2012 Golden Cylinder Award Winners
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TA B L E O F CO N T E N T S p.54
Features 14 The Exploration of Gravure in Photovoltaic Processes By Rosie Bubb
19 Silicone Coatings Offer Opportunities for Food Contact Paper Performance By Kris Verschueren and Christian Parein
Cover Feature 22 2012 Golden Cylinder Awards
51 In Memoriam – Warren Robert Daum 52 E-Boss By Gary White
54 Putting an End to Patchwork Prepress By Carol Werlé
56 European Publication Gravure Award 2012 60 ERA Annual Conference in Turin
2 Publisher’s Message Change, New Horizons and Best Wishes
4 Editor’s Desk Honoring Gravure Excellence
10 Industry News 13 People 57 Product
p.57 GRAVURE/Fall 2012
Change, New Horizons and Best Wishes
t has been a pleasure serving as your President and CEO of the Gravure Association of America these past seven and one-half years, as well as serving as Publisher of the APEX award winning Gravure Magazine and working with Bernadette Carlson managing the Gravure Education Foundation. Working with the GAA board of directors, the GEF board of trustees and the GAA team these past years has been a real pleasure. The majority of my working career has been with 3M. During those 25 years, I had the opportunity to meet and work with several department chairs and professors at our resource centers as well as their students. It was during this period that I sat on both boards of GAA and GEF. Boy, could I tell you some stories! I am proud of the work we at GAA and GEF were able to accomplish— overcoming challenges, rebuilding and re-branding of the organizations— and w i l l a l wa y s c h e r i s h t h e m a n y individuals I was fortunate enough to meet and work with on the various industry committees. One of my tasks was to build a marketing and business plan with a 90% new staff. I would be remiss if I did not recognize the hard work, commitment and talent of these dedicated individuals, a group that really cares about our members and doing what is right. It is no secret that our industry has
gone through many challenges and changes the last few years. However, change and technology provide opportunities for business growth. There are several new developments on the horizon. The timing is right to pool the best of the resources of GAA and PLGA Global to better serve the Gravure industry. This is something that has been discussed and recognized for many years and a challenge I was given by our board a few years ago. In the past months you have received correspondence announcing that plans are in place to create a new organization to better serve and meet the needs of the packaging, product, publication and specialty Gravure market segments. My plans were to “Take it down a notch” next year; so this comes at a perfect time as after several years of service with GAA and GEF I will be semi-retiring. I will still be involved with GAA and GEF during the transition, offering my input and assistance as we move forward. So now we move on with the potential to build a better organization for the benefit of the Gravure Industry across the Americas for all market segments. My sincere thanks for all your help and support. Best Wishes this Holiday Season and throughout the New Year. Sincerely, Bill
President & CEO Bill Martin, Publisher of Gravure Magazine Director of Conference Planning & Administration Pamela W. Schenk Business Manager/CPA Linda Pfingst Association Manager Michelle Giuliano Administrative Assistant Susan L. Schippits Technical Support JD Harris Executive Director of GEF Bernadette Carlson IT Webmaster Allen Krusenstjerna
Publisher: Bill Martin Editor and Associate Publisher: Linda M. Casatelli Gravure Association of America, Inc. P.O. Box 25617 Rochester, NY 14625 Phone: (201) 523-6042 Fax: (201) 523-6048 E-mail: email@example.com. www.gaa.org
THE GOLD STANDARD IN GRAVURE
From pioneering the use of gravure technologies to Weâ€™re working every day to discover the innovations that help gravure perform even better for our customers. How far are we stretching the limits? Weâ€™re pioneering the use of gravure technologies to produce printed electronics. Because answering our customers' most important challenges is the gold standard in gravure. GLOBAL PRODUCTS AND SERVICES books . business communication services . business process outsourcing . catalogs . commercial print . content creation, management and distribution . direct mail directories . distribution, print fulfillment and kitting . document outsourcing and management . e-business solutions . financial printing and communications forms, labels and office products . global print and packaging supply chain services . logistics services . magazines . proprietary digital print technologies real estate services . retail inserts . RFID and barcoding . strategic creative services . supply chain management solutions . translation services
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E D I TO R ’ S D E S K
Honoring Gravure Excellence
ravure has traditionally been known as the process for extremely high quality printing. Each year, the Gravure Association honors those printers who have achieved printing excellence using the gravure process by means of the Annual Golden Cylinder Awards Competition. For those printers who win, the honor of winning not only offers an opportunity to achieve peer recognition, but it also increases exposure in numerous graphic arts publications and promotes customer relations. This issue showcases the winners of the 2012 Golden Cylinder Awards (beginning on page 22) in all categories—packaging, product, technical innovation and publication. We have pushed the publication of the fall issue until later in November so we can include the publication winners, who are announced at the Gravure Publishing and Premedia Conference (GPPC). The packaging and product winners were announced at the GAA Packaging Conference in October. The Technical Innovation winners are announced at the conference where the innovation falls, i.e., packaging or publication category. Another highlight in the issue is the third winner of the Flint Group Technical Writing Contest — “The Exploration of Gravure in Photovoltaic
Processes,” by Rosie Bubb (page 14). It is interesting that one of the topics in the contest dealt with the emerging field of printed electronics. One of the exciting presentations at the packaging conference was Kate Stone’s discussion of “interactive printing.” She showed examples of printing that enabled differentiation of product from the competition—all using materials and processes already in use in printing plants today. In today’s shrinking printing market, the area of printed electronics and interactive printing offers great potential for new products. An excellent place to learn more about what is going on in this area is the GAA’s Printed Electronics Symposium, to be held in the spring at Clemson University. In addition, the issue offers articles on a new embossing process; improved software; and silicone coatings for food contact paper. It also honors Warren Daum, former President of the Gravure Technical Association and founding president emeritus of the Gravure Education Foundation, who recently passed away. I hope you enjoy the issue as the last days of fall—with its colorful foliage, scarecrows in pumpkin patches and harvest produce—begin to make way for winter. And I want to wish you a Happy Holiday season.
Publisher: Bill Martin Editor and Associate Publisher: Linda M. Casatelli
Subscriptions Gravure is available free of charge to employees of GAAmember companies. Subscriptions for non-members in the U.S. and Canada are $67/year or $130/two years.
Business, Advertising, & Editorial Offices Gravure Association of America, Inc. P.O. Box 25617 Rochester NY, 14625 Phone: (201) 523-6042 Fax: (201) 523-6048 E-mail: firstname.lastname@example.org www.gaa.org
Vol. 26, No. 3 ISSN 08944946 USPS 000-565 Gravure magazine is published online three times a year.
TE A D E H T E SAV
GAA Printed Electr Since the discovery of conductive polymers by 2000 Nobel Chemistry Prize winners Alan MacDiarmid, Hideki Shirakawa and Alan Heeger over 1000 academic research organizations around the world have been working on the development of materials, equipment and processes for printed electronics with the potential to reduce the cost of electronics by an order of magnitude… while simultaneously making flexible circuitry and new product form factors possible. After over a decade of R&D in academic research centers and several early attempts at commercialization printed electronics is about to move out of the lab and into the marketplace. Growing demand for packaging and products incorporating printed electronics is expected in consumer packaged goods, pharmaceutical packaging, soft packages used for shipping, point of purchase displays and consumer electronics as well as in lighting, energy storage and track-andtrace applications. High value applications for printed electronics include intelligent “e-packaging.” Intelligent “e-packaging” alone is soon expected to be a multi-billion dollar market. According to research firm ID TechEx the global demand for intelligent packaging is expected to grow from $.03 billion in 2012 to $1.7 billion worldwide by 2020 with consumer packaged goods e-packaging having electronic functionality reaching 35 billion units by 2022. The electronics industry is now on the brink of a cost reduction sea change in the mass production and mass customization of electronics devices, and once again the electronics industry’s potential for dramatic growth is being made possible by technologies developed by the printing industry... only this time the opportunities for growth are also likely to include the printing industry. It is not widely know, but since the first mass-producible electronic circuitry was developed in the early 1900’s the printing and electronics industries have been intertwined. In fact, the first patent ever for electronic circuitry was British patent 4,681, filed in 1903 by Albert Parker Hanson for “printed” circuits on paper created additively through the deposition of metal powder in a medium of conductive ink or adhesive. Thomas Edison’s laboratory notebooks from the same period also indicate that he was thinking to apply patterns gum to linen paper with graphite powder to create flexible circuits. Also, much of the technology that led to the growth of today’s multi-billion dollar silicon semiconductor industry was based on photomasking methods originally developed for making printing plates.
ronics Symposium Printed electronics represents an unprecedented growth opportunity for leaders in the printing and electronics industries and related industries to address new multi-billion dollar markets for the widespread production of very low-cost electronics for applications that do not require high performance. Similar to conventional printing, printed electronics is based on the additive deposition of conducting, semiconducting and insulating “functional ink” layers on flexible substrates and while the future of printed electronics will rely on technologies derived from the full spectrum of commercial printing processes, gravure printing technologies and processes are likely to play a central role because of s that allow for use of a wide array of ink chemistries and viscosities, high resolution circuit features, and low-cost long production run lengths. To address these new market opportunities printers will require new materials, new process capabilities, new sources engineering support, market intelligence, a competent workforce and effective go-to-market strategies. To succeed they will also need to forge new collaborative relationships with key stakeholders from the electronics industry and academia. For this reason the Gravure Association of America (GAA), The International Electronics Manufacturing Initiative (iNEMI) and the Envelope Manufacturers Association (EMA) Foundation are collaborating to present The 2013 GAA Printed Electronics and Intelligent Packaging Symposium to be held Clemson University in Spring, 2013. Check the GAA website for details as they are confirmed. The Symposium will bring together consumer goods company packaging professionals, print service provider technical and business leaders, as well as public and private sector product, logistics, packaging, mailing and security professionals with leaders from the electronics industry, printed electronics materials manufacturers, process technology manufacturers, printed electronics market analyst firms, engineering firms and academia. Key topic areas that will be addressed include:
• Printed electronics market and application trends • High growth markets and high value applications for printed electronics • The iNEMI printed electronics technology roadmap • Moving printed electronics technologies out of the lab and into production • Required printed electronics knowledge competencies • Printed electronics circuit design and simulation • Configuring a printed electronics pressrooms • Hiring and managing talent for printed electronics • Substrates and functional inks for printed electronics • Quality assurance for printed electronics • Marketing and selling printed electronics and intelligent packaging • Case study presentations of successful productization • Cost/performance targets for printed electronics
RIT Creates Cross-Media Innovation Center The School of Media Sciences at Rochester Institute of Technology has created a Cross-Media Innovation Center to promote interdisciplinary research between RIT faculty and the graphic communications industry. These research areas may include the creation and organization of digital content, analysis of consumer and business data to better understand behaviors, the layout and assembly of graphical images and the deployment of content to all media channels. The center will be a vendor-equipped laboratory with the most current software and systems from firms that make up the cross-media value chain such as Adobe, HP and Xerox Corp. RIT’s School of Media Sciences is expanding its labs to accommodate a cross-media innovation lab, a marking technology lab (lithography, flexography, screen and digital printing systems) and a material science lab. All these labs will be used for research and education for the school and the Cross-Media Innovation Center. The center will foster on-going dialogue with industry partners by hosting an annual summit. Participants will come from all areas of the graphic communications industry. This year’s summit took place Oct. 18–19.
