(See Figure 7.4). Gravure Printing Inks Industry, 2018 Market Research Report - The 'Global and Chinese Gravure Printing Inks Industry, 2013-2023 Market Research Report' is a professional and in-depth study on the current state of the global Gravure Printing Inks industry with a focus on the Chinese market. Gravure units are typically added as part of a combination press configuration. Gravure and rotogravure. Label press configurations and ancillary equipment, Die-cutting and Tooling: A guide to the manufacture and use of cutting, embossing and foiling dies, anvils and cylinders, The digitalization of labels and packaging production, Traditional method photographically using carbon tissue and acid etch called chemical etching, Excellent print quality - excellent sharpness and reproduction, Precise inking with no color variation throughout the print run, Consistent and substantial ink film weight, Wet on dry - excellent half-tone reproduction, Long cylinder life - making repeat runs very economical, Most suitable process for printing of metallic inks, Laser engraving high quality - 70,000 cells per second variable screen, High preparatory and origination costs, but due to improved technology these have reduced, Most gravure ink systems solvent based (environmental issues), Self-adhesive labels. The majority of inks used in the gravure process are solvent based, however there are some gravure printed self-adhesive labels that are printed using UV gravure inks. The web path of the litho and flexo press travels downwards after leaving each printing head. The ink transfer can also be influenced by the absorbency of the substrate being printed. E.g. In gravure it can be produced as two 36-page froms with a four-page cover. Electro assist generates an electric field in the ‘nip’ area. As previously explained the image cylinder rotates in the ink duct coating the whole surface of the image cylinder with liquid ink including the image cells. GRAVURE PRINTING TECHNOLOGY A TO Z and Quality Trouble Shooting Tips at Hotel Mulia Senayan - Jakarta Nov 19, 2013 ORIENT SOGYO CO., LTD. Hidenori Harada GRAVURE PRINTING TECHNOLOGY A TO Z What is happening in Japan Gravure printing industry? The impression roller applies the downward  force to the print cylinder. Gravure is an excellent process for applying metallic inks and finishes with a high level of lustre. This method gives a very bright and highly reflective appearance  resembling that of foil blocking. One of the major differences between the in-line gravure press and the in-line litho and flexo presses is the position of the drying system. This type of gravure unit is usually incorporated into a dedicated in-line litho or flexo press or a multi-process platform press. Find high quality Gravure Printing Sample Suppliers on Alibaba. Gravure (noun) intaglio printing Gravure imaged cylinders or sleeves are manufactured with a copper outer surface on a steel base, If the cylinder is to be imaged with a mechanical engraving system then the copper layer is sufficient, however if the cylinder is to be direct laser engraved then an additional zinc layer is required. The substrates on the rotogravure press go through on average 4~6 meters of distance between color stations; on a flexographic press, goes through 4-6cm. The surface of the impression roller is rubber covered and the ‘shore hardness’ of the rubber can be varied to increase or decrease the dwell time ensuring that there is maximum dwell at the point of contact between the substrate, impression cylinder and the image cylinder. The cylinder, which includes the picture, gets engraved, implying that minor openings are created into the cylinder, which symbolizes the point image. However the use of gravure in the label industry has been increasing, particularly as the facility to produce highly reflective metallic inks and specialised coatings by the gravure process means that gravure units are now used as individual units on combination label presses. The positioning of the doctor blade assembly is important. The transfer of the ink from the cell to the substrate is a capillary action. Gravure label presses are now used for both wet glue and self-adhesive label manufacture, particularly for the long run paper and filmic label market. The self–adhesive label market tends to service the short to medium run markets and the gravure process has never been considered by the label printer as the most suitable. The gravure printing process is done with flat plates or, more commonly, with cylindrical surfaces. At this stage, irregularities in the process that cause recurrent defects can be determined and an instant warning is given to prevent further defects. Maintaining the correct ink viscosity is critical and the viscosity readings can be made manually or automatically. Types of gravure printing block –plate – cylinder Gravure printing Prof. Dr. Ulrich Moosheimer Seite 14 substrate material ink printing cylinder impression cylinder doctor blade Figure 7.2 - Principles of gravure process. Building on earlier printing methods, modern gravure began in the late 19th century, and became widespread in the early 20th century. The metallised particles are easily suspended in the solvent medium used in the gravure process