PrintPromotion Newsletter No. 92

No 92 • April 2013

Newsletter

Training Information & News in Printing and Paper Converting Technology

PrintPromotion Print Media Conferences in India As part of the quality initiative launched In India last year, PrintPromotion organised several Print Media Conferences from 1 to 7 December 2012. The events with the motto “Enhancement of competitiveness – Better quality in the printing industry” were aimed at raising awareness for quality in the domestic print market in India

and at making Indian products attractive for the world market. In total, the conference tour comprised four Indian cities. Seven representatives of German manufacturers shared their know-how on how to improve production processes and the quality of printed products.

Contents PrintPromotion Print Media Conferences in India ......1 Conference tour through South America.....................2 learn4print ......................................................................3 Calendar of events .........................................................3

Company news Baumann: 35 years of innovative engineering ...........4 bielomatik: bielomatik supports sustainability initiative ..........................................................................4 Goebel: All-in-one security printing solutions............4 H.C.Moog: Trends in sheet-fed gravure printing.........5 Heidelberg: Anicolor technology revolutionizes printing of very short runs in offset .............................6 White Paper with packaging solutions ........................6 Visionary applications ...................................................7

Discussions and the exchange of experience started at the registration desk already …

... and were continued during the breaks. (On the left: Prof. Anayath Rajendrakumar)

IST Metz: International UV event .................................7 Koenig & Bauer (KBA): Higher output and less effort with short grain...................................................8 KBA Asia Pacific in Singapore celebrates 10th

Speakers and presentations Sheet-fed gravure presses: High quality – your success

Achim Kurreck, H.C. Moog, Rüdesheim am Rhein

Paper converting at its best

Harald Stumpp, bielomatik Leuze, Neuffen

Quality in sheet-fed offset technology from KBA

Chris Waschke, Koenig & Bauer, Radebeul

Quality characteristics of a UV system – Enhancement of competitiveness through the use of UV technology in the printing process

Thomas Gohl, IST Metz, Nürtingen

Journey to print quality & production enhancement

Improve quality by cutting correctly

Consistency in hard cover book production

anniversary .....................................................................8 Roadshow in Taiwan with debut for Rapida 106 and RotaJet 76 ................................................................9 Rapida 145 welcomes “big sister” KBA Rapida 164 ....9 Kolbus: Bookbinding systems engineered for more than books ......................................................... 10 Planatol: Edge sensor for the Combijet 9NET fold gluing system............................................................... 10 New PUR adhesives ..................................................... 10 POLAR Mohr: POLAR celebrates its 55th anniversary 11 Special cutting systems for the Chinese market ...... 11 E.C.H. Will: Risk minimization thanks to new control system ............................................................. 12

Prof. Anayath Rajendrakumar and Guenther Keppler, Heidelberg India Pvt. Ltd., Chennai Peder Rejmers, POLAR Mohr Maschinenvertriebsgesellschaft, Hofheim/Taunus Bastiaan de Winter, Kolbus, Rahden

Alexander Wassermann becomes CEO of Papersystems Group ................................................... 12 Windmöller & Hölscher: In-house EXPO exceeded expectations ................................................................ 12 Winkler + Dünnebier: Innovative concept for envelope overprinting ................................................ 13 PrintPromotion Partners ............................................ 13 Imprint.......................................................................... 13 Printers` Guide............................................................. 14

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The speakers always had the full attention of the audience.

The Indian book market is growing rapidly. The interest in the presentation of Bastiaan de Winter from bookbinding specialist Kolbus was correspondingly high.

The conferences in Mumbai, Kolkata, Hyderabad and Cochin were attended by a total of 300 participants. In detail, the numbers of participants were: Mumbai on 1 December 2012 121 Kolkata on 3 December 2012 47 Hyderabad on 5 December 2012 56 Cochin on 7 December 2012 80

A special topic – sheetfed gravure printing. Achim Kurreck from H.C. Moog was pleased to converse with the attendees and answer specific questions individually.

Conference tour through South America South America is one of the fastest growing regions in the world. The economic upturn is accompanied by an above-average increase in demand for packaging and packaging printing. Therefore, PrintPromotion organized Print Media Management Conferences in five South American countries, i.e., Chile, Colombia, Ecuador, Peru and Argentina. Brazil was not part of the conference schedule. This largest single market of that continent is already

clearly more advanced than its neighbouring countries. The German printing technology manufacturing industry wants to play a leading role in this dynamic growth market in South America,” said Dr. Markus Heering, Managing Director of PrintPromotion, who gave the opening speech at the conferences. In the five countries visited, the share of packaging printing in the total print vol-

The papers given at these Conferences were: Efficient package production for premium products

Christof Hongsermeier, Kolbus, Rahden

Automation, Versatility, Control = Efficiency, Competitiveness, Profit

Mike Engelhardt and Stefan Deuster, Koenig & Bauer, Würzburg

State-of-the-art flexo- and rotogravure printing technology based on Latin American requirements

Jürgen Wunderlich, Windmöller & Hölscher, Lengerich

Advantages and fields of application of UV technology in packaging printing

Manuel Blauensteiner, IST Metz, Nürtingen

Print enhancement for folding cartons – “Add profits by adding value”

Achim Kurreck, H.C. Moog, Rüdesheim am Rhein

New Heidelberg technologies for packaging production, and the new models and application areas

Gunnar Vogt, Heidelberger Druckmaschinen, Heidelberg

Profit Print: same revenue, more earning!

POLAR – the solution provider

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Number of participants: Argentina

65

Chile

70

Colombia

160

Ecuador

78

Peru

135

ume is between 45 and 50 per cent and hence even above the average in South America. According to a study of PIRA, a market research institute for the international printing and paper industry, the market for printing technology in those five countries had a volume in excess of USD 1.5 billion. Up to 2017, PIRA forecasts an increase to USD 2 billion. This is a dynamic development which cannot be found in the traditional markets any longer. In 2011, the total market for packaging in all countries in South America amounted to USD 36 billion and is expected to rise to USD 46 billion by 2016, which is equivalent to an increase of approx. 28 per cent.

The stops of the tour of the representatives of German print technology manufacturers were: Bogota/Colombia

12 March 2013

Fabio Pisa, technotrans, Brazil

Quito/Ecuador

13 March 2013

Lima/Peru

15 March 2013

Carsten Schaller, POLAR Mohr, Hofheim/Taunus

Santiago de Chile/Chile 18 March 2013 Buenos Aires/Argentina 19 March 2013 Newsletter • No 92 • April 2013

After each presentation, the participants had the opportunity to discuss the key ideas and to ask questions arising from the presentation with the speakers and the other participants.

An important reason for the growing demand for packaging and, as a result, packaging printing in the aspiring emerging countries in South America is the food industry. More and more food is packed, reflecting the need of a growing middle class. At the same time, the machines of many companies have become obsolete. Therefore, the representatives of the German companies met with strong interest when they presented their solutions.