Flint Group Awards German Scholarship The German Scholarship Program was established by the German government under the patronage of Prof .Dr. Annette Schavan, German Minister for Education and Research. The objective of the Program is to support talented and Lechner received her certificate from Dr. capable apprentices, to Erich Frank, Head of Technology Management/Regulatory Affairs at Flint honour excellent perfor- Group. mance and to encourage a new culture of foundation in Germany into action. In addition to particular success at school or university, special value is placed on high social commitment. Now two scholarships have been awarded by the Stuttgart Media University (HdM), which are financially supported by the government and selected companies. There were more than 30 applicants for the two scholarships, and one of the two awardees was Yvonne Lechner from the German-Chinese double degree program for printing and media technology. This globally unique course leads to a double degree as an engineer-bachelor of the HdM and of the Xi’an Technological University. Advanced knowledge of media technology as well as the Chinese language are taught as core subjects of the degree program. Flint Group is particularly interested in promoting a competent next generation in the subject of printing and collaborates on joint projects with the HdM in Stuttgart as well as other Universities around the world. For example, the K+E-Award has been presented for almost 60 years, twice per year, for the best master thesis in printing technology.
Schober Announces R & D Capabilities Schober USA has recently installed a new rotary die-cutting machine in their Fairfield, OH facility to provide research and development services for North American customers. This new machine, which is complemented by two similar units at the Schober GmbH facility in Germany, makes it easier than ever before to assist customers with die-cutting, punching, creasing, embossing, and other rotary application research and development. Additionally, this machine can be used on a contract basis for product or process development, running samples, or even small production runs converting various materials such as nonwovens, films, paper and more. This machine can handle web widths up to 16” (400 mm) wide and roll diameters of up to 24” (600 mm). The tension controlled servo-driven system is equipped with a web guide and nip stations both before and after the module station to create a controlled environment from which reliable data and quality samples can be extracted. Schober USA is the North American subsidiary of Schober GmbH – a worldwide leader in rotary web converting technologies for the Label, Packaging-, Personal Care, and general Paper, Film and Foil converting industries.
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RIT Honors American Antiquarian Society Each year, Rochester Institute of Technology’s School of Media Sciences honors a person or an organization with the Isaiah Thomas Award in Publishing in recognition of their outstanding contributions to the industry. This year’s award honors the American Antiquarian Society, a national research library and learned society in Worcester, Mass. Currently celebrating the 200th anniversary of its founding by the patriot printer and publisher Isaiah Thomas himself, AAS is dedicated to preserving the legacy and advancing the mission of its founder. Its vast and highly accessible collection of history, literature and cultural documents spans the life of America’s people from the colonial era through the Civil War and Reconstruction. Ellen Dunlap, president of the American Antiquarian Society, accepted the award at a September event “Celebrating the Life of a Patriot Printer: A Tribute to Isaiah Thomas.” This year also marks the 75th anniversary of RIT’s School of Media Sciences (formerly the School of Print Media), which established the Isaiah Thomas Award in 1979. The award is named in tribute to Thomas, an early leader of the American printing industry who in 1770 created The Massachusetts Spy at a Boston print shop known as the “sedition factory” by the British colonial government. In 1775 he escaped to Worcester and continued to publish using the wooden printing press he brought with him, which is now part of the AAS collection. The American Antiquarian Society donated an original copy of the Nov. 9, 1808, issue of The Massachusetts Spy to RIT in 1981. Additionally, in 1810, Thomas wrote The History of Printing in America, which was regarded as the basic source of information on early American printing and publishing.
Dovetail Partners Inc. Joins Two Sides Two Sides today announced that Dovetail Partners Inc. has joined the organization as an allied partner and that Dovetail’s Executive Director Kathryn Fernholz will become a member of the Two Sides U.S. Sustainability Committee. Dovetail Partners is a non-profit corporation whose highly skilled team fosters sustainability and responsible behaviors by collaborating to develop unique concepts, systems, models and programs. Dovetail excels at solving complex business problems, helping responsible firms to become successful, and helping regions define programs that increase job creation and the job quality of resource-based industries. “Dovetail’s mission is to provide authoritative information about the impacts and trade-offs of environmental decisions, including consumption choices, land use and policy alternatives,” says Fernholz. “Our collaboration with Two Sides will give us new opportunities to help clarify complex environmental issues related to the use of print and paper and in doing so, to increase people’s understanding of and their capacity to make good business decisions related to this communications medium.”
Printed Electronics Materials Swell to $2.6 Billion in 2017 Driven by the need for cost reductions, conductive inks and pastes, new transparent conductive films, and semiconductor inks will grow the market for printed electronics materials to $2.6 billion in 2017, according to a report by Lux Research. “Much of the promise of printed electronics lies in the potential to manufacture devices through low-cost, highthroughput manufacturing,” said Jonathan Melnick, Lux Research Analyst and the lead author of the report titled, “Inking Money: The Prospects for Materials in Printed Electronics.” “But realizing this potential requires materials that offer good enough performance and are compatible with printing processes – without becoming too costly themselves.” Lux Research analysts examined a range of materials, varying widely in complexity, performance, and cost – to assess their value proposition. Among their findings: • Silver thrives while alternatives see slow uptake. The market for opaque conductive inks alone will grow to $2.4 billion in 2017, from $1.4 billion in 2012, with medical and RFID among the fastest-growing segments. However, silver paste will still dominate and other materials will only find traction in solar applications. • Rapid smartphone adoption offers bonanza. Transparent conductive films (TCF) to replace indium tin oxide (ITO), widely used in touch screens, will grow to $705 million, with $112 million coming from the inks. Growth is led by smartphone touch screens, with tablets a distant second. • Displays lead the way for printed semiconductors. Printed semiconductors will grow to $68 million in 2017, with solution-processed OLED emissive materials the lead application. The report, titled “Inking Money: The Prospects for Materials in Printed Electronics,” is part of the Lux Research Printed, Flexible, and Organic Intelligence service.
Frank Romano Receives Double Honors Graphic Arts of the Americas has named Professor Frank Romano, a world-renowned author, consultant, speaker, as the recipient of its 2013 Graphic Arts Leader of the Americas (GALA) Man of the Year. Established in 1982, the annual GALA Award is one of the printing industry’s most prestigious honors. It is given to professionals who excel in management, technology, business and quality; and those who significantly contribute to the graphic arts industry as well as back to the community. Members of the Printing Industry of America and CONLATINGRAF associations nominate the award recipients - one representing Latin America (Latin American GALA Award Recipient - Sr. Gustavo Adolfo Morales Velilla ) and the other, North America. RIT Professor Emeritus Frank Romano’s career has spanned 54 years in the printing and publishing industries. Many know him as the editor of the International Paper Pocket Pal for 30 years, or have read one of the thousands of articles he has written. He is the author of 52 books, including the 10,000-term Encyclopedia of Graphic Communications (with Richard Romano), the standard reference in the field. Romano lectures extensively and was the principal researcher on the landmark EDSF study, “Printing in the Age of the Web and Beyond.” He has been quoted in many newspapers and publications, as well as on TV
and radio. He appeared on the History Detectives PBS program and serves as president of the Museum of Printing in North Andover, MA. Romano’s distinguished career in education has resulted in a generation of students who advance the printing and publishing industry worldwide. RIT has also honored Romano. Rochester Institute of Technology—where Romano has taught for 22 years and still teaches online courses—honored the professor emeritus and worldrenowned printing expert with a surprise award of appreciation and recognition during this year’s Isaiah Thomas Award in Publishing ceremony. “I was surprised to win the award, but extremely honored,” Romano says. “The most important thing is that I’ve had the opportunity to teach students and work at RIT. For me, the real award is watching my students graduate and go on to work in the industry and help to build a better industry. That’s my real award.” He is recognized as a leading authority on graphic arts technology and trends, and in 1977 founded TypeWorld (later Electronic Publishing), one of the industry’s leading trade publications throughout the desktop and digital printing revolution. Romano has closely analyzed the future of newspapers, magazines, libraries and bookstores in the digital age. He was also involved in the development of an electronic version of the Congressional Record.