and align smoothly and easily to the clear label substrate. The image areas consist of honey comb shaped cells or wells that are etched or engraved into a copper cylinder. Unlike letterpress and flexo printing which are relief processes, the gravure process prints directly onto the substrate. Reticulation can be created by inks that are either too thin in viscosity or the solvent balance is incorrect. Printing Technology using the lower parts of the printing block for ink transfer. Our technology serve as an opportunity to show who you are as a company. mechanical and laser. (2011) and the use of an industrial gravure printer for OPV preparation by Yang et al. Digital PrintingIn an inkjet printer the image that needs to be printed is created by small droplets of … Just be sure: You can control 100% of your product at any stage of the process chain. The gravure doctor blade unit is far more sophisticated than the type used in the flexo system. All the gravure press configurations used for self-adhesive label manufacture are in-line This means that there is a one printing unit per color and there are no real limitations on the number of printing heads used on an in-line press, (See Figure 7.1). The intaglio process was further developed in the early 17th century when intaglio printing, also known as gravure printing, began to use metal plates which carried the etched image which was then printed onto the substrate. • Gravure cum Kiss coating method for very low viscosity coatings Some Modifications of Gravure Printing orSome Modifications of Gravure Printing or coatingcoating • Gravure cum Kiss coating method for very low viscosity coatings 67. The use of chemical etching for gravure printing within the label industry is very limited and this article will focus on the two main engraving systems used today i.e. An example of early rotogravure was the introduction of newspaper supplements 1930s –1960s which carried rotogravure printed photographs. More recently it has made inroads into narrow and mid-web presses for self-adhesive labels where the ability of gravure to apply varnishes , lacquers and top coatings offers  particular advantages. Figure 7.7 - Location of docter blade on gravure unit. The units, which are in a fixed position, are located in the press to give the best position to achieve the optimum printed result for highly reflective metallic inks and special coatings. The angle of attack to the cylinder can be adjusted from a 90 degree angle to a much sharper 45 degree angle and this facility allows the printer to achieve the optimum position for a clean wipe and the best possible printed result. The main examples of this printing technology are letterpress which, until a few decades ago, was the dominant printing technology and flexography which, by the middle of this century, had started to be used more and more in packaging printing. By varying the thickness of the doctor blade  the printer can also control the volume of ink left in the cell. Historically it was used for the production of wet glue labels but has now largely died out. Gravure Printing MachinesGravure Printing Machines 4/19/2018 69 68. FUTEC’s 100% print inspection guarantee: How to automate your quality control on typical defects occurring in gravure, flexo and label printing. In Figure 7.2 you can see the configuration of the gravure unit of the type used in a multi-process combination press with the web, after printing, traveling upwards  into the drying head and then passing downwards over a chilled roller and then into the next print unit for printing the next color. This way, you are always sure about the quality and able to deliver 100% transparency. The depth of penetration of the stylus is controlled by the digital information and follows the tones and densities of the original artwork. 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 causes and how to correct them. Beside the printing savings, this could eliminate one pocket in the bindery, saving about $1/M-$1.20/M catalogs printed. The screen process has a similar characteristic. Traditionally the doctor blade would be removed and re-sharpened by the printer using an oiled stone, and this would be done at intervals throughout the print run. 4.3 - Doctor Blade –Structure, Types and Mechanisms of doctor blade. Stop Scuffing in Its Tracks. However the gravure press will usually have only one printing unit and not multiple print heads and therefore will print only one color at a time. Gravure press configurations fall into three categories: sheet-fed presses, dedicated in-line presses and single units used in combination with other printing processes. Gravure Printing - Here, the printing elements are recessed. Source- Bobst Rotomec. An example of early rotogravure was the introduction of newspaper supplements 1930s –1960s which carried rotogravure printed photographs. The doctor blade is positioned close to the point where the two cylinders are in contact with the substrate which is sandwiched between these cylinders. The configuration of the sheet-fed gravure press is very similar to the litho press with a feeder and sheet delivery system. Figure 7.1 - Modern gravure printing press. Developments exist where vacuum metallised particle inks are reverse