Dr. Markus Heering, Managing Director of PrintPromotion. He outlined the dynamic development which is going on in the packaging market in South America.

Innovative cutting solutions for packaging production were presented by Carsten Schaller from POLAR Mohr.

A rare picture: The speakers of the PrintPromotion Management Conferences in South America without inquisitive conference participants.

The participants were all ears and eyes when the presentations were given.

Calendar of events 2013 the e-learning platform for the printing industry, has been supplemented with three new modules, i.e. Module 7 Color management, Module 13 Sheetfed offset printing in practice, and Module 15 Printing inks. learn4print enables newcomers and experienced print professionals to gain, update and consolidate their knowledge wherever and whenever they wish. Animations and graphics make the contents visible, and interactive tasks as well as exercises make learning more effective and practice-oriented. For more, see: www.learn4print.com

Newsletter • No 92 • April 2013

International Specialist 29 May – 26 June 2013 Teacher Course in Chemnitz / Germany Autumn 2013

Specialist Teacher Seminar in Colombo/Sri Lanka

Autumn 2013

Print Media Management Conferences (venues to be announced)

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Company News Baumann

35 years of innovative engineering

Despite all insecurities and difficulties in the graphic arts industry, there is a really good reason to celebrate at Solms: 1 July 2013 will be the 35th anniversary of Baumann Maschinenbau Solms. The “starting signal” for the production of rationalisation devices was given already more than 40 years ago when Heinrich Baumann Grafische Systeme decided to design and manufacture peripheral equipment for cutting. On 1 July 1978, the subsidiary Maschinenbau Solms GmbH & Co.KG was established as a full member of the Baumann-Wohlenberg group. The production range has consistently been expanded. Numerous machines and systems that are now standard parts of printing houses and paper converting machines have their roots at Solms. The Baumann Maschinenbau Solms staff are proud to say that they are always “listening” to the market. The customers’ wishes and ideas are taken up and applied wherever possible. At the beginning of this millennium, for instance, cooperation with

TU Darmstadt resulted in the development of a prototype of a fully automated

Volker Assmann, Managing Director of Baumann Maschinenbau Solms: “In the course of time, we have grown into a technological leader in our core business thanks to the innovative Baumann products and by offering solutions tailored to the requirements of the individual customers.”

bielomatik

bielomatik supports sustainability initiative In February 2013, bielomatik’s efforts to put sustainable engineering, ecological, social and economic aims into the focus of its entrepreneurial activities gained recognition. The company became a member of the Blue Competence Alliance initiated by the German Engineering Federation (VDMA). Blue Competence (www.bluecompetence. net) networks the mechanical and plant engineering sectors in the field of sustain-

ability and pools resources, know-how, and strengths of the VDMA. Within the association, various VDMA bodies and other organizations from the mechanical and plant engineering sectors are involved. Individual companies and institutions are also able to take an active part in the initiative. To become a partner of the initiative, the companies have to declare that they fulfill the following criteria: • The partner has defined goals for his

jogging unit which formed the basis of the BASA which, by now, has become firmly established in the market. Besides the standard range which Baumann-Wohlenberg can supply “off the shelf“, the company gives high priority to special solutions which are tailored to the requirements of the individual customer. The spectrum of machinery manufactured at Solms ranges from manually operated peripheral equipment like pile lifting devices and jogging machines to semi-automatic and fully automatic pile tuners and fully automatic cutting systems. The Baumann-Wohlenberg Cutting Centre is always equipped with different configurations of cutting systems, but also single machines, and is used for demonstrations and tests with customers` materials as well as basic and special training courses for technicians and users. Over and above that, Baumann-Wohlenberg relaunched its presentation on the internet with a modernised website and also opened an online shop for pile turners. The company also shows its systems and machines on a YouTube channel and is on Facebook.

products and staff which include sustainable acting. • The partner offers services which include professional guidance for energy efficiency and preservation of resources. • The partner agrees to declare the sustainable activities of his company/ products with at least one case for quantification. • The partner has implemented a management system. • Responsibility for sustainability is assigned to a person in the management of the company

Goebel

All-in-one security printing solutions Goebel, one of the most innovative manufacturers of web-fed printing machines for the printing and converting industry, especially focuses on security printing. One example for the outstanding machines for this area is the security printing press GOEBEL sp 410 with a web width of 410 mm. This machine prints tax stamps reel to reel or reel to sheet. Applicable

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printing technologies are offset in sleeve technology with the options true rainbow printing, intaglio, gravure, flexo and screen printing. Inkjet printing heads, a laminating unit with vertical die cutter and matrix rewind are included. As an option, a hologram application system can be added as well. The production of tax stamps that com-

A comprehensive solution for security printing: The GOEBEL sp 410

Newsletter • No 92 • April 2013

Goebel bine all the different effects and features generated by intaglio and offset, not to mention other applied features and personalization, can be a big order. Security printers, particularly government security printers, normally have most or all of the required production technology at one place or another. But Goebel offers a solution which means they can have all this technology as an integrated line comprising as many of the different production elements as required. Goebel’s concept is driven by what it calls hybrid printing, i.e., the ability to combine different technologies, which has increasingly become a must for the production of the current generation of tax stamps, through process flexibility and operational simplicity. Goebel’s answer is a modular inline press offering a range of different print options that can be incorporated, rearranged and even taken away – intaglio and offset, screen, gravure and flexo, and, not to forget, digital printing. The finishing process can be integrated as well – e.g., hologram application, laminating as well as slitting and rewinding units. Flexibility of the line is ensured by a novel method

...and rainbow printing enable to add advanced features to security printing products. The modular GOEBEL sp 410 can be configured with units that can be arranged and rearranged as required along a rail above this modular printing press line.

Options like hologram application...

for moving the different units around – by means of a rail above the line along which the units can be moved back and forward and slotted into alternative positions as required. A typical configuration would comprise offset for background printing, flexo or screen printing for special effects, an inkjet unit for personalization and a hologram application unit. If, however, the tax stamp specification requires the hologram to be overprinted, the application