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GRAVURE/Fall 2012 13 2012-08-14 09.51
GR AV U RE F O R PRINT ING
The Exploration of Gravure in
Photovoltaic Processes By Rosie Bubb
Gravure, arguable an outdated process, has the potential for a renewed resurgence in the realm of printed electronics. Although the high front end cost and detrimental effects of the process previously served as drawbacks, currently the need for a high-quality, accurate process such as gravure is apparent in the context of printing polymer solar cells. Polymer solar cells are unrivalled in terms of processing cost, processing speed, processing simplicity and efficiency. Research is currently being conducted to maximize the efficiency of the process of producing these cells in large quantities. The attention shifts to the elegantly simple direct print gravure process. The comparison between current polymer coating techniques and gravure has been made. The results indicate that the roll-to-roll compatible process of gravure is superior in terms of cost, high-production suitability, quality, and potential power conversion. The ability to use low viscosity inks with varying concentrations of solvents gives a lot of flexibility in determining the optimal printing process for coating the polymer solar cells. The solar cells must be coated so that they achieve a perfect balance of efficiency, stability, and a suitable production method. Because gravure has the flexibility to adjust various printing parameters such as a wide range of printing speeds, ink viscosities, placement of the doctor blade, and cell geometry, gravure is an ideal process for the printing of solar cells. As gravure becomes the prominent method for this application, it has the potential to retake a significant market share – only not in the traditional print market but in a unique market that would present gravure as a sustainable and necessary process.
he high quality and application of gravure printing is undeniably unsurpassed. Although some may question gravure’s dominance in today’s print markets, the process consistently yields a high definition, vibrant, and very attractive product. The high initial cost of copper plating, 14
engraving, and chrome plating the cylinder is in stark contrast to the other processes utilizing computer-to-plate technology. However, the value of gravure is unmatched for long runs: a much cheaper flexographic cylinder has a brief lifespan in comparison and typically yields a lower quality product. Yet, with increasingly
tighter margins and shorter run lengths becoming more and more the norm, the gravure market’s dominance continues to diminish.1 The growth of gravure has been non-existent—declining in usage steadily over the last 10 years. The projected use of gravure processes being 11% by 2015.1 In addition to the shift in market demand, gravure printing is undeniably not an attractive process in terms of sustainability. Despite efforts to minimize the volatile organic compounds (VOCs) released and control the emissions, the process is more harmful than not. Most gravure inks contain toluene—a common, highly flammable solvent that has the potential to be harmful to humans. EPA standards require printing plants to recover 96-99% of the solvent; thus solvent-recovery systems are quite effective but there still remains some minute amount of unrecoverable solvent. Winfrid Schoen, head of publication gravure inks at Gebr. Schmidt, Frankfurt, Germany claims “it has become physically impossible to develop a waterbased ink which can work effectively on the thin papers required for high-speed publication gravure presses.” 2 Yet despite all of this, gravure has the potential to become dominant in a field where it could have positive effect on the environment. New research reveals that gravure printing may be the perfect option for printing photovoltaic cells. The challenge in production lies in finding the proper unification of production, stability, and efficiency. The solar cells should be produced rapidly at a low-cost through a reliable process that allows a high power conversion efficiency of the final product.3 Typically solar polymer cells are produced via film forming techniques such as spin coating and casting. These processes are commonly used although not the best choice for high volume production. Polymer solar cells could be more efficiently produced through more desirable film forming techniques—including direct
G R AVU RE F O R PRINT ING print gravure. The application of this process in terms of production of solar cells warrants more exploration.
termine if gravure is the best method and what factors make it so.
The simplicity of the direct printing method paired with the viscosity of the inks as well as high speed capabilities make gravure a natural choice for the coating of the polymer layer of solar cells. Ink factors such as surface energy and surface tension are to be controlled to allow a smooth, wet pattern to be produced without smearing or running. Through the study of the effects of process parameters such as contact angle, ink concentration, ink viscosity, solvent characteristics, the power conversion efficiency of photovoltaic cells is found to be unmatched by other printing processes. All three layers have been demonstrated to have been printed by gravure—at a high power conversion efficiency.4
In order to examine how gravure printing is best suited for printing photovoltaic cells, secondary research was conducted— resulting in analysis of a compilation of scientific studies. In order for gravure to become the most widely accepted method for the printing of polymer solar cells, a direct comparison must be made between
Roll-to-roll processes are relatively simple as they include unwinding, coating, and rewinding with the possibility of cleaning, heating, and drying stages. Solar polymer cells are ideally printed via a process such as gravure. The roll-to-roll compatibility of gravure implies high volume production at a low process cost. Roll-to-roll process also implicates the use of low basis weight substrates such as film. Because the polymer is a thin, flexible substrate, rollto-roll gravure is a natural choice. The shape of the cell used to print is an important factor in any facet of printing. Cell geometry takes on a new importance in the printed electronic application. Because ink can dry in the cell during printing, not all the ink is applied to the substrate. Research has been conducted to determine the ideal cell shape for printing as well as the other printing parameters that affect ink transfer. The idea of printing gravure on solar cells is contingent on the process. One must ask why gravure specifically is ideal for this application? The exploration of the possibilities for gravure in this potentially environmentally minded process is necessary to de-
The unification challenge: selecting a highvolume, low-cost process with the capacity to generate a stable, highly efficient product.
the current processes and the gravure process for printing on polymer solar cells. As stated, the current and accepted processed include spin coating and casting. The challenge existing in selecting the best process is known as the unification challenge— this is pictorially represented in Figure 1.5 The film-forming technique of casting is the simplest—only a work space is the equipment needed. The solution is cast onto a substrate and dried. While, a simple and stable process, this method lacks the control over film thickness and has inconsistent drying due to surface tension inconsistencies. Spin coating has been the most dominant over the years in the field of coating polymer solar cells. It is also a stable process that is highly reproducible. A very consistent film over a large surface area can be achieved with this method. However, the thickness that results, the morphology and the surface structure are
influenced by the rotational speed, viscosity, and concentration of the solutes. Spin coating fails to meet the unification challenge in that the process is wasteful, i.e., not efficient. Another downfall of the process is that it is not roll-to-roll compatible. Because it is not compatible as a roll-to-roll process, it may not be as efficient to produce in a high-volume production context. Another crucial limitation of the process the lack of the ability to print a pattern onto the film. Without a pattern, the electronic component will not function. An examination of gravure is necessary to determine if it is a more unified process to utilize in polymer solar cell coating. Comparing the gravure process versus the popular spin coating procedure is necessary to determine if gravure has the potential to be at the forefront of polymer solar cell production. `To determine the efficiency of gravure printed solar cells and the effects of the printing parameters, researchers in Finland carried out a series of trials. Using an Schläfli Labratester, a simple gravure print run was conducted in which various conditions were altered to determine the most ideal parameters for printing the surface with the highest efficiency. The Schläfli Labratester, basically a table-top printing unit, demonstrated the simple process of gravure: the printing cylinder with engraved cells on the surface comes in contact with the ink pan and then the doctor blade which in turn, removes the excess ink before the ink is transferred to the surface of the substrate. The machine has the capacity to run at different speeds with various nip pressures, doctor blade angles, distance between the doctor blade and printing plate, and doctor blade pressures. 6 PET film covered with tin oxide served as the test substrate. The substrate was cleaned, rinsed with de-ionized water and dried in an oven for a few hours. Specially formulated ink was applied on top of the substrate through the gravure process. The next layer, the photoactive layer, was GRAVURE/Fall 2012
GR AV U RE F O R PRINT ING also processed via gravure printing. To measure the voltage of the cell, a Keithley 2400 source unit was used. The thickness of the film layer was measured using a Detak 150 surface meter. The viscosity of the ink was determined with a rheometer. To find the optimum printability of the gravure printed photoactive layer, ink concentration, ratio of solvent mixtures, cell shape, line density, and speed of the press were all varied. The optimal ink should result in controlled ink, not spreading out from engraved pattern. The process was tested at a printing speed of 7 m/min and 18 m/min while two different line densities were used: 80 l/cm and 45 l/cm. To assert gravure’s potential for printing electronics, it is necessary to demonstrate that the pattern thickness is adequate to cover the product in a fine film and to determine what characteristics of ink are necessary to achieve this. Research done at Microelectronics Laboratory in Finland aimed to demonstrate this while determining the best way to determine this and the best way to address quality on electronic substrates. 7 The experiment was done with a gravure printer form Grauel GmbH, a doctoring device with fixed angles, an engraved cylinder with 30 micrometers deep, rectangular cells. The speed of the ink doctoring was 5-30 cm/s, while the pickup speed of the ink was near to the same. The viscosity and yield stress measurements were recorded with a Bohlin rheometer. Surface thickness and line height was measured via a Veeco Detak surface profiler. The parameters recorded after each trial were the compression-thickness where ink is picked up, the compression thickness when the ink is laid down, the time from doctoring to pickup, the speeds of doctoring, pickup and print. A further point of research involves how the engraved pattern affects the performance of the substrate. The geometry of 16
the engraved cells—whether it be square diamond, or hexagonal—can influence the outcome. Researcher, Leonard Schwartz, examined this affect and built a mathematical model to determine which cell geometry was the most desired. Based on the amount of ink that was left after each rotation, the amount of ink not transferred as it was dried up in the base of the cell, the productivity of the process can be calculated.8
The following tabled comparison of all current and potential polymer solar cell coating methods is displayed in the following table. The current and most common method of spin coating stands out due to it high ink waste. Based on the comparison, gravure appears to be a good compromise of all factors. The ink waste is low as the direct print process is highly efficient in terms of ink usage. A two-dimensional pattern is achievable with the potential for more dimensions as more layers of the cell are printed via gravure. The speed is among the highest as gravure is roll to roll compatible, meaning more surface area can be covered in less time as the substrate web is pulled through the unit at a controlled speed.
Because of other factors currently under examination, including gravure cell geometry and the numerous printing parameters that can be adjusted in the gravure process, gravure looks to be a standout option for printing polymer solar cells.
(Risø National Laboratory for Sustainable Energy, Technical University of Denmark) Note: Ink waste: 1 (none), 2 (little), 3 (some), 4 (considerable), 5 (significant). Pattern: 0 (0-dimensional), 1 (1-dimensional), 2 (2-dimensional), 3 (pseudo/ quasi 2/3-dimensional), 4 (digital master). Speed: 1 (very slow), 2 (slow<1 m min−1), 3 (medium 1–10 m min−1), 4 (fast 10– 100 m min−1), 5 (very fast 100–1000 m min−1). Ink preparation: 1 (simple), 2 (moderate), 3 (demanding), 4 (difficult), 5 (critical). Ink viscosity: 1 (very low <10 cP) 2 (low 10–100 cP), 3 (medium 100–1000 cP), 4 (high 1000–10,000 cP), 5 (very high 10,000–100,000 cP). The results of the Finnish study are evident in Table 2 and Figure 3. The printing speed of 7 m/min was unsuccessful as the ink spread outside of the cells, accumulating outside of the engraved area. When the
G R AVU RE F O R PRINT ING geometry and the affect of cell performance can be summarized in mathematical models formulated by research Leonard Schwartz.
speed was increased to 18 m/min, the ink flow was improved and the ink was contained to the patterned printing area. To get the uniformity required, it was necessary to test a lower line density or a greater cell volume. As apparent in Figure 2, sample e was the most successful at an 80 l/cm screening, 18 m/minute speeds and 150 mg/ml. The layer thickness for this sample also had the least variation when the total concentration and line density was increased. Table 2. Layer thickness measurement result of the printed layers presented in Figure 3. The overall highest power conversion efficiency achieved in this fully gravure print experiment was 2.8%. This in effect, asserted gravure’s potential to manufacture polymer electronics. Results from the study done at Microelectronics Laboratory demonstrate that inks that are high in viscosity and in internal cohesion, give the best results. Inks with high viscosity require lower doctor blade speeds. The experiment with the more
solid the ink contained, the better transfer occurred as the printed mass increased with the solid content of the ink (as seen in figure 3).
