ink

Inks are of two types, liquid inks and oil based paste inks. Offset printing needs oil based

paste inks in which the main elements are pigment, vehicle and additives. The rheological properties

of lithographic inks are viscosity, tack, thixotropy, flow and length.

Ink Viscosity and Tack

Viscosity is the resistance towards flow of liquid. Viscosity is the ratio of shearing stress (force

per unit area) to shearing rate (strain rate or velocity gradient of flow). Lithographic inks are

substantially non-Newtonian as viscosity is not constant but is shear rate dependent. This non-

Newtonian behavior necessitates viscosity measurement over the full range of shear rate that inks can

encounter.

Tack is the stickiness observed when printer taps out a thin film of ink on the flat surface. Tack

can be defined as the resistance of the ink film to splitting.

• The tackier inks in offset print are sharper and clearer at line and halftone areas and it

has less tendency to waterlog or breakdown and emulsify in dampening solution.

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 • If inks are too tacky, they damage the paper and print poor solids and if inks are less

tacky, they print poor halftones and lines and setoff onto other sheets in the pile.

• Ink- Water Balance

Water is emulsified in the ink, which has the effect of lowering the tack. Higher levels

of water retard the setting and development of tack after printing, both of which affect

trapping i.e. superimposition of a colour on the preprinted colour to achieve the desired

shade. To achieve the best trapping it is important to keep the damp level to the absolute

minimum.

• Temperature( affecting the viscosity of ink)

The viscosity of all liquids changes rapidly with the temperature. The temperature

coefficient of viscosity for inks may be ± 5% per degree Fahrenheit (about 9 - 10% per

degree Celsius) or even greater. The high negative temperature coefficient of viscosity has

severe implications for the printing. In the first place, if a multicolor press is not warmed to

working temperature before printing starts the color changes may take place as the press

warms up. Further change in the temperature on one of the units, the flow of inks changes on

that unit. Due to this there is change in colour of print. In lithographic printing, the press and

the pressroom temperature must have controlled temperature before attempting to feed paper

into the press.

• Ink Trapping

The measurement of trapping aims to quantify the ink transference of one ink on to

previously printed inks. To facilitate the trapping measurement we require control strip

comprising 3 process colors, 3 overprints, and the knowledge of the order of printing. Trap

can be measured by

% Apparent Trap = [(D0P-D,) / D2 ] X 100

/ here/Dop = density of 2-color over print, minus paper density

D| = Density of first ink down, minus paper density

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 Di = density of second ink down, minus paper density

Variations in trapping result in color variation in offset process.

A thin film will not trap properly on thick film, so that even if the ink tack is properly controlled, ink

film thickness must be controlled.

2.3.2 Plates

Printing plate is carrier of image and non-image areas. It is mounted on plate cylinder of the offset

machine.

• Surface Tension of the Ink accepting area,

• Surface tension of the dampening solution accepting areas,

• Surface roughness, especially of the free/non-image surface,

• Capillary action, microstructure of the non-image surface,

2.3.3 Paper

An offset printing paper includes news print, ground wood and supercalenderd. The surface

of offset paper should resist picking and be relatively free of dust and lint. The paper should resist

moisture, thus preventing fountain solution from loosening the surface fibers or coating pigments. It

must also exhibit good ink receptivity and high holdout.

2.4 INKING SYSTEM OF OFFSET PRINTING MACHINE

The inking system of the Offset printing machine has four basic functions as shown in Fig.2.2.

1. To move the ink from the ink fountain to the plate.

2. To break down the thick charge of ink into a thin, uniform film around the rollers.

3. To workout the ink into printing conditions.

4. To remove image repeats on the form from previous printing cycle.

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 Rubber Rollers- 5,6,11,12,13,17
Copper Rollers- 3,7,8,9,10,12,15,16,18
P- Plate Cylinder

Fig.2.2 Inking System of Offset Printing Machine

The inking system of Offset presses consists of following parts:

• Ink fountain- A pan that contains ink supply.

• Ductor roller- A transfer roller that alternately contacts the ink fountain roller and the first

roller of the inking system, often an oscillator.

• Oscillator or Vibrators- Gear or chain driven rollers that rotate and oscillate from side to

side, distributing and smoothening out the ink film and erasing image patterns from the form

roller.

• Intermediate rollers-

i) Distributor rollers - These are gravity driven rollers which are always in contact with two

rollers.

ii) Rider rollers - These rollers are always in contact with single roller.