H.C. Moog

Trends in sheet-fed gravure printing Everybody knows gravure printing and its advantages over the other printing methods as regards quality and achievable print results. These advantages are even topped by sheet-fed gravure printing, a method which combines the advantages of gravure printing with the advantages of the sheet and, therefore, produces only the minimum of waste. When it comes to these machines, H.C. Moog has become a preferred supplier. Sheet-fed gravure printing is more and more used in packaging finishing for improving the chances of the product at the POS and thus enabling it to be optimally positioned. The combination of different printing methods is also an indication of an optimally priced high-quality product as the ones used in security printing. The challenge is to create a unique selling proposition in order not to be drawn into price wars. For the printer, this means that he can use different printing methods at exactly the right point, i.e. gravure printing before the other printing methods or, alternatively, as the last printing method or in between. As a result, an offline-solution is offering much more possibilities for the production of a most versatile range of innovative packages and labels. Sheet-fed gravure printing is nowadays also used for Newsletter • No 92 • April 2013

varnishing, coating and embossing. Whenever it is getting difficult or even impossible for other printing methods, gravure printing is in great demand as a production method. Odour and taste free print products, e.g., are produced at favourable costs with solvent-based or water-based printing inks without the need to sacrifice quality. The use of UV inks and varnishes is possible as well, which enables to create special effects. The range of applications here comprises matt and glossy varnishes, haptic effects and film-like metallic effects. Metallised or plastic substrates can be printed with low energy consumption. There is no problem as regards adhesion in

unit can easily be moved to the start of or indeed anywhere else along the line. A presetting system ensures that all the different units operate in perfect register from the outset. Within this configuration, Goebel has also introduced a new variable sleeve for the cylinders in the offset units that can be changed by hand within minutes, as opposed to the normal cassettes whose change can take several hours. The line can print in widths of 406 and 510 mm at speeds up to 200 m/min and on substrates ranging from 15 – 250 microns. The range of repeat lengths is 18 – 25” in 1/8” steps.

gravure printing. Silver, gold, pearlescent gloss, electrically conductive applications and colour consistency are the domain of gravure printing, even where a costfavourable substrate is used. An innovation is the WSA-52D photopolymer plate for gravure printing which enables to produce even shorter print runs. Fast availability, environmentally-friendly production as well as low transportation and storage costs are just a few examples. The Moog sheet-fed gravure printing machines enable to use conventional printing cylinders, embossing cylinders and clamping cylinders for printing and embossing. Due to the consistent use of high-speed dryers, hot-air, infrared and UV dryers in one drying path, the sky is the limit for the user. The 1-TBR Compact sheet-fed gravure printing machine from H.C. Moog offers the user great flexibility in the production of highquality print products, e.g. unique packages with special effects.

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Heidelberg

Anicolor technology revolutionizes printing of very short runs in offset Countless print shops worldwide are using cost-effective Anicolor inking unit technology to respond to the growing trend toward short runs and frequent job changes. Compared to a press with conventional inking unit, the benefits of Ani-

all this with optimum offset quality and maximum user-friendliness. Over 1,200 printing units and more than 250 presses in the Speedmaster SM/SX 52 Anicolor series have now been installed all over the world. Commercial, packaging, and label

Over 150 customers from around the world were given a comprehensive overview of the benefits and key areas of application for the Speedmaster SX 52 Anicolor and Speedmaster XL 75 Anicolor during the “Anicolor Days” at the Print Media Center in Heidelberg and on print shop visits.

color can be summed up as “90:50:50” – which means that Anicolor inking unit technology results in 90 percent less paper waste (which first and foremost benefits the environment), 50 percent shorter make-ready times, and 50 percent higher productivity. Thanks to extremely fast and stable inking-up, OK sheets are often achieved after just ten sheets, and

printers use the presses to ensure competitive production of short runs. They are available in configurations from four to ten colors with perfecting device and UV technology. Heidelberg launched this innovative technology in the 35 x 50 centimeter (13.78 x 19.69 inch) format in 2006. As the next logical step, the successful Anicolor tech-

nology was extended to the 50 x 70 centimeter (19.69 x 27.56 inch) format with the Speedmaster XL 75 Anicolor in a world premiere at the 2012 drupa trade show. The Speedmaster XL 75 Anicolor is a particularly good option for customers looking to achieve cost-efficient production of short and very short runs in the 50 x 70 centimeter format for commercial and packaging printing applications. What’s more, the press is ideal for web-to-print applications with mixed forms that require simple standardization and consistently high quality. The Speedmaster XL 75 Anicolor will initially be offered as a straight-printing press with up to eight inking units – with or without coating unit and with a print speed of up to 15,000 sheets per hour – and will go into series production from the start of 2014. There are plans to also offer the Speedmaster XL 75 Anicolor as a perfecting press and with UV technology by the end of 2014. Considering the global trend toward shorter runs and frequent job changes in all formats, Heidelberg showcased the benefits of Anicolor technology to its customers at the “Anicolor Days” at the end of January. Over 150 customers from around the world were given a comprehensive overview of the technology and key areas of application for the Speedmaster SX 52 Anicolor and Speedmaster XL 75 Anicolor at the Print Media Center in Heidelberg and during print shop visits.

White Paper with packaging solutions The packaging market is growing. Heidelberg offers tailored solutions for the entire value-added chain in packaging printing, including appropriate services and consulting support. These are now summarized in a White Paper which is available as download. Based on facts and figures relating to the development of the packaging market, and to both current and future market trends, the paper demonstrates how Heidelberg turns the packaging market’s requirements into solutions. It also provides an overview of the entire current portfolio in the packaging segment and the associated services. The trend is no longer exclusively toward shorter runs. It is vital to use the optimum run length for each job to ensure more efficient and cost-effective production that will meet the growing demand from producers of branded goods for ECR (Efficient Consumer Response) and JiT (Just-in-Time)

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production concepts. Even more automated quality and efficiency control processes will therefore be necessary in the near future - something that will only be possible by integrating the appropriate technology

in equipment and the workflow. Furthermore, packaging manufacturers will need to be able to develop ECR and JiT concepts for their customers to boost efficiency through even leaner processes. Heidelberg concentrates on solutions for producing folding cartons in the high-quality segment and in high-volume production, including services, consumables, and consulting. The White Paper shows some of them.

Newsletter • No 92 • April 2013

Heidelberg

Visionary print applications For all interested to see, Heidelberg is now showcasing the Innovation Gallery first shown at drupa 2012 with visionary application concepts based on innovating printing processes at the Heidelberg site’s Research & Development Center (FEZ). The exhibits highlight the areas where Heidelberg is looking to play an active role in shaping the future of print. Market-ready and demonstration products show just how much is already possible in the area of surface finishing. Other areas of application, such as printing on 3D objects, digital imaging, and drying are displayed as pioneering technologies for the future. The FEZ’s Innovation Gallery will also cover other key topics and document the progress made. In addition, the FEZ will be exhibiting some extraordinary things to highlight the full scope of future developments. The Innovation Gallery demonstrates that printed communication has long ceased to be confined to paper. Heidelberg believes such applications offer great potential for manufacturers of branded goods, advertising agencies, and print media companies and is looking to enter into dialog with exactly these groups to move beyond the conventional image of print and provide a glimpse of the progress being made at its research laboratories. One application that sets products apart from the competition in traditional sheetfed offset printing is already set for market launch. In the “Fascinating surfaces” section, the “Cristala” creative concept demonstrates how existing drip-off coating equipment can be used to produce new finishing effects. Specially prepared prepress data creates structured surfaces with a strongly accented gloss effect that is quite unique in the sheetfed offset industry. Structured coatings create different gloss effects depending on the angle of inclination and the direction of viewing. The exhibition also includes examples of surfaces with geometric lines, textures,