Figure 2. Indicates that sample 3 was the most successful Note: P3HT:PCBM 50 mg/ml in o-DCB (80 l/cm), speed 7 m/min, (b) 50 mg/ml, 80 l/cm, speed 18 m/min, (c) 50 mg/ml, 45 l/cm, speed 18 m/ min, (d) 100 mg/ml, 80 l/cm, speed 18 m/min, (e) 150 mg/ml, 120 l/cm, speed 18 m/min. Source: Microelectronics Laboratory for both images
In the case of the more viscous, more solid ink, 100% ink transfer to the substrate occurred; thus, beneficial for electronic products such as photovoltaic cells where a complete coating is necessary to functionality. The research involving the cell
The diagram in Figure 4 demonstrates each of the input parameters used by Schwartz used to calculate the efficiency of each cell shape: hexagonal, diamond, and square. He found the cell size rather than the geometry was the main determinant of how much ink was life the in the cell. In general, increased cell sizes will empty more completely. However, cells too large will
Figure 3. Printed mass vs. solid content of inks. Source: Micorelectronic Laborator
create a non-uniform surface, which is an undesirable result – especially in printed electronics applications where the uniformity of the surface is necessary to the function of the final product. Cells too large also have the potential to damage the web. Through his calculations, Schwartz discovered that the surface tension is also directly proportional to the liquid left in the cells. He found that it is the refilling
Footnotes 1. “Converting Today - One Foot in the Gravure.” Converting Today - The Leading Magazine for the Converting, Packaging and Printing Industry. Globe Trade Media, Oct. 2010. Web. 20 Nov. 2011. <http://www.convertingtoday.co.uk/story.asp?storycode=64227>. 2. Officials debate future of gravure: while some see brighter future built on quality, others see solvent issues leading to further decline 3. Fabrication and processing of polymer solar cells: A review of printing and coating techniques 4. Voigt, M. M., Mackenzie, R. I., Yau, C. P., Atienzar, P., Dane, J., Keivanidis, P. E., & ... Nelson, J. (2011). Gravure printing for three subsequent solar cell layers of inverted structures on flexible substrates. Solar Energy Materials & Solar Cells, 95(2), 731-734. doi:10.1016/j.solmat.2010.10.013 5. Frederik C. Krebs, Fabrication and processing of polymer solar cells: A review of printing and coating techniques, Solar Energy Materials and Solar Cells, Volume 93, Issue 4, April 2009, Pages 394-412, ISSN 0927-0248, 10.1016/j.solmat.2008.10.004. (http://www.sciencedirect.com/science/article/pii/S0927024808003486) 6. Kopola, P. P., Aernouts, T. T., Guillerez, S. S., Jin, H. H., Tuomikoski, M. M., Maaninen, A. A., & Hast, J. J. (2010). High efficient plastic solar cells fabricated with a highthroughput gravure printing method. Solar Energy Materials & Solar Cells, 94(10), 1673-1680. doi:10.1016/j.solmat.2010.05.027 7. Marko Pudas, Juha Hagberg, Seppo Leppävuori, Printing parameters and ink components affecting ultra-fine-line gravure-offset printing for electronics applications, Journal of the European Ceramic Society, Volume 24, Issues 10-11, September 2004, Pages 2943-2950, ISSN 0955-2219, 10.1016/j.jeurceramsoc.2003.11.011. (http:// www.sciencedirect.com/science/article/pii/S095522190300863X) Keywords: Ag; Conductor inks; Gravure offset; Inks; Intaglio; Thick-films 8. Schwartz, Leonard W., Numerical modeling of liquid withdrawal from gravure cavities in coating operations; the effect of cell pattern, Journal of Engineering Mathematics, Volume: 42, Issue: 3, April 1, 2001, Pages 243-253, http://dx.doi.org/10.1023/A:1016136130268 9. Schwartz, Leonard W., Numerical modeling of liquid withdrawal from gravure cavities in coating operations; the effect of cell pattern, Journal of Engineering Mathematics, Volume: 42, Issue: 3, April 1, 2001, Pages 243-253, http://dx.doi.org/10.1023/A:1016136130268
GR AV U RE F O R PRINT ING process that influences the final pattern as he states: “The pattern inﬂuence is restricted to the reﬁlling process, with the hexagonal pattern, for which the cells are more closely packed, suffering a greater degree of reﬁlling.” 9
Gravure, previously a process linked with environment concerns, can now be associated with decreasing the cost of solar energy; thus, reducing reliance on non-renewable sources. Gravure, being the standout option for printing polymer solar cells, has the potential to be at the forefront of the renewable energy movement. Although the traditional market for gravure may be diminishing, the new application in a sustainable rather than harmful process could be just what the gravure industry needs to reassert itself among other printing processes. The implication of gravure in photovoltaic polymer printing is profound. Gravure, previously a harmful process could become a process linked with improving energy efficiency; thus, a po-
Figure 4. The three cell patterns considered. The dimensions a, b, c are input parameters. Because of symmetry, only a portion of the domains shown need to be calculated. Note that (iii) is the square pattern (i) rotated 45 degrees Source: (University of Delaware, Department of Mechanical Engineering)
“Gravure, being the standout option for printing polymer solar cells, has the potential to be at the forefront of the renew able energy movement.” tential for a resurgence of gravure is possible outside of the conventional markets that currently exist. Gravure in the context of printing electronics is an up and coming topic in the print industry. New research is required to further solidify gravure’s potential to infiltrate the electronics market. The need for continued exploration of gra-
vure in this application is obvious. The rise of gravure and other printing methods in unconventional markets will likely increase, even as traditional print media declines. Rosie Bubb, a student at California Polytechnic State University, was one of the winners of the Flint Technical Writing Contest.
Additional References: 1. Kopola, P. P., Aernouts, T. T., Guillerez, S. S., Jin, H. H., Tuomikoski, M. M., Maaninen, A. A., & Hast, J. J. (2010). High efficient plastic solar cells fabricated with a high-throughput gravure printing method. Solar Energy Materials & Solar Cells, 94(10), 1673-1680. doi:10.1016/j.solmat.2010.05.027 2. Frederik C. Krebs, Fabrication and processing of polymer solar cells: A review of printing and coating techniques, Solar Energy Materials and Solar Cells, Volume 93, Issue 4, April 2009, Pages 394-412, ISSN 0927-0248, 10.1016/j.solmat.2008.10.004. (http://www.sciencedirect.com/science/article/pii/ S0927024808003486) 3. Voigt, M. M., Mackenzie, R. I., Yau, C. P., Atienzar, P., Dane, J., Keivanidis, P. E., & ... Nelson, J. (2011). Gravure printing for three subsequent solar cell layers of inverted structures on flexible substrates. Solar Energy Materials & Solar Cells, 95(2), 731-734. doi:10.1016/j.solmat.2010.10.013 4. Ding, J. M., de la Fuente Vornbrock, A., Ting, C., & Subramanian, V. (2009). Patternable polymer bulk heterojunction photovoltaic cells on plastic by rotogravure printing. Solar Energy Materials & Solar Cells, 93(4), 459-464. doi:10.1016/j.solmat.2008.12.003 5. Marko Pudas, Juha Hagberg, Seppo Leppävuori, Printing parameters and ink components affecting ultra-fine-line gravure-offset printing for electronics applications, Journal of the European Ceramic Society, Volume 24, Issues 10-11, September 2004, Pages 2943-2950, ISSN 0955-2219, 10.1016/j. jeurceramsoc.2003.11.011. (http://www.sciencedirect.com/science/article/pii/S095522190300863X) chwartz, Leonard W., Numerical modeling of liquid withdrawal from gravure cavities in coating operations; the effect of cell pattern, Journal of Engineering Mathematics, Volume: 42, Issue: 3, April 1, 2001, Pages 243-253, http://dx.doi.org/10.1023/A:1016136130268 6. “Converting Today - One Foot in the Gravure.” Converting Today - The Leading Magazine for the Converting, Packaging and Printing Industry. Globe Trade Media, Oct. 2010. Web. 20 Nov. 2011. (http://www. convertingtoday.co.uk/story.asp?storycode=64227>.
Learn more about Gravure for Printing Electronics at the GAA Printed Electronics Symposium at Clemson University, Spring, 2013.
C O AT INGS
Silicone Coatings Offer Opportunities for Food Contact Paper Performance By Kris Verschueren and Christian Parein
he food industry continues to evolve as a diverse and sophisticated entity, providing an expanding range of products in developed countries as well as emerging economies. Global consumers depend on packaging technologies to keep pace with innovation in the variety of food products available for an array of cultures. Meanwhile, food producers are creating distinctive ways to package food for preservation, shipping and storage.
Release Papers for Food Contact
Two primary paper applications exist where food contact is required. The first is the general category of food release liners, where the major function of the paper is to perform with easy and clean release from the surface of processed food (Fig-
ure 1). Food release liners can be designed for single or multiple use, in professional applications or for the home market. Reusable baking papers, interleaves or singleuse papers fall into this category. The range of uses for release liners in general has led to a significant global market: in 2010, total global release liner production was approximately 2.40 million tons.1 In the food industry alone, use of silicone-coated paper for food applications has doubled in less than five years, now representing 81% of food release applications, and about 178,000 tons per year.2 Another family of papers designed for food contact is greaseproof and greaseresistant papers. Applications for this type of treated paper include the packaging and protection of all types of greasy food, including wet and dry products. Greaseproof and grease-resistant papers are commonly used with fresh food, fast foods and snack wraps, bagged and boxed items, pet food, microwave cooking products, margarine and butter, and bakery products.