• Form rollers- A series of three to four rollers, usually of differing diameters, that contact the

printing plate and transfer ink to it.

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2.4.1. Ink roller setting

When rollers are being set, it is the resilient rollers that are adjusted, not the hard rollers.

Following are several general recommendations to follow while setting rollers.

• Back off all adjustments completely before setting any rollers.

• Always set a roller by moving it forward in contact with the plate.

• Never set a roller by backing it away from the plate or contacting roller.

Setting the Form roller to Oscillator

The accepted method of setting the form rollers to the oscillators is called the strip method. A

set of thin packing paper or plastic strips are inserted between the form roller and the oscillator, and

the strips are pulled out, providing a "feel" that can be used to judge if the rollers are properly set.

Paper strips are used to set the form rollers when no ink is on the rollers and plastic strips are used

when the rollers are already inked. The strip method of roller setting provides a measurement of

following factors:

• Pressure between two rollers being set.

• Width of the nip between them.

• Roller hardness Stiffness versus flow and Glaze condition of the roller surface.

2.4.2 Effect of Temperature on Viscosity

Viscosity is one of the most important properties of a printing ink. The viscosity range chosen

is based on a combination of factors such as press inking system (injector or fountain), press speed

and ink delivery (bulk handling or pumped from containers). The formulating chemist also Sets y j l ^ S

viscosity specifications at a temperature that is within a normal operating range of most offset

printing press, however since viscosity is dependent on temperature it is important to recognize that a

large fluctuations in temperature can change viscosity and ultimately ink performance. The Fig."2.3

predicts the viscosity of a typical sheet fed offset ink over a ranee of temperatures, Viscosity

markedly decreases as temperature increases. Therefore viscosity at temperature extremes can be

significantly different from the range chosen during the formulation range.

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 Fig.2.3.Effect of Temperature on Viscosity

2.4.3. Effect of temperature on printing performance

Printing with lower viscosity ink may lead to several different problems. A significant

increase in viscosity will restrict ink flow and can result in print density fluctuations or starvation

because the correct volume of ink can no longer be delivered to the press. Ink transfer through the

roller train can be impeded resulting in inconsistent or mottled print an increase in viscosity can also

contribute to excessive lining. •0U

A common problem in pressroom is ink dripping, misting, and spitting the ink viscosity. If

the temperature varies then these variables will also vary day to day in some presses in summers ink

viscosity is increased so that due to increase in temperature ink misting or dripping will be reduced.

The temperature measurement in the ink roller train is a critical measurement. The roller temperature

can be measured with a contactless temperature sensor.

The fountain solution plays an important part as the press is running the fountain solution

backs its way into the ink roller train due to emulsification. The fountain solution acts as a coolant

due to evaporation which results in the cooling of the roller train. The ink roller train temperature is

critical in maintaining good printability.

2.5 PRINT QUALITY PARAMETERS

The main parameters related to print quality are described below in brief.

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2.5.1 Density

Print Density is defined as degree of blackness or whiteness. It is log of Opacity. Measurement of

light reflected from a printed area compared as a ratio to that reflected from unprinted area, it

provides us with the 'reflection factor', which forms the base measurement for calculating optical

density. As the printed ink film absorbs light, the thicker the ink film, the more light is absorbed and

the darker the appearance of the print.

Need to measure Density

.Measure D-Min of the film in clear area, to assure there is no fogging. D-Min is typically
0.03 D, and not more than 0.05 D for most films. Measure D-Max of the exposed (black area) to
assure proper exposure and processing. Recommended D-Max is typically 3.8, and 4.0 D and higher
for some laser films. Excessive D-Max may reduce resolution, and low D-Max may cause toning in
the non-image area on the printing plate.

Density = logio x 1/R Where R = Reflectance

The standard Density values for three common printing conditions for North America are as mention
in the Table 2.1.