IST Metz

International UV event From 17-20 June 2013, the sixth UV DAYS of IST METZ GmbH will take place. This year, the international event on the topic of UV technology focuses on multi-functionality and sense perception. Together with renowned partners from the printing industry, the company will present a programme for the participants to see, hear, touch and Newsletter • No 92 • April 2013

The “Cristala” creative concept paves the way for new surface finishing effects that produce a strongly accented gloss finish. The printed record exhibits fine structures on the substrate that look and feel as though they have been embossed.

ornaments, and contone images and typographical samples. Many applications in the area of functional printing are still little more than visions for the future. Printed, intelligent surfaces called touchcodes that Heidelberg is showcasing in the form of interactive printed ID cards with an integrated electronic structure are one example of an application that has already reached the market-ready stage. Placing a touchcode card of this kind on an iPad opens an app or web browser that offers access to specific content. The card therefore serves as a copy-protected license for electronic information in protected or closed applications, for example, thus building a bridge to mobile terminals. Unlike conventional QR codes, there is no need to take a photo using a smartphone. The touchcode acts as a paper key and is simply placed on the display. In cooperation with Chemnitzbased Printechnologics GmbH Heidelberg has developed touchcode technology applications for particular market segments and shows, how these applications can be employed. Another new application from Heidelberg is the “Smart Shelf”, which delivers concepts for the packaging shelf of the future. In this case, both the folding carton and

taste. On different printing presses, IST Metz will show recent and future opportunities that UV technology offers. A future-oriented and multifunctional folded box manufactured in UV sheet-fed offset appeals to all the senses at the point of sale. Advertising features include

the surface of the shelf are equipped with printed electronic components to communicate information such as the shelf’s fill level. This technology can also be used with point-of-sale applications for interaction with the customer. The “decorative printing on any surface” section showcases possible applications for printing on any curved surface. Although the development from 2D highproductivity industrial printing to 3D is still in the early stages, initial applications are already possible. The focus here is on how everyday objects such as furniture, sports goods, toys, cars, industrial products, architectural elements, and entire facades can be decorated with customized and, if appropriate, reversible designs. In the “drying and structuring surfaces”

“Smart Shelf” ideas for the packaging shelf of the future involve the use of packaging with imprinted, electronically active components.

section, new dryer technologies and systems are presented, including energy-efficient UV LED dryer modules and a laser drying technology that heats only the ink and not the substrate, a development that is advantageous from a process engineering perspective. The major benefit is that the waiting times between press and postpress can be cut drastically. The display also features a laser module concept that enables the partial drying or structuring of surfaces. This digital multi-channel module opens up the possibility of further potential future applications in the area of digital imaging.

the use of new and interactive media. Further highlights are 3D varnishing in UV inkjet, digital label printing and LED UV technology on a flexographic printing press. The programme will be concluded by further information and demonstrations about the topic “Future of Print”, e.g. interaction and printed electronics. Participation in UV DAYS is free of charge. For registration, please contact IST Metz.

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Koenig & Bauer (KBA)

Higher output and less effort with short grain Currently, there are several new trends in commercial web offset. On the one hand reaching the highest possible page output per cylinder revolution with so called highvolume presses with up to 96 long-grain pages and on the other hand there is a fo-

*) long-grain presses Calculation based on max. page count x max. speed (iph) Comparison of productivity in page output/h

cus on achieving the highest possible quality, production flexibility and economic efficiency supported by shorter makeready for smaller job runs up to 10,000 copies.

The cutting-edge 16-page KBA C16 is tailored to the second trend. It works with long grain pages, with the pages arranged on the plates in the direction of the web travel. Short-grain double-circumference presses, with the pages arranged at right angles to the web travel, are less common and not as well-known. These presses have enormous potential in terms of format flexibility, productivity and saving time when finishing. The concept of the new 56-page short-grain KBA C56 SG is based on exploiting this potential. Maximum output is limited by the maximum possible web speed. Individual drives commonly found in modern presses like the C16 and C56 SG could achieve higher web speeds than the physical characteristics of the substrate used allow, in terms of stability, stretching and shrinking. Shortgrain presses can produce about 30% more printed sections per hour compared to long-grain presses running at the same production speed because of their smaller cylinder circumferences. A further advantage can be seen in the folder. When printing A4 (8.27 x 11.7in) or similar sized products long-grain presses must have a quarterfold. In short-grain production, the

KBA Asia Pacific in Singapore celebrates 10th anniversary “Sprinting ahead” was the banner unfurled to kick off last year`s KBA Asia Roadshow in the German Centre in Singapore on 5 December 2012. Further stops on the tour

were Bangkok and Kuala Lumpur. The opening event was at the same time an opportunity to celebrate the 10th anniversary of KBA Asia Pacific, the subsidiary of

Group photo with part of the team of KBA Asia Pacific in Singapore

The superstructure with skip slitter on the 2nd former opens up a raft of unique production options, makes finishing easier and ultimately saves time and money

web is slit and the ribbons are processed individually. Only the first length fold and the first cross fold are needed to produce products similar to long-grain products. The C48 SG’s superstructure configuration allows for production with up to six ribbons. Up to eight ribbons can be processed by a former in the C56 SG. Optional extras, such as a skip slitter, a ribbon and section stitcher, can lead to a raft of new product options.

Koenig & Bauer AG in Singapore. The KBA sales and service subsidiary in Singapore has been growing constantly since its founding in 2002, and has had its offices in the German Centre since August 2006. Stefan Segger, managing director of KBA Asia Pacific, and Sales director Dietmar Heyduck from the German parent company welcomed high-ranking representatives of the sheetfed and newspaper print branch, as well as a number of guests of honour from Singapore and Germany. At the subsequent social evening in the German Centre, the guests were also able to enjoy a taste of traditional German cuisine, served together with the fitting German beers and wines. “It has been a fantastic evening,” said Jürgen Veil at an already advanced hour, “and I think we have demonstrated clearly that we are very much a committed and reliable future partner for printers in the Asia-Pacific region.”

Roadshow in Taiwan with debut for Rapida 106 and RotaJET 76 The KBA Roadshow is already a well-established tradition for the printing industry in the People’s Republic of China, the AsiaPacific region and India. In March, the suc-

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cessful series extended its list of venues to include also Taiwan. Three events attracted a good attendance in each of the country’s most important print centres: Tainan

in the south, Taichung in the central region and Taipei in the north. The technical highlights placed in the spotlight were UV technologies for sheetfed offset, in-mould Newsletter • No 92 • April 2013

Koenig & Bauer (KBA) label printing, the digital web press RotaJET 76, and the Rapida 106, the world champion press in terms of make-ready and production speed. Akio Pong, managing director of KBA sales partner Shining Graphics, welcomed the guests. The importance attached to the meetings was reflected in addresses given by the presidents of the printing associations in the three regions, and in the presentations by KBA users such as Wu Weng Hsiung, chairman of the Just Shine Printing Company, and Chen Cheng Hsiung, president of the Printing Technology Research Institute.