Greater Opportunity for Silicone
Figure 1. Use of silicone-coated paper continues to grow in the food industry.
In addition to their broad use in food release liners, silicone coatings hold potential for use in greaseproof or greaseresistant papers. The majority of materials used for greaseproof packaging are plasticbased, where primary applications are in the fresh, fast-food and pet food markets.
Only 26% are paper-based, and of that segment, only 43% represents chemicallytreated paper, including use of waxes and fluorochemicals.3 Although plastic-based applications are growing twice as fast as those using paper, recyclability is increasingly viewed as important by consumers. This preference indicates a primary advantage of paper and board. In recent years, several market trends have influenced the growth of various food contact papers. In addition to economic drivers, the food contact segment has been driven by environmental considerations, both on the part of manufacturers and consumers. Due to concerns over toxicity related to incineration, the market has shifted away from heavy metalbased paper coatings such as chromium, which was broadly used in the bakery paper segment. Meanwhile, interest also has increased with regard to monitoring long-term exposure to perfluoroalkylated substances because of suggested health risks. Several initiatives have encouraged reduction in the use of fluorine-based substances on a voluntary basis. Although systems based on the use of fluoro-chemicals have been dominant in the greaseresistant paper markets for many years, other options are available and are likely to become more common if resistance to the use of fluoro-chemicals increases further. Some industrial users have already replaced fluoro-chemicals, while others have announced their intent to do so in the future. Even recycling issues with GRAVURE/Fall 2012
C O AT INGS wax-coated paper have come to the fore. Because the waxes used are not biodegradable, additional chemistry is required in terms of wetting agents and dispersants to prevent buildup of deposits over time. Economic drivers include growth of the fast food and processed food segments, along with the demand for greater speed. These changes are triggered by urbanization, shifts in eating habits and a changing and growing population. Responding to these differences has become in part an ease-of-use approach, where greater use of food contact paper leads to greater efficiency. For example, with the use of food contact papers, cleaning may not be required on surfaces that were in contact with food after its heating or baking. Trends of this type continue to drive changes in the coated paper industry. Silicone coatings for bakery papers are becoming more popular, particularly in the EU, where greater than 90% of the market has switched. In contrast, only a minority of the American market has made the change, due in part to less demanding requirements in terms of release and greater popularity of single-use papers. The change to silicone-coated paper does not necessarily lead to an increase in cost of use because of factors such as coat weight reduction and better performance. An increasing focus on sustainability, including recyclable liners, renewable materials, and energy consumption efficiencies also is driving the market toward great use of silicone-coated papers. Geographic expansion, primarily driven by developing markets in India, China and South America, has led to an increase in food processing, with resulting greater demand for performance and cost efficiency in food contact paper. In developed countries, a reduction in average household size (due to more single-person households or single-parent families) has resulted in more individual households and greater use of packaging. 20
In summary, there are several drivers for change in the food contact paper segment. The search for higher product value by paper mills encourages the development of value-added products. In response, the success of a new product will be determined not only by its cost in relation to barrier performance, but also by its ease of application (i.e., low equipment cost) and compatibility with existing converting processesâ€”or the ability to use new technologies on existing equipment. Predictability and consistency of performance are linked to any potential advances. The case for environmental responsibility and renewability argues against wax and film barriers, while opening the door to more high performance materials. A growing sense of corporate social responsibility in terms of sustainability, renewability, recyclability, and waste managementâ€”in short, a stronger concept of cradle-to-grave responsibilityâ€”can alter the entire continuum of manufacturing, waste disposal, and recycling.
In release coating applications such as food and labels, the water-based silicone coating system consists of two reactive parts that are combined and mixed just before application. Part A of the emulsion coating contains the polymer and a cross-linker. Part B contains the platinum catalyst diluted in a polymer for easy handling. Application of the silicone emulsion is easy and can be done online as part of the paper manufacturing process, eliminating the need for a separate process by a converter. As part of the online process, the reactive silicone emulsion is applied to the paper before the last drying step, and the silicone is dried and cured in the final process stage (Figure 2).
Silicone Emulsion Technology in the Marketplace
Silicone coating technologies have a long history, and with time, they have become more appropriate for food applications. The first, and oldest, technology is solvent-based coating, which depends on using a solvent as a carrier to deposit silicone on the paper substrate. This approach is no longer a preferred method, and is gradually being phased out of use due to safety concerns associated with some solvents. Another method, solventless coating, is primarily used in labeling applications. Emulsion technology is the preferred coating method for a variety of applications including food contact. This technique is based on a platinum-catalyzed reactive system. This method produces low levels of byproduct and is in fact commonly used for curing silicone for medical applications, where safety and purity are sensitive issues.
Figure 2. A siliconization step can easily be integrated at the end of the paper manufacturing process. Figure courtesy of Dow Corning.
Paper coated with as little as 0.30 g/m2 silicone offers outstanding release properties and multiple uses. The resulting waterproof material is microwavable, repulpable and compostable. Figure 3 shows a cross-section of such a paper. Several properties of siliconized paper make it useful for food contact and also show potential for use in greaseproof applications. For
C O AT INGS of silicone technology for release papers, considerable opportunity exists for technology transfer to greaseproof applications and further penetration into the packaging market.
Figure 3. Cross-section of silicone-coated paper. Red line indicates paper surface with coating. Photo courtesy of Dow Corning.
food release, key characteristics of silicone are its outstanding release properties, without sticking. Silicone coated paper has a low Cobb60 value of approximately 8 to 15 g/m2 , which indicates a high resistance to absorbing water. A low value of this type is primarily important for frozen food processing. Greaseproof paper requires good resistance to grease over time, also important for packaging. A siliconemodified coating can give a Kit test value up to 12.
The food contact segment of the industry is a high growth market segment, driven by economics, changing populations,
technology advances and environmental concerns. Silicone release papers are primarily used for bakery and food release operations, and market penetration of the silicone application is growing. The appropriate silicone technology for producing greaseproof papers is established and holds promise for the food industry, with the added benefit that silicones already comply with requirements for foodcontact applications. Given the success
Kris Verschueren with a PhD in Chemistry from the Free University of Brussels, spent over 12 years in coating development and pressure sensitive adhesives marketing at UCB ( which became Cytec in 2003). He also spent 3 years as a marketing manager at Sappi, a leading paper producer, responsible for the specialty papers division. In 2011, Kris started at Dow Corning as marketing manager, first for the coatings market, recently in the paper & pressure sensitive Industry. Christian Parein joined Dow Corning in 1983. After 10 years in the sealant manufacturing department, he moved into the research and development department of silicone release coatings. Christian is now specialized in the development of water based release coatings for the paper & pressure sensitive Industry.
References 1. The Future of Specialty Papers to 2015, Pira International Ltd. (2010). 2. Specialty Papers and Paperboards Global Sourcebook, Alexander Watson Associates (2010) and Dow Corning data. 3. Dow Corning data
Because of the merger of GAA and PLGA, some of the conferences for next year are not finalized. Be sure to check the GAA website (gaa.org) for the calendar of events for 2013 GRAVURE/Fall 2012
2012 Golden Cylinder Awards
ach year, the Gravure Association of America conducts the Annual Golden Cylinder Awards Competition to promote the gravure process and to provide peer recognition for technical achievement. Submissions from around the world were received, cataloged, and displayed for the intensive two days of judging and deliberations. The quality of the entries was excellent, making the evaluation process challenging. Even though the Judges for the competition represent specific sectors, all judges examine all the entries. From the packaging/product sector, the judges included: Todd Luman, Laser Engraving Manager, Interprint, Inc.; Chiawei Wu, Engraving Manager Packaging Corporation of America (PCA); and Gary White, Plant Manager, Pamarco Global Graphics. The Educator sector was represented by Bob Chung, Professor at Rochester Institute of Technology. The judges from the publication sector were Sue Raleigh, Senior Tech Project Manager, Flint Group; Brian Fenner, Printing Research Scientist/ Service Mgr., NewPage Corp.; and Clayton Burneston, Technical Director, Manufacturing & Quality Assurance, National Geographic Society. The Golden Cylinder Awards for the Packaging and Product categories were announced at a luncheon at the GAA Packaging Conference at McCormick Place in Chicago on October 11. The Golden Cylinder Awards for the Publication category were announced at a luncheon at the Gravure Publication and Premedia Conference (PPC) at the Waldorf Astoria Hotel, Naples, Florida on November 12.
Seated (left to right): Bob Chung, Professor, Rochester Institute of Technology; Sue Raleigh, Senior Tech Project Manager, Flint Group; and Brian Fenner, Printing Research Scientist/ Service Mgr., NewPage Corp. Standing (left to right): Chiawei Wu, Engraving Manager, Packaging Corporation of America (PCA); Gary White, Plant Manager, Pamarco Global Graphics; Todd Luman, Laser Engraving Manager, Interprint, Inc.; and Clayton Burneston, Technical Director, Manufacturing & Quality Assurance, National Geographic Society.
2012 Cylinder Society Inductees At each of the conferences, some of the inductees for the Cylinder Society were honored. The Gravure Cylinder Society (GSC) is an honorary Society founded in April 1981 by the Gravure Technical Association and Gravure Research Institute. Each year the Society nominates industry leaders who have rendered outstanding or extraordinary contributions to the Gravure industry. The Society members are involved in activities that promote and support gravure. This year’s inductees include: Dr. Thomas Schildgen, Arizona State University; Robert Cedar, Quad Graphics; Jim Niemiec, NewPage Corp.; Robert Chung, RIT; David Gray, UPM; Ott Jensen, Dominion Pkg. ; George Battrick, ERA (European Rotogravure Association); and Bob Whitton, Arellton Group LLC.
At the packaging conference, Bernadette Carlson, Executive Director of GEF (left) honored cylinder society inductees—Robert Chung, RIT; Ott Jensen, Dominion Packaging; Bob Whitton, Arellton Group LLC— with the help of Liz Scherer, Sun Chemical Corporation, Cylinder Society co-chair (right). Cylinder society inductees present at the GPPC conference included: (left to right) Jim Niemiec, NewPage Corporation; David Gray,UPM; Robert Cedar, Quad Graphics; and George Battrick, European Rotogravure Association.