Table : 2.1 Standard Density Values for all colors [7]

TYPES OFFSET CYAN MAGENTA YELLOW

BLACK
MACHINE Density Density Density Density
SHEET-FEED, 1.3-1.4
1.4-1.5 1.3-1.4 0.9-1.1
Commercial
WEB-OFFSET,
1.6-1.7 1.20-1.30 1.40-1.50 0.9-1.0
Magazine
NON-HEATSET
1.03-1.04 0.8-1.0 0.8-1.0 0.7-0.9
WEB, Newspaper

Density Absolute as reported from GRACoL Standard from America

2.5.2 Dot Gain

Dot gain is the difference between the apparent dot area measured in the film with a
transmission densitometer, and the apparent dot area measured on the printed substrate or proof with
a reflection densitometer.
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Need to measure Dot Gain

Most of the information, or detail, in printed halftone pictures is carried in the tonal, or tinted
areas. In the pressroom, measuring dot gain at 25% (highlight), 50% (mid-tone), and 75% (shadow)
for each color is a quick indication of tone reproduction quality. In four-color process printing, the
balance of dot gain between the three process colors, cyan, magenta and yellow, is critical for gray
balance, and for maintaining critical overprint colors such as flesh tones, green grass, and blue sky.

Apparent Dot Area

The Murray/Davies Dot Area Equation: Apparent Dot Area = 1-10 -(D(t)-D(b))
1UU
1.10-(D(s)-D(b))

Where Dm = Density of film tint

D/s\ = Density of solid, or D-Max
D(t>) = Density of film base

Dot gain is the difference between the apparent dot area measured in the film with a
transmission densitometer, and the apparent dot area measured on the printed substrate or proof with
a reflection densitometer. Note from the equation that Dot Gain is a function of Density, and
compares a tint patch to a solid patch. Dot Gain, as measured and calculated by the densitometer as
shown in Table 2.2.

Table : 2.2 Standard Dot Gain Values for all colors [7]

TYPES OFFSET BLACK CYAN MAGENTA YELLOW

MACHINE % % % %

SHEET-FEED,
20-22 15-17 15-17 16-18
Commercial

WEB-OFFSET,
25-27 21-23 22-24 20-22
Magazine

NON-HEATSET
32-34 30-33 30-33 28-30
WEB, Newspaper

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2.5.3. Print Contrast

Print contrast is a good indication of print quality because shadow detail carries important
information in many images. It is often used as a guide for maintaining ink/water balance.

Need to measure Print Contrast

Print Contrast is a good indication of print quality because shadow detail carries important
information in many images. Print Contrast values correlate well to the subjective evaluations of
print quality, such as "flat" (low Print Contrast values) versus "jumps off the page" (high Print
Contrast values). The values are as shown in Table 2.3
% PRINT CONTRAST = (Ds - Dt)/Ds * wo

Where, Ds = density of solid and Dt = density of tint (typically 70%)

Table : 2.3 Standard Print Contrast Values for all colors [7]

TYPES OFFSET BLACK CYAN MAGENTA YELLOW

MACHINE % % % %

SHEET-FEED,
37-39 42-44 31-33 23-25
Commercial

WEB-OFFSET,
37-39 45-47 35-37 30-32
Magazine

NON-HEATSET
16-18 13-15 12-14 15-17
WEB, Newspaper

2.5.4 Trapping

Trap is an indication of the ability or inability of a printed ink to accept the next ink printed
compared to how well paper accepts that ink.

Need to measure Trap

Poor trapping will result in a hue (color identification) shift in overprint reds (magenta and
yellow), greens (cyan and yellow), and blues (cyan and magenta). Poor trapping characteristics will
make it difficult to achieve and maintain a color match.

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2.6 QUALITY TOOLS FOR PRINT MEASUREMENT

2.6.1 Elements of control strip

There is a wide range of control elements available as shown in the above strip. Some are
intended for visual assessment while others facilitate measurement. They are available as individual
elements, or may form part of a comprehensive continuous control strip.

2.6.2 Densitometer
The densitometer helps the press operator to control ink film thickness in order to match a
colour proof. It does not measure ink film thickness directly as density is relative to the ink film
thickness. The densitometer is also used to calculate total dot gain, grayness, hue error, and percent
ink trap.

Densitometry Specification
Status-ANSIE
Filter - Polarization Relative Density
Dot area equation - Murray/Davies
Yule - Nielson equation
for Plate dot area and n = 1.2
Backing - Black film (approx. density 4)
Parameters Measured-Density.
Dot area,
Print contrast and Trapping.

Fig. 2.4 Densitometer and its specifications

2.7 CLOSURE

In this chapter, information regarding offset printing process and the make-ready steps are
explained which is followed by variable affecting print quality. Finally the various tools for print
quality measurement are described as the present research work is related to critical analysis of the
offset lithography.

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