Walter Zehner (right) presented a model of the six-colour Rapida 106 to David Liu, managing director of the Glory Innovations Group, as thanks for the company’s confidence and outstanding hospitality.

In Taipei, the managing director of KBA Greater China, Walter Zehner, thanked the management of the Glory Innovations Group for two special “firsts”, namely the installation of the first Rapida 106 in Taiwan and the opportunity to present this high-tech press live in action to other Taiwanese printers. Alex Hong from Shining Graphics explained the press features and process sequences in more detail during a print demonstration on the Rapida 106, and drew attention to the extremely fast make-ready achieved with the dedicated plate cylinder drive system DriveTronic SPC. Subsequently, the gathered print professionals were able to take a closer, firsthand look at the press.

Rapida 145 welcomes “big sister” KBA Rapida 164 At drupa last year, KBA celebrated the official launch of the Rapida 145, its latest series of high-performance large-format presses in format VI (106 x 145 cm). At the beginning of 2013, but without pomp or a special welcome party, the Rapida 145 was joined by its almost identically equipped and automated “big sister”, the KBA Rapida 164 in format VIIb (120.5 x 164 cm). With a maximum production speed of 15,000 sph (with high-speed package) and extremely short make-ready times, KBA has once again redefined the yardstick for this format class. The new Rapida 164 supersedes the vastly successful Rapida 162 and 162a series, which could rightly be described as institutions on the book printing and packaging markets. With the Rapida 164, practically all the automation solutions and highlights of the mediumformat make-ready world champion Rapida 106 are now also available in format VII. The new press incorporates the same DriveTronic components as the Rapida 106 and Rapida 145. The format has also been enlarged slightly relative to the predecessor series, namely by two centimetres in the sheet width and half a centimetre in the sheet length compared to the Rapida 162a. The “KBA DriveTronic” concept stands for dedicated drive technologies, maximum operator convenience and exceptionally fast make-ready and job changes. Consistent implementation of the modern drive concept on the Rapida 164 starts at the shaftless DriveTronic feeder with its individual, direct drives for all controlled motions. DriveTronic Infeed provides for motorised adjustment of the front lays, and a touchscreen display with direct function keys ensures reliable and intuitive press operation. One feature which is not only new in this format class, but indeed unique to KBA, is the sidelay-free infeed DriveNewsletter • No 92 • April 2013

Tronic SIS. Besides avoiding marking issues with sensitive substrates, the sidelay-free infeed eliminates all need for operator intervention and guarantees the highest possible alignment accuracy. In addition to the plate changing variants SAPC (semi-automatic; change time approx. 110 seconds per unit) and FAPC (fully automatic, with new optimised change process; change time 3 minutes for all units), the Rapida 164 can now also be configured with plate cylinder direct drive for simultaneous plate changing (Drive-Tronic

provides a multi-purpose washing circuit to permit the use of different solvent types (UV/conventional), and in this way guarantees a first-class wash-up without timeconsuming manual cleaning for users who need to switch frequently between different ink systems. With CleanTronic UV, blankets can be washed while the UV lamps are in standby mode, and the CleanPrint function can even replace blanket washing altogether with short runs, through targeted stripping of the remaining ink from plate and blanket. Like its “little sister” Rapida 145, the new Rapida 164 incorporates the full spectrum of DriveTronic direct drive technology. It also differs from its predecessor by way of the high-level delivery, a higher production speed and faster makeready thanks to parallel processes.

SPC). In this case, the total plate changing time is reduced to just 110 seconds, irrespective of the press length. When the Rapida 164 is equipped with DriveTronic SPC, the blankets and impression cylinders can both be washed parallel to the plate changing. To this end, the press possesses a second washing beam (CleanTronic Synchro). The two washing beams can also be used together for blanket washing – for a time saving of up to 50 per cent. But CleanTronic Synchro is not the only feature geared to shorter washing times. With the function ReInk, ink roller washing – normally one of the longest make-ready processes on the press – is accomplished in 90 seconds. CleanTronic Multi, furthermore,

Two different coater towers are available for the Rapida 164. The standard version pairs the chamber blade coating system with automated forme changing (SAPC). The positioning of the forme cylinder for changing is here automatic – as is also clamping and tensioning of the coating forme. Since drupa 2012, all Rapida models – and thus also the Rapida 164 – are supplied with the new ErgoTronic console with wall screen. This console is able to accommodate various online systems for quality control, such as the automatic colour measuring system ErgoTronic ColorControl or the register measuring systems ErgoTronic ACR and ICR.

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Kolbus

Bookbinding systems engineered for more than books Kolbus has always set new standards in postpress processing. Continuous innovation has been the driving force behind this pre-eminence. Markets are in a constant

KOLBUS is currently working on new machine concepts for packaging production, for instance, to manufacture rigid and lay-flat luxury packaging.

state of flux and Kolbus engineers know the importance of seeing change as a positive challenge to be met with fresh ideas. Current trends indicate roughly a split of 80% to 20% between non-classical hardcover productions and postprocessing of digital print products. There is also a discernible and growing trend towards automated production of packaging material using techniques from book cover making. As always, it is a question of meeting rising customer expectations while at the same time reducing costs. One example is exclusive presentation boxes for luxury products. Packaging manufacturers partnering with Kolbus benefit from on-going know-how transfer; the company’s expertise in fully automated casemakers translates into efficient packaging production. Kolbus casemakers are known for easy operation, fast set-up and a twin-roll gluing system for ultra-thin and uniform glue application. They are capable of processing any coloured, printed and enhanced substrates. Product quality is excellent

and the machines offer the best possible basis for production on an industrial scale. Highly automated processes turn out packaging for luxury items, covers, slipcases and boxes with very little manual work. Kolbus is currently working on new machine concepts for packaging production, for instance, to manufacture rigid and lay-flat luxury packaging. To further optimise automated packaging production, Kolbus has brought out the new NM 100 (up to 65 cycles/min) for scoring grooves in 1 to 4 mm thick bookbinding cardboard. This is the first step to highquality volume production with absolute dimensional and angular accuracy. The machine can be teamed up with the proven casemakers DA 260 (40 cycles/min) or DA 270 (65 cycles/min) to produce boxes of stiff laminated paperboard with firm, rigid edges. Kolbus is setting new quality standards for luxury packaging thanks to slick automated processing of delicate cover materials.

Planatol

Edge sensor for the Combijet 9NET fold gluing system Planatol has now equipped the Combijet 9NET fold gluing system, which is used for gluing print products in the folder of the web printing machine, with a new edge sensor system. This system scans the paper web and stops glue application when the paper web is not there. The web edge sensor is a fully integrated laser scanning system which monitors the gluing process at the paper web edge and switches off the heads individually if the paper web is running off track or tears occur. The response time of the system is so short that it can switch off the application heads even at maximum web speeds (20 m/s) in

order to prevent the glue from accumulating on the rollers. The sensor is adapted directly at the gluing head and can be configured individually by means of the Combijet 9NET operator panel. Other advantages of the system which help the printing companies to meet the rising cost pressure and higher and higher quality demands are: Reduction of waste through early fault detection; shorter make-ready times through easy positioning by means of red laser point; in the event of faults in the machine configurations, the heads without paper web remain switched off. The system can be retrofitted to all existing Combijet 9NET systems.