The National Geographic Society congratulates
Bob Cedar on his induction into the GAA Cylinder Society. His outstanding service in printing National Geographic
is greatly appreciated.
2012 Golden Cylinder Awards BEST OF THE BEST PACKAGING | Flexible Packaging-Film Product: LEGO® Hero Factory Re-closable Stand-up Pouch Submitted by: Sonoco Flexible Packaging Lego wanted to transform the toy aisle for their Hero brand by implementing a reclosable stand-up pouch. The new stand-up pouch delivered a reclosability option, high impact graphics and differentiation on the store shelf versus the existing carton. To create differentiation, Sonoco implemented a shaped pouch to catch the consumer’s eye. To meet the high impact graphics, Sonoco chose to use their internal graphics management team, Trident, to produce the rotogravure cylinders and separations. The use of the gravure process was instrumental in delivering the intricate detail needed for the Hero brands. The fine-screened colors are produced from both line and process colors. Tight registration and color control ensures the impeccable detail and color balance on the package. The superiority and quality of the gravure process is clearly evident in the design. By having the close alignment with the graphics, Sonoco was able to deliver the consistency and “pop” required by the customer. Separator: Sonoco Trident Engraver: Sonoco Trident Printer: Sonoco Trident
Press Manufacturer: Schiavi 2 Substrate Manufacturer: SKC, Celplast metalized and NEX Ink Manufacturer: Siegwerk Ink
Congratulations to all recipients of the 2012 Golden Cylinder Awards.
Innovative People Redefining Print
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PACKAGING | FLEXIBLE PACKAGING – PAPER Birthday Cake Cookies Submitted by: Sonoco Flexible Packaging Kraft created a new Oreo flavor—Birthday Cake—to celebrate the 100th anniversary of the Oreo brand (1912-2012). The Birthday Cake Oreo will be available throughout the year in both the US and Canada. Along with the new flavor, Kraft created a series of Birthday graphics to appear on the package in honor of the celebration. The Canadian business unit decided to replace the standard Oreo blue background with a metalized gold to increase the excitement level of the package. Normally for paper jobs, electro static assist is required to get ink to release from the rotogravure cells. Because the background color was produced using a metallic ink, Morristown was unable to use electro static assist due to safety concerns. Close collaboration between the Morristown plant, the design agency and the engraver was required to develop a design that would run effectively with these limitations. Kraft is happy that the resulting package promotes the new cookie flavor and with the quality printing delivered by Sonoco—which effectively celebrates the 100th birthday of the Oreo Brand. Designer: Pigeon Branding & Design Separator: Southern Graphics Systems Engraver: Trident USA Printer: Sonoco Flexible Packaging Press Manufacturer: Cerutti Substrate Manufacturer: Paper-Dunn Paper; Outer OPP layer- Exxon Mobil Ink Manufacturer: Siegwerk Ink
PACKAGING | Labels/Wrappers- 26“& Less Narrow Web on any Substrate Product: Cuties Juice Submitted by: SleeveCo, Inc. Cuties Juice is a fun package that appeals to many target markets. When designing this label, the customer wanted to incorporate the matte finish in order to give depth to key elements (brand, name, etc.) as well as a texture look and feel. The mixture of surfaces allows the package to differ from its competitors and charming consumers to choose Cuties. The coatings and tight registration would not have been accomplished if not for rotogravure printing. Engraver: Alliance Graphics Printer: SleeveCo, Inc. Press Manufacturer: W.R. Chestnut Engineering Substrate Manufacturer: SKC Ink Manufacturer: Flint Group
2012 Golden Cylinder Awards PACKAGING | Paperboard-Board Substrate Product: Miracle-Gro 12.5 lb Submitted by: Packaging Corporation of America This package is excellent to represent the gravure printing process. There is optimum tone reproduction for four-process colors, image reproduction and achieving gray balance. There is fine-line screen ruling electromechanical engraving for four-process color area with special engraving specifications for fine types and background spot colors, and unique UV coating on 31” circumference cylinders. Good solid print background to show gravure printing rich solid print and excellent color coverage, and overprint without streaks and bleeding. Unique high-performance UV curable coating is applied with special engraving specification on cylinder. The cured films are high in gloss, abrasion resistance and also meet customer’s rub and slide angle requirements. The UV coating is also protecting the printed boxes through die cutting and putting on the tear tape without any scratches on the print surface. Fast speed printing on gravure web press and fast conversion on laminator makes the manufacturing process more efficient. This entry tied with the entry from Amcor for the category. Designer: BUDDY’s Plant Plus Corporation Separator: Southern Graphic Systems Engraver: Packaging Corporation of America Printer: Packaging Corporation of America Press Manufacturer: North American Cerutti Corporation Substrate Manufacturer: International Paper Ink Manufacturer: Sun Chemical
Dallas Hairston from Packaging Corporation of America
PACKAGING | Paperboard- Board Substrate Product: Camel Metalized Boxes Promotional Packs Submitted by: Amcor Tobacco Packaging Americas The Camel metalized boxes are gravure printed on a metalized transfer board. The number of colors varies from seven to nine colors. Various transparent colors are used to allow the foil board to show through. Two styles (crush and crush bold) come in a round corner box design while the menthol styles come in a square box design. All four styles were limited edition packs. This entry tied with the PCA entry in this category. Engraver: Southern Graphic Systems Printer: Amcor Tobacco Packaging Americas Substrate Manufacturer: Unifoil Ink Manufacturer: Sun Chemical
Jim Davis from Amcor Tobacco Packaging
2012 Golden Cylinder Awards PACKAGING | Labels/Wrappers-Paper Product: Bush’s Best Gameday Original Baked Beans Submitted by: Mundet Tennessee Bush Brothers & Company approached Mundet Tennessee with a fall 2011 program concept centered around Football Gamedays. The use of gravure printing for exceptional color reproduction and outstanding print quality was a key factor in the selection of Mundet as the supplier of the labels, as well as Mundet’s embossing capabilities. The label consists of 10 colors—four-color process, three Bush Logo Colors, a gold designed to mimic Bush’s metallic look and two varnishes. There are three rotating label designs—each with a different “Gameday Tip” in the information panel. A low gloss matte varnish was applied to the body element, with a high gloss varnish applied to the hero image and logo aspects to give a visual pop. Print register of the two varnishes was key in maintaining the intent of the design. The labels were embossed with a sculpted die to give visual depth and a textured feel to the beans and football bowl image. The gold logo and the foam finger were also embossed. The innovative use of registered, textured embossing along with quality printing gave the Gameday Label immense shelf appeal and proved a successful campaign for Bush Brothers & Company. Designer: Deskey Separator: Mundet Tennessee Engraver: Southern Graphic Systems Printer: Mundet Tennessee Press Manufacturer: Schiavi-Bobst Substrate Manufacturer: NewPage Corporation Ink Manufacturer: Sun Chemical Corporation
Reba Meek and Stephen Young from Mundet Tennessee.
PACKAGING | Labels/Wrappers -Film Product: McDonald’s Rio Happy Meal Milk Jug Submitted by: Printpack, Inc. This nine-color job is a promotion for McDonald’s milk jug. It is reverse printed four across on PVC shrink film. The one-time order required fast turnaround and exact timing to coincide with the other elements of a McDonald’s Happy Meal and the release of the movie, RIO. From the time of receipt of artwork, preproduction review, warping of the design to fit the contours of the bottle, separations, engraving, printing, slitting, seaming and delivery to seven different dairies around the country in a compressed timeframe was a challenge. The vibrant colors of the design create pop and convey a fun atmosphere. The busy design and multiple elements required excellent registration control Good color matching and consistency were a must for the stringent studio requirements. This entry tied with the Multi-color Corporation entry in this category. Designer: The Marketing Store Separator: Southern Graphics Engraver: Southern Graphics Printer: Printpack Inc. Press Manufacturer: Rotomec Substrate Manufacturer: Bonset Ink Manufacturer: Sun Chemical
John Cave from Printpack Inc.
2012 Golden Cylinder Awards PACKAGING | Display Product: Iggesund Black Box Project Submitted by: Van Heertum Design VHD
Designer: Van Heertum Design VHD Engraver: GRT GmbH & Co. KG Printer: Gestel Premium Printing Press Manufacturer: H.G. Moog GmbH Substrate Manufacturer: Iggesund Paperboard Europe Ink Manufacturer: Siegwerk Druckfarben AG & Co. KGaA
When invited by Iggesund to participate in this special project, we did not have to think twice. Invercoate is an exceptional material, which we apply when working on complex projects. The structure of the paperboard gives a reliable and predictable reaction to whatever technique is used. The beautiful thing about this project was that there were no project boundaries (except that it had to fit in the black box), so there was real creative freedom to show our expertise. After the final choices, all creative documents were rebuilt into high resolution technical files. Other sheets with materials were made and the production planning was set. Because different companies were responsible for different production steps, thorough logistic planning was important and every step had to be performed according to a tight schedule. We divided the 12 cards that go inside the box, on three separate printing sheets: one sheet for six cards, one sheet for four cards, and a sheet for two cards. The six-card sheet started with gravure, because we wanted to use fluorescent ink and wanted to go for the most intensive result. In gravure, application of this fluorescent ink is better and more consistent than with offset. Also the transformation of bigger pigments is possible. We used a five-color sheet-fed gravure press from Moog.
Achim Kurreck from H.C. Moog (left) and Frans van Heertum from Van Heertum Design VHD
BEST OF THE BEST PRODUCT | Decorative Laminates Product: Breccia Nouvelle Submitted by: Interprint The design Breccia Nouvelle was challenging to create for several reasons. The demand for added “visual depth” present in the original sourced stone material was the goal to replicate within a two-dimensional printing process. The substrate made from various Eucalyptus fibers was a challenge to print on. Prior to printing, precision calculations had to be made to allow for paper expansion, resin penetration, tear resistance and porosity levels in order for the paper to be properly treated in a melamine resin bath and transformed into laminate material for counter tops, flooring, furniture. While typical inks used for décor printing are solvent-based for optical density, this design used specially formulated No/Low VOC water-based inks. This presented a challenge in attempting to replicate the visual aesthetics of a strong accented dark hue stone and provide depth of feel. Interprint has converted all its printing inks to No/Low VOC for environmental impact. The design concept was to emulate the experience a consumer has when visiting a stone-yard to purchase a granite countertop. To achieve this, we scanned a 5’ by 8’ slab of original stone and edited the resulting raw image to the final repeat dimensions of 130 cm x 158.5 cm. This edit was painstaking so the visual appearance will retain all the scale elements and movement of the original stone, yet be able to function on the printing process.