printed by the gravure process onto a clear substrate, such as a PP. The image is transferred directly to the substrate from the recessed image which is etched onto the gravure cylinder (See Figure 7.3). The drying heads on the gravure press are positioned ‘above’ each print head which means that the web will travel upwards after leaving each printing head. GRAVURE Printing - cylinder engraving Those out of tolerance can be marked with the option to be cut and removed later. Featuring the latest technological advances, industry news, case studies and opinions, it is the leading resource for printers, brand owners, designers and suppliers. However, this is not the case with laser imaged cylinders as the laser can engrave half a cell, producing a straight edge.This control over the engraving process illustrates the level of print quality that can be produced by the gravure process. Prior to this newspapers had published very few photographs. The file contains all the data required to reproduce the exact tonal values and detail that are required for the correct image reproduction. This saw edge is a characteristic of the process and is created by the outer edge section of the individual cells which make up the image. Gravure inks can be formulated using different types of solvent systems and the printer must ensure that any solvent used is of the correct system. The invention of photography led to the method of transferring a photo image onto a carbon tissue coated in a light-sensitive gelatine which allowed the etching of an image onto a steel, copper covered cylinder. This was the beginning of the modern rotogravure process. It uses a depressed or sunken surface for the image. Because gravure inks are a solvented system and dry very rapidly, it is necessary to keep the distance between the doctoring process and the print ‘nip’ to a minimum, ensuring that the ink remains as open and liquid as possible. The steel doctor blade is supported by a backing blade to give better stability. Gravure printing is still widely used for the commercial production of post cards, magazines, newspapers, and corrugated cardboard (and other packaging materials). Gravure printing is a particularly promising printing technique because it combines high print speed with high resolution patterning. The laser engraves directly onto the zinc surface of the cylinder and is considerably faster than mechanical engraving, producing a cell formation at 70,000 cells per second. However the modern doctor blade is now a replaceable item which removes the need for re-sharpening by hand. Depending on the quality, the resulting print may look similar to, or the same as those produced with the traditional photogravure process using etched cylinders. Rotogravure can also be defined as a remedy printing press that utilizes an engraved, repeatedly metal, print container to transmit a design by spinning through ink and onto printing textures. The mechanical engraving of gravure cylinders started around the 1960s and is called a Klischograph system. The gravure process can be easily identified by the saw tooth or serrated edge visible on the printed text and on the edges of solid color areas. Figure 7.8 - Gravure unit showing drying head. The gravure cylinder revolves in a liquid ink with the ink being applied to the whole of the imaged print cylinder i.e. For most purposes, the minimum size is 4 point to 10 point type, but that is a wide range. Because the gravure ink is a solvented system the sheet-fed press will have an extended sheet delivery system into which a hot air drying system is located, this will also include an extraction system to ensure that the solvent vapor is removed. Gravure printing is a direct descendent of older intaglio printing (gravure and intaglio, commonly used synonymously, are different processes; all gravure printing is intaglio, yet all intaglio printing is not gravure—for example, copperplate printing, which is an intaglio process without being considered a gravure process) Sheet-fed gravure is rarely used in self-adhesive label printing. Using our tried and trusted flaw detection systems, you can automate your quality control checks and gain 100% transparency of your printing process. By comparing the master picture with the data of the printed product, the defects can be classified as either in or out of tolerance. (See Figure 7.5). The ink used in Flexographic and Gravure printing (aka. E-Mail: sales@futeceurope.com The facility to produce varying cell size and also cell shapes means that the cells can be tailored to produce very high resolution tonal values, particularly for vignettes with no ‘saw edge’ effect on small text and a much improved ink transfer. Photopolymer plate systems for gravure have been developed as well as computer-to-cylinder systems. GRAVURE PRINTING IN LABELS. The drying system on the gravure label press differs from the systems used on litho, flexo and screen presses. Prior to this newspapers had published very few photographs. The web or sheet travels through these two cylinders and considerable pressure is applied between the two cylinders causing the ink in the recessed image cells to be transferred onto the substrate. 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