The web edge sensor stops glue application in the Combijet 9NET system when no paper web is there very fast.

New PUR adhesives Planatol has recently developed a new product family specifically for the needs of the graphic industry. Planatol 2880 PUR is an adhesive for the back spine, which achieves excellent adhesion also on difficult papers. The Planatol 1142 PUR is the first PUR adhesive for use in photo books, illustrated books and other high-quality products.

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Planatol 1142 PUR also offers strong adhesion while being soft enough as to enable excellent lay-flat behaviour. The product is the first PUR adhesive to be ideally suited for the use in photo books, illustrated books and other high-quality books. Planatol 1265 PUR helps to reduce energy consumption and emissions. This PUR can be used without restrictions at working temperatures below 100°C. Newsletter • No 92 • April 2013

POLAR Mohr

Special cutting systems for the Chinese market a synonym for automated cutting procut® generates cutting programs outside China is an important market – for POLAR cesses. The loading, turning and waste rethe high-speed cutter while it continues Mohr, too. At this year’s China Print in moval operations are automated. The Authe production. This procedure is based May, POLAR will be exhibiting not only a toturn turning gripper combined with the on the sheet layouts transferred as ppf or standalone 115 PF cutting machine, but Autotrim cutter is the automation centerjdf files from the prepress. Depending on also the P-Net service Compucut® in Chipiece here. While Autoturn automates the the setup of the sheet, the program can nese language as well as two systems: turning and positioning cycles of the cutbe generated either manually, semi-autoCutting System L-137-T and Cutting Systing ream, the Autotrim feature automatimatically or, ideally in a fully automated tem L-R-137-T PACE. cally removes the waste cuttings. These process. To ensure the best possible proCutting System L-137-T has been contwo components are interacting and algramme cycle, cutting programs are autoceived especially for the precutting of palow to automate the first five cuts (fourmatically optimized adding the required per. A stack lift allows the operator to load side and dividing cuts). While the cutting comments, additional functions and inthe uncut material into the high-speed cutter at a favourable working height. The material is cut into the required format. After that, a Transomat unloading unit piles it, ensuring optimum ergonomic conditions. The material is easily pushed onto the transport pallet of the Transomat. This unit automatically deposits parted or complete The L-R-137-T PACE is one of the cutting systems demonstrated by POLAR Mohr in China. reams on a pallet. Meanwhile the operator continsystem is automatically cutting, the operformation for the user. It allows the proues his/her cutting work. With its paator can conveniently prepare the next gramming time at the high-speed cutter tented movable pallet tip the POLAR ream on the automatic jogger. A continuto be reduced to almost zero while the Transomat achieves perfectly aligned ous workflow is ensured. This working machine efficiency is increased. edges so that the material can be directly method offers the advantage that the opIn addition, POLAR will be presenting its processed on the printing press or folding erator can carry out a quality control durnew PF high-speed cutter which has been machine. ing the jogging process. Besides, it allows customized for the Chinese market. This The automated PACE cutting system L-Rto easily process even materials which are model which is available with cutting 137-T provides an enormous potential for difficult to handle. width 115 and 137 is produced in China savings. Compared with a manual cutting The P-Net service Compucut® enables and for China. It’s not just the design that system operated by two the high level of customers to streamline their working seis different, but compared to the Hofautomation allows to obtain the same quences at the high-speed cutter or cutheim-manufactured high-speed cutters it output with just one operator. PACE (POting system even more. POLAR Compualso offers a reduced range of functions. LAR Automation for Cutting Efficiency) is

POLAR celebrates its 55th anniversary Already in 1958, POLAR built the first peripheral units to optimize the processes around the high-speed cutter and the company has sold thousands of units of these helpers around the high-speed cutter during these 55 years. This has been a significant contribution to establish POLAR as a trendsetter as well as market leader in the industry and as partner No. 1 when it comes to cutting. Therefore POLAR has put together a very attractive birthday package for selected peripheral units for its customers. Until 30 June 2013, customers get an extensive package of accessories free of charge when ordering an Automatic Jogger RA or a Transomat Unloader TRE. For further details please visit the website of POLAR Mohr. Newsletter • No 92 • April 2013

The Automatic Jogger RA from POLAR Mohr enables material preparation in reams outside the cutting machine with automatic air removal. The precise alignment of the cutting reams improves the quality considerably. Blocks can be formed more easily from the layers owing to mechanized removal of air. The customer benefits from an increase in productivity of the cutting machine of up to 40%, because cutting can be continued while new material is prepared.

Transomat E unloads the high-speed cutter efficiently and easily by automatically stacking the material with precisely aligned edges. The consistent stacking quality allows the direct processing in the printing / folding machines. Further customer benefits are the very short start-up times within seconds or the improved ergonomic conditions. Stacking is performed simultaneously with cutting which leads to an increase in productivity of the cutting machine of up to 50%.

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E.C.H. Will

Risk minimization thanks to new control system Since 2010, E.C.H. Will has offered its Technical Improvement Program (T.I.P.) for converting machines such as exercise book lines and ruling machines. The modules included concentrate on improving the efficiency of the equipment, increasing machine availability, higher production speed or the replacement of parts that are no longer available, so-called “obsolete parts”. In particular, the modular combinable control and drive concept for converting machines of the model series 280 – 282S (T.I.P. E 3030 Siemens S5 to S7 Simotion upgrade) has already met with a very positive response from customers around the world. After the timely upgrade, all ma-

chines are running stably and, above all, reliably since spare parts are available again in the long term. Such an upgrade is an important step for minimizing risk since a potentially unforeseeable and above all costly problem is often lying “dormant” in the background: The rapid further development and subsequent discontinuation of electrical components. From a purely mechanical perspective, a well-maintained E.C.H. Will converting machine can continue to produce at full capacity for many years to come. Therefore, the financial expense for the modernization of converting machines is definitely worthwhile.

The T.I.P. modernization concept from Siemens S5 to Siemens S7 also includes a Siemens Simotion motor management integration. This is especially important for machines with multi-motor technology. Depending on the budget, the degree of modernization can be extended to AC drives, for example. As part of such a modernization of the machine control, it makes sense to simultaneously replace the no longer available Lauer control panel. The T.I.P. E 3065 Touch panel changeover module replaces the old device with a touch control panel which is already preconfigured and, hence, can be quickly replaced.