Breccia Nouvelle --- Todd Luman from Interprint, Inc.
2012 Golden Cylinder Awards PRODUCT | Floor Covering Product: Sobella Omni-Poseidon Submitted by: Mannington Mills The gravure printed pattern in Sobella Omni-Poseidon showcases design innovation, extraordinary cylinder repeat and enhanced engraving and printing technology. Mannington strives to be styling leaders. Poseidon is a one-of-a-kind pattern that epitomizes all the characteristics found in ancient biblical limestone. The large 16” tile layout depicts awesome realism featuring fine lines, authentic surface character and rich color variation. The repeat size of 48” x 144” utilized the entire expanse of the 12’ cylinder set, giving the consumer 27 uniquely different tiles creating realism and variety and closely replicating a natural stone installation. From a technology perspective, Poseidon is printed on a fiberglass substrate that uses six of the seven print stations on the 12’ Magnat rotogravure press. Mannington’s state-of-the-art NatureForm® HD process, integrates digital design and prepress workflows with material science, allowing achieving very tight registration. This pattern utilizes the highest fidelity cylinders currently run on press. The pattern uses a 150 fine-line screen and eco-friendly water-based inks. This combination delivers a sharp visual in vibrant colors bringing this high definition design to life. Designer: Terry Marchetta Separator: Terry Marchetta Engraver: Standex Engraving Printer: Mannington Mills Press Manufacturer: Magnat Substrate Manufacturer: Mannington Mills Ink Manufacturer: Penn Color
PRODUCT | Vinyl Substrates Product: Lotus Sandstone Submitted by: Canadian General Tower Ltd. Lotus Sandstone was a custom design for the customer inspired by the petals of a lotus flower. The task was to create a pool liner design that used the lotus as a model while integrating deep blue, sand and tan hues that would work in a natural environment for the end consumer. Gravure printing was perfect for this project as it was printed on a vinyl substrate. In order to achieve the vivid colors and consistency throughout numerous thousand-yard press runs, gravure was employed. As our customer needed to use this type of product in a pool environment, the physical properties of vinyl are unmatched by anything else in order to achieve a flexible result in the finished product. We were able to adjust and customize the weight, yield and thickness of the end product (pool liner) to whatever our customer needed.
PRODUCT | Postage Stamps & Security Printing Product: Send a Hello & US Merchant Marine Submitted by: Avery Dennison- DES Clinton S.C. Send a Hello stamp was printed using four-color process inks. The stamp pane was full of all the challenges that a gravure printer/ separator/engraver can face on a four-color process job—details in the eyes with highlights; legibility of small type; textures of hair/ fur; tight registration of 0.003” in knock-outs in four-color process balloons; tonal range of color and holding color consistency with solvent-based phosphorescent coating over stamp images for over a million feet of material; wiping the gradation from color-to-color on background in non-machine running direction; backprint continuous tones of PMS color; more linear diecuts than normal stamp panes. The U.S. Merchant Marine stamp also has loads of detail and registration challenges in the four different ships. The rigging and sail lines had to be converted from YMCK to black only to hold the 0.02” line weights. YMCK knockout of USA in stamp was challenging for holding register. This pane was produced at 300-400 line screen and used two PMS colors on the background and header. Engraver: WRE Colortech Printer: Avery Dennison-DES Clinton S.C. Press Manufacturer: Dai Nippon Kiko 10-color rotogravure Substrate Manufacturer: Fasson Ink Manufacturer: Siegwerk
PRODUCT | Giftwrap Product: Sports Ball Toss Submitted by: American Greetings The colors are vibrant, registration excellent, sharp and well-printed. The solid color is very even, the process exceptional with few flaws. It is good use of the water-based ink system and the overall challenges were numerous. Graphics has a complex use of vignettes, details are precise and clean; sports images appear to have a 3-D effect. Design focused at sport lovers capturing the natural pose and coloring of the equipment. High levels of technical skills demonstrated, resulting in a good job on a difficult design. Combination of solids, halftones, vignettes provides this paper with ample display appeal. Engraver: Southern Graphics Press Manufacturer: Cerutti Ink Manufacturer: Sun Chemical
2012 Golden Cylinder Awards BEST OF THE BEST PUBLICATION | Lightweight Coated (Under 40#) Catalog Product: Victoria’s Secret Major Fall 3 Submitted by: RR Donnelley- Lynchburg This catalog was particularly challenging to the printer in that it combined very high quality expectations while maintaining an extremely aggressive production schedule. Through a proprietary color management system, the printer was able to achieve gray balance color and provide “top notch” quality very quickly. Flesh tone smoothness is given top priority as are swatch matched products throughout the catalog. Printability can be challenging on lightweight coated paper as well as potential “show through” concerns. Small reverse type on dark backgrounds requires tight register control and constant monitoring. Experienced craftsmanship and constant focus is required in order to meet the customer’s high quality expectations and tight schedule requirements. Separator: Hudson Yards Printer: RR Donnelley- Lynchburg Substrate Manufacturer: UPM 34# Cote G NA FSC (Offset Cover) Ink Manufacturer: Flint Group
UPM is thrilled that one of our own— David Gray— is a new member of the GAA Gravure Cylinder Society. 34
PUBLICATION | Supercalendered-Catalog Product: Office Depot, Big Book 2012 Submitted by: RR Donnelley Office Depotâ€˜s Big Book offers office supplies, computers, business machines and office furniture. The diversity of the products, combined with the utilization of two printing processes (offset and gravure), created complex challenges for print reproduction while providing unique opportunities for the printer. Gravure printing was challenged by almost white-on-white office supplies. Dense ink coverage required for furniture and office machines looked rich and smooth. The sharpness, detail and contrast of the images found within the book were enhanced by the gravure process. Careful, ongoing measurement of ink viscosity, temperature and density is imperative for consistent reproduction on 35lb paper. These quality issues coupled with the size of the book and number of pages created a challenging environment. Designer: Phil Tucciarone, Jason Silverman, Anthony Carey Separator: Office Depot Engraver: RR Donnelley Printer: RR Donnelley Press Manufacturer: Cerutti/Motter Substrate Manufacturer: NewPage Corporation Ink Manufacturer: Flint Group
NEED A CONTENT DISTRIBUTION STRATEGY?
Now more than ever communications need to align for success RR Donnelley develops cutting edge communications strategies that help distribute and aggregate content across media. We work collaboratively with customers worldwide to develop custom solutions that reduce cost, enhance ROI and draw on the optimal mix of print, mobile and online media.
Copyright K 2012 R. R. Donnelley & Sons Company. All rights reserved.
2012 Golden Cylinder Awards PUBLICATION | Supercalendered- Retail Product: 6/19/11 Target Event Submitted by: RR Donnelley-Lancaster East Rich color, fine shape and detail are all packaged in 20 pages of 35lb SCA stock; that is the 6-19 Target Event. That is correct— a 35-lb SCA, not a lightweight coated stock. It is a blend of just enough density of ink application to give the coated look without over inking to expose the show through aspects that can be an issue on light weight stocks. It happens every week on the target circular—the look of a fine printed gravure piece. This entry tied with RR Donnelley’s entry for Kohl’s 4/12/11 Event in this category. Designer: Target Engraver: RR Donnelley Lancaster East Printer: RR Donnelley Lancaster East Press Manufacturer: KBA Substrate Manufacturer: NewPage Corporation Ink Manufacturer: Flint Group
PUBLICATION | Supercalendered-Retail Product: Kohl’s 4/12/11 Event Submitted by: RR Donnelley-Lancaster East Kohl’s, one of the most widely circulated retail pieces in today’s market, supplied high-quality digital files making use of our internal expanded gravure color space ICC profile. Produced on a state-of-the-art KBA press under a tight schedule, it posed unique challenges everywhere, from reverse type to complex crossover alignment, color balance, in-line press stitching, and a pop-up-section inside the book. Yet our skilled crews kept quality at a high level while meeting demanding schedules. The measurement of ink viscosity, ink temperature, and density controls were crucial to printing smoothly on supercalendered 32-lb paper that has a “coated gloss look.” This entry tied with RR Donnelley’s entry for Target 6/19/11 Event in this category. Printer: RR Donnelley Press Manufacturer: KBA Substrate Manufacturer: Norske Ink Manufacturer: Flint Group
CYLINDERS ALWAYS LOOK GOOD IN GOLD
Weâ€™re proud to join in congratulating the 2012 Golden Cylinder Award winners ... and even prouder to have produced so many of the projects that were recognized this year. With every program, for every customer, we work hard to spin cylinders into gold. GLOBAL PRODUCTS AND SERVICES books . business communication services . business process outsourcing . catalogs . commercial print content creation, management and distribution direct mail . directories . distribution, print fulfillment and kitting document outsourcing and management . e-business solutions financial printing and communications forms, labels and office products . global print and packaging supply chain services . logistics services magazines proprietary digital print technologies . real estate services . retail inserts . RFID and barcoding strategic creative services . supply chain management solutions . translation services
www.rrdonnelley.com Copyright K 2012 R. R. Donnelley & Sons Company. All rights reserved.