Alexander Wassermann becomes CEO of Papersystems Group The management of Papersystems Holding GmbH, the holding company of the three companies E.C.H. Will GmbH, Pemco Inc. and Kugler-Womako GmbH, all leading providers of machines for the paper manufacturing, converting and packaging industry, is expanding. As of 1 March 2013 Alexander Wassermann (47) has taken over chairmanship of the Management Board as CEO. He is thus following Klaus Aarestrup, who departed the group on 1 December 2012 in order to accept a new

challenge. Alexander Wassermann, who is coming from Voith Papier, is an acknowledged expert in the paper industry. He possesses detailed technical knowledge about the production and converting of paper and in the construction and maintenance of paper machines. The Management Board of Papersystems Holding now comprises Alexander Wassermann as CEO and Chairman, Daniel Walk as CFO and Dr Volker Heidtmann as COO.

Alexander Wassermann

Windmöller & Hölscher

In-house EXPO exceeded expectations “Competence in Flexible Packaging – Your Partner for Customized Solutions” was the welcoming message at the Windmöller & Hölscher in-house EXPO, which took place in November last year in Lengerich, Germany. The EXPO was a resounding success. Six months after drupa, W&H printing presses continue to generate a great deal of interest. In the foreground is the new Heliostar SE, in the rear is the Miraflex CM 10.

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It was attended by 650 visitors from 51 countries, many from overseas, particularly from Asia. The company showcased its latest developments to whet its customers’ appetite for what is to come. Thirteen machines in extrusion, printing and con-

verting were in operation and represented the company’s full range of machinery for the production of flexible packaging. But the real “hero” of the event wasn’t the machines, rather the products that were produced on them. As a part of the product demonstrations, W&H ran stretch hood films with gussets for strengthened load stability on the Optimex blown film line. A collation shrink film for packaging beverage bottles was produced on a 5-layer Varex blown film line featuring a Maxicone P die. By distributing functional properties among the individual layers, film properties are improved while reducing film thickness (downgauging). The Miraflex and Visaflex flexographic presses as well as the Heliostar SE gravure press demonstrated excellent print quality. These presentations highlighted the benefits of the EASY automation modules, which were designed to decrease both make ready times and waste. Newsletter • No 92 • April 2013

Winkler + Dünnebier

Innovative concept for envelope overprinting Many marketers are rushing into electronic mailing with the result that envelope volumes have decreased. Nevertheless, the direct mail market is still strong and the most effective in terms of generating a response, plus, the envelope is very effective as a marketing overprint document. A special solution for envelope overprinting is offered by Winkler + Dünnebier – the W+D 234d. This inkjet system incorporates variable data printing and can deliver graphics on the front and back of the envelopes. The W+D 234d`s capability to print a different message on alternate envelopes, in one pass, means that the user can offer marketers personalized print effectively, efficiently and at a competitive price. Since 2011, when the W+D 234d ConceptD machine was delivered to a customer, it has gone through a rapid transfor-

mation. W+D has already designed an upgrade – a more streamlined model that maximizes all the machine`s original qualities while adding some more capabilities. The 234d is an industrial-grade, highspeed 4 colour ink-jet envelope overprint press, developed specifically for envelope manufacturing companies, traditional envelope printers, inserters, print shops, letter shops, direct mailers, transactional printers and advertising agencies looking

to take advantage of the growing demand for personalized direct mail and a more efficient solution for rapidly declining batch or job sizes. The press with a print width of 108 mm / 220 mm (4.25” / 8.66”) supports a wide range of envelope sizes and runs at speeds of up to 30,000 envelopes per hour for full colour (CMYK) personalized direct mail. Native print resolution is up to 600 x 600 dpi (with 4 grey levels, equivalent to 1000 dpi resolution).

Envelope printing and overprinting with the W+D 234d can offer great business opportunities.

PrintPromotion Partners Baumann Maschinenbau Solms www.baumann-mbs.de

Heidelberger Druckmaschinen AG www.heidelberg.com IST METZ GmbH www.ist-uv.com

bielomatik Leuze GmbH & Co. KG www.bielomatik.com Koenig & Bauer AG (KBA) www.kba-print.com Goebel GmbH www.goebel-gm.com

H. C. Moog GmbH www.hcmoog.de

Kolbus GmbH & Co. KG www.kolbus.com

Planatol Klebetechnik GmbH www.planatol.de

Imprint

Postal address:

Published by PrintPromotion –

Lyoner Strasse 18 D-60528 Frankfurt am Main Phone: +49 69 6603-1453 Fax: +49 69 6603-2453 e-mail: info@printpromotion.de Website: www.printpromotion.de

Corporation for the Promotion of the Printing and Paper Converting Industry

Newsletter • No 92 • April 2013

PrintPromotion GmbH

POLAR MOHR Maschinenvertriebsgesellschaft GmbH & Co. KG www. polar-mohr.com

E. C. H. Will GmbH www.echwill.com

WINDMÖLLER & HÖLSCHER KG www.wuh-group.com

WINKLER + DÜNNEBIER GmbH www.w-d.de

Managing Directors: Dr. Markus Heering, Roger Starke Layout / printed by: Henrich Druck + Medien, Frankfurt/Main, Germany

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No 92 • April 2013

Printers‘ Guide Training Information & News in Printing and Paper Converting Technology

Flexographic printing by Ronald Weidel (azp Chemnitz) 1. Printing method (see No 91, December 2012)

2. Printing forme production 3. Printing process (to be published in No 93, August 2013) 4. Print quality (to be published in No 94, December 2013)

2. Printing forme production For flexographic printing, an elastic printing forme with a relief of the printed areas is required. As far as printing forme production is concerned, various methods and materials have been widely used which as of late have also become competitors. Depending on the purpose of application, the printing formes are either produced as printing plates or printing rolls made of photopolymers or elastomers. Until the 1970s, the elastomer printing formes (rubber printing plates) were dominant. Their production required much time and material. Before the rubber printing plate could be produced, a reverse-reading block (matrix) was needed for moulding. For the matrix, on the other hand, first of all an etched metal block was required as the master. Then an untreated rubber plate made of caoutchuk

was placed on that matrix and subsequently vulcanised in a strong press for approx. 10 to 15 minutes at a temperature of 140 to 150 °C. Pressure and temperature caused the natural rubber to flow into the moulds of the matrix where it interlinked and became a permanent elastic printing forme. Then the dimensions of

Figure 2: Production of a rubber printing plate

Etched metal block

Moulding of the matrix

Flexographic printing plates

Photopolymer printing plate

Printing rolls

(seamless, on-the-round on a carrier sleeve)

Printing plates

Solid polymer systems

Elastomer printing plate

Printing rolls

(seamless, on-the-round on a carrier sleeve)

Liquid polymer systems

Figure 1: Overview of printing formes in flexographic printing

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the rubber printing form were corrected by grinding; afterwards it could be mounted. The printing properties of the rubber printing plates only enabled to produce rather simple and coarse halftone images. Significant progress was made with the launch of photopolymer materials. The

Printing plates

(no longer relevant)

Moulding and vulcanisation

Finished printing plate

time and material consuming production of matrixes was no longer required and replaced with a photochemical process in which the printing plate could be made directly from a repro film. As a result, the time needed for the process chain was much shorter, and it was, for the very first time, possible to produce acceptable halftone prints. The initial incompatibility of the new plate materials with the printing inks and solvents commonly used in flexographic printing at that time were soon overcome. Compared to the previously used elastomers, the photopolymers rapidly convinced due to the significantly lower thickness tolerances of the raw Newsletter • No 92 • April 2013

plate materials, their homogeneous material structure and the fineness of the relief structures that can be produced. For the production of analogue photopolymer printing plates, a reverse-reading negative is required as the original copy. Exposure with UV light and development proceeds in 6 work steps. During the first step, the full surface of the reverse side of the plate is exposed to UV-A light without a light scattering film and vacuum. Hardening of the base (polymerisation) takes place during exposure of the reverse side. The base is needed in order to provide the printing elements with sufficient stability. At the same time, the relief depth of the plate is set via the base height. If the relief depth were too shallow, the form would get dirty during the printing process too quickly, which would continuously necessitate stops for cleaning. If the relief depth were too deep, there would be the risk that the printing elements are not sufficiently linked with the base and would break off during plate washing or the printing process. The information is transferred onto the plate and the printing relief is produced with the main exposure. For that, the original is placed on the plate and covered with a scattering film. In addition, a vacuum is produced in order to remove even the smallest amounts of air trapped between the film and the plate completely. The printing relief emerges in the exposed areas. The main exposure is followed by the washing-off process. During this step, the unpolymerized areas of the photopolymer plate are dissolved under the influence of a solvent and with rotating brushes in the washing unit (processor) leaving the clean printing relief on the exposed base. During the washing-off process, the printing plate takes up a large amount of the solvent and expands so that the plate needs to be dried. After drying, post-exposure of the plate is required. Post-exposure ensures that those areas at the relief edges that have only partly polymerized stabilize and the plate is given its final stability. Finally, the plate is exposed to UV-C light during the finishing process. This step removes the remaining stickiness of the plate and improves inking of the photopolymer. The necessary exposure times as well as the wash-off and drying times differ strongly

and, as a rule, depend on the plate thickness and the concrete formulation of the photopolymer. In order to reduce the washing and drying times required in this process, a thermal system (FAST) has been developed. In contrast to the washout plate, this plate is heated after reverse-side exposure and main exposure in the processor. The unpolymerized photopolymers evaporate

the original. The original is fixed on the copying frame and covered with a transparent protective film. Then a liquid photopolymer layer is applied and covered with a transparent carrier film, followed by the main exposure (from below) and the reverse side exposure (from above). Polymerisation causes the forming of the printing relief and support backing. At the same time, the carrier film crosslinks with

Protective layer Schutzfolie

LAMS-Schicht LAMS layer Fotopolymer Photopolymer Trägerfolie Carrier film Analogue printing Analoge Platteplate

Digital printing plate Digitale Platte

Figure 4: Analogue monolayer printing plate and digital monolayer printing plate

and are taken up by a fibre cloth. This process is repeated until the printing relief is absolutely freed from unpolymerized material. The advantage of this variant is that no drying time is needed. Post-exposure and finishing can be carried out immediately after the processor. Analogous to the developments in offset printing, work has been done in flexographic printing to develop a variant of the direct imaging of printing plates (ctp computer to plate) without the use of a separate repro film. In the 1990s, the digital wash-out plate was launched as a supplement to the analogue wash-out plates. As far as their basic structure is concerned, they differ from the older ones by an additional LAMS (laser ablation mask system) layer on the photopolymer. Compared to the ctp application in offset printing, the printing plate is, however, only imaged and no exposure is made. With the ctp laser, the LAMS layer of the digital plate is partly destroyed. On the surface of the plate, a mask of transparent and black areas is produced. Afterwards, the printing plate is processed like in the analogue process. A third photopolymer application is the liquid photopolymer system. In this process, the printing plate is created above

Carrier film Liquid photopolymer Protective layer Original Glass plate (copying frame) Figure 5: Liquid photopolymer system

the support backing. After the exposure process, the liquid photopolymer can be pulled off and channelled back to the storage container. Washout and drying are not necessary and the plate can be used after a short after-treatment and finishing process. The manufacturers especially focus on the development of photopolymer sleeve systems. A sleeve consists of a fibre-reinforced plastic sleeve on which a photopolymer layer is applied, optionally with a compressible base. There are two variants: The plate-on-sleeve system for which the plate is mounted with a double-sided adhesive tape and the plate gap is then closed as well as the seamless sleeve (in-the-round) system for which a

Figure 3: Production of an analogue washout printing plate

UV-A Light

UV-A Light

UV-C Light

Post-exposure

Finishing

UV-A Light

Reverse side exposure

Main exposure

Newsletter • No 92 • April 2013

Wash-out

Drying

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Elastomer

Photopolymer Gap Compressible base

Carrier sleeve

Photopolymer sleeve (plate-on-sleeve)

Photopolymer sleeve (seamless sleeve)

Elastomer sleeve

Figure 6: Sleeve variants

polymer layer is applied directly onto the sleeve. Processing is similar to the digital plate materials. Thanks to the finished sleeve, plate mounting is, however, no longer required. With the launch of the photopolymers, the development of elastomer printing

Graded relief Undercut

Figure 7: Elastomer printing plate with relief

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plates didn`t come to a standstill at all. Elastomer printing plates were still preferred for specific fields of application as, e.g., wallpaper and napkin printing. At the end of the 1980s, the first direct engravings with lasers were carried out. The results were so convincing that this method was refined over the following 20 years so that direct imaging, photopolymer and directly engraved elastomer printing plates now even compete with each other. Direct engraving also requires the use of the elastomer blank in the form of a sleeve. These elastomer sleeves have a multi-layer structure. They are also based on a thin sleeve made of fibre-enforced plastic material. The basic sleeve can additionally be coated with compressible plastic foam and/or a basic elastomer layer with the engraving elastomer being the top layer. After vulcanisation, the blank is ground for the required dimensions and for precise concentricity and can then be en-

graved. Engraving is carried out in accordance with the external drum principle. The rotating cylinder is guided along the laser. The high energy of the laser burns off the elastomer so that it partly evaporates. The resulting residues are extracted. After the engraving process, it is only necessary to clean the surface from residues of the burning-off process completely. In contrast to the photochemically controlled imaging process of the photopolymers, direct engraving of the elastomers with the laser enables to produce a perfect mould of the printing relief. It is, e.g., possible to produce relief elements in graded conical forms or with undercuts. The large variety of methods in printing plate production will continue to have a strong influence on the development of flexographic printing.

Laser

Optical system

Sleeve

Engraving area

Figure 8: Basic principle of direct engraving

Newsletter • No 92 • April 2013