2012 Golden Cylinder Awards PUBLICATION | Supercalendered-Magazine Product: Ladies Home Journal – August 2011 Submitted by: NewPage Corporation Ladies Home Journal is one of the oldest woman’s publications currently in print. With a focus on Real Beauty at any age, this issue explodes with photography utilizing a wide variety of tones and color families, including soft flesh and dense garden stories that printed with exceptional contrast and detail. Page make-up included two and four-color editorial type and crisp reverse type that presented unique challenges in maintaining register with a consistent color balance. Color consistency was maintained by an inking system which closely monitors the temperature, density and viscosity of the ink during the print cycle. The color is constantly reviewed and adjusted as was the fold and lineup, which were also critical to maintain this consistent high-quality product. All the quality issues mentioned above, as well as a demanding production schedule provided a unique challenge for the printer. Designer: Robert O’Connell Separator: Meredith Content Center
Engraver: RR Donnelley Printer: RR Donnelley Press Manufacturer: Cerutti/Motter
Substrate Manufacturer: NewPage Corporation Ink Manufacturer: Flint Group
PUBLICATION | Lightweight Coated (Under 40#)-Magazine Product: Better Homes and Gardens – October 2011 Submitted by: NewPage Corporation No other magazine resonates with America’s families like Better Homes and Gardens. The body of this book was printed utilizing both the gravure and offset printing processes wrapped by an offset cover. The wide tonal ranges in this 232-page magazine encompasses everything from subtle flesh tones in light and airy editorials to heavy dense ink coverage found in some of the food and garden stories. The sharpness, detail and contrast in the images found within this book are exemplified by the gravure process. All pages present unique challenges from maintaining register to a consistent color balance throughout the press run. This is especially evident in the smooth and even tonal transitions throughout this magazine. Ongoing, meticulous measurement of ink viscosity, temperature and density is imperative for obtaining successful results on 38# coated paper. Fold and line-up were also critical in maintaining the integrity of this special product. All quality issues mentioned above coupled with a demanding production schedule provided a challenging environment for the production of this very special magazine. Designer: Michael Belknap Separator: Meredith Content Center Engraver: RR Donnelley Printer: RR Donnelley
Press Manufacturer: Cerutti/Motter Substrate Manufacturer: NewPage Corporation Ink Manufacturer: Flint Group
2012 Golden Cylinder Awards PUBLICATION | Lightweight Coated (Under 40#)-Catalog Product: Talbots “Wish & Tell” Holiday 2011 Submitted by: NewPage Corporation The catalog opens with an immediate challenge of carrying Talbot’s “signature red” color consistently across the opening spread, which had an offset cover form and a rotogravure body form. It also incorporated a perforated customer take-away offer on the gatefold cover flap, which increased the challenge, but also the effectiveness of the piece.
Designer: Talbots Creative Separator: Quad Graphics Engraver: Quad Graphics Printer: Quad Graphics Press Manufacturer: Cerutti Substrate Manufacturer: NewPage Corporation Ink Manufacturer: Quad/CRT
Opening with red and finishing with glimmer, the printing is in excellent register, and crossovers are well color-balanced and perfectly bound for a seamless read by the customer. Color range runs the gamut from intense (red) to almost pastel (light lavenders and greens) with a fair amount of neutral grays—and all colors are well matched to the original swatches. Black merchandise is rich, but allows for a good read of details. Flesh tones are natural and consistent. Paper printed smoothly, with no skip dots and a smooth ink laydown. Last year, Talbot’s moved from 34# to 32# on most of its catalogs, bringing postal savings and reducing paper consumption, which is an environmental plus. The catalog was printed four-color using process inks and gloss UV coating on the gate, front and back cover. Adding to the difficulty of this job was the heavy ink coverage and full-page bleed throughout the body, plus the small reverse type, which made registration critical. Thin reverse type is a challenge for the press, but using a high tech Autotron System proprietary to Quad/Graphics, the press is able to execute the highest quality register.
Jim Niemiec, NewPage Corporation with Hubert Metzger, Chema Technology president and Cylinder Society Chair, who made the presentations.
PUBLICATION | Coated (Over 40#)-Retail Product: jcpenney Direct Mail-Rebranding Submitted by: RR Donnelley-Warsaw and jcpenney This entry may look like a catalog, but jcpenney considers it a retail direct mail. Both RR Donnelley and jcpenney were mutual winners in the category. For many years, the prepress has been accomplished through the combined talents of RR Donnelley Premedia and jcpenney Color Systems. The rebranding process brought a significant change with all information very confidential. The new workflow consisted of fewer pages, but more critical images which required added attention to detail and a challenge to think outside the box to achieve quality enhancements. Further complicating things, two different printers and three different plants ran the job with different presses, binding equipment, workflows and specifications. A new paper was supplied, which had not been tested prior to live production. Using the 70 raster coated set-up achieved a good start-up. RR Donnelley included an eight-step brown scale into the press color bar, which allowed performing mini fingerprint tests, to tweak gradations prior to the next event. Additional color management included a color software program. The company had printed 60# gravure before, just not this finish or coating. There were some initial issues with smoothness and coating build-up in certain tones and color families. Another consideration to address in the pressroom was re-establishing and documenting new ink density targets for future jobs. The binding process was also a challenge. The crossover process was helped by moving 1/16â€? image from left to right and vice-versa in prepress. However, because of the time constraints, the pages were not rebuiltâ€”they were adjusted. Designer: jc penney Media Corporation Separator: RR Donnelley Engraver: RR Donnelley Printer: RR Donnelley Press Manufacturer: North American Cerutti Substrate Manufacturer: UPM-Kymmene Inc. Ink Manufacturer: Flint Group
2012 Golden Cylinder Awards PUBLICATION | COATED (OVER 40#) â€“ MAGAZINE Product: Cover Tobacco Journal #5-2011 Submitted by: Van Heertum Design VHD As a design agency, we keep in mind the technical possibilities during the design process and can guarantee that our designs will be no problem in the production phase. The first run was Iriodine Rutile Sterling Silver, a pigment that gives a metallic look to the ink that is printed over it in the offset stage. The second run used Iriodin 6103 Icy White together with the Securalic 6103 GT. The first gives a pearlescent effect and the second one is a hidden pigment that is only traceable with a special infrared light or with a special sound meter. This pigment is used for brand protection. The next run was the gold color on the front side, a combination of Iriodin 323 Royal Gold Satin and 325 Solar Gold Satin. To show the new Moog press is consistent, we did this run two times over each other and printed point-to-point; this also increased color intensity. The next run was a primer to get a higher result of the metallic effect of the silver. We did proofs before running production.
Designer: Van Heertum Design VHD Engraver: GRT GmbH & Co. KG Printer: H.G. Moog GmbH Press Manufacturer: H.G. Moog GmbH Substrate Manufacturer: Iggesund Paperboard Europe Ink Manufacturer: Siegwerk Druckfarben AG & Co. KGaA
The pallets with the print sheets were carefully packed and transported back to Germany for the last gravure part on the Moog machine. For run 342, we chose a silver coating that is a new and patented product from Henkel. MiraFoil is a special silver ink with tactile touch. The proofs showed the material brought onto the paperboard through the special photopolymer plates of the Flint Group. We did this in gravure. The image, the roof of the Olympic Stadium, was perfect for this option. This entry tied with National Geographic submitted by Quad Graphics for the category.
Achim Kurreck from H.C. Moog (left) and Frans van Heertum from Van Heertum Design VHD
PUBLICATION | Coated (Over 40#)-Magazine Product: National Geographic-Sept 2011 Submitted by: Quad/Graphics, Inc National Geographic Society prides itself on the brand which they have built over the last 123 years and expect perfection for the magazine. This issue demonstrates how this publisher moves away from the norms of gravure printing to differentiate itself from other publications. While traditionally the editorial pages use gravure printing to recreate photographs, this issue took some of the advertising pages and printed them gravure instead of offset. These included Toyota, Bridgestone, Chase and Energizer. Both offset and gravure pages are printed on a 50 lb coated #4 dual purpose sheet to minimize noticeable differences between the two printing processes.
Designer: National Geographic Society Separator: National Geographic Society Engraver: Quad/Graphics Printer: Quad/Graphics Press Manufacturer: Cerutti Substrate Manufacturer: Verso Paper Ink Manufacturer: CRT- a division of Quad/Graphics
Some features that make this issue unique are the deep rich black backgrounds that frame the photographs, the small reverse type sets and the wide range of stores and colors on the same set of cylinders. Some of the reverse type was designed with small fonts and fine serif fonts. The color reproduction was critical because each story had a different look and feel. In the Antarctica story, four-color process was used to reproduce the older black-and-white shots so they looked like the originals. The issue was well received and allowed Quad/ Graphics to showcase beautiful photography with high-quality gravure printing. This entry tied in this category with the Tobacco Journal Cover submitted by Van Heertum Design.
Ron Williamson, National Geographic Society (NGS); Bob Cedar, Quad Graphics; and Phil Schlosser, NGS with the National Geographic award.
2012 Golden Cylinder Awards PUBLICATION | COATED (OVER 40#) – CATALOG Product: 2011 Target Holiday Toy Catalog Submitted by: RR Donnelley/Scout Sourcing, Inc./ Target/UPM This entry was a mutual winner for all four companies: RR Donnelley/ Scout Sourcing, Inc./Target/UPM. Target: The tone and visuals of the Holiday Toy Catalog were very simple and clean, just like the aisles of Target, using lifestyle imagery to enhance products and the brand, with just enough “magic” to portray the season. The challenges were in marrying two different size formats (8.25x 9.8125” and 8.25x8.8.125”) and substrate weights (MyBrite 57.4# and 47.3#) for the catalog and coupon book to ensure one cohesive catalog while maintaining a bright and colorful look throughout and managing the logistics of numerous different versions that were delivered via Direct Mail, Newspaper and in-store. Myllykoski/UPM: The partnership between Myllykoski/UPM and Scout Sourcing, Inc. to supply paper for the 2011 Target Holiday Toy Catalog began during the Gravure Publishing Council Conference in November 2010 in Naples, FL. The more we discussed the project, the more sense it made to combine the strengths of both companies to help Target achieve their goal of a successful holiday catalog. Scout Sourcing: Our initial collaborative meeting with the Target Holiday Toy Catalog team covered most of the parameters of the
project. Numerous paper options were discussed and determined that My-Brite— a No.3 coated wood-free product with greater than 10% recycled content and PEFC certification, specifically designed for rotogravure printing— was a uniquely perfect fit. Numerous sample catalogs were produced with three different page counts and three different basis weights to establish look, feel and help calculate distribu-
Mutual entry winner for the Target Toy Catalog with Jan Lindquist, Target; Walter Vail, Scout; Nancy Walsh, Scout; Cathy Scalise, RR Donnelley; Deb Schuh, Target; and Craig Nelson, UPM.
tion costs. The final decision was to produce a 32-page catalog on 57.4# No.3 CWF, with a 20-page coupon book on 47.3# No. 3 CWF inserted in the catalog at the bindery, along with a gift card applied to the outer back panel. While Target reviewed the sample catalogs, Scout worked with the mill in Platting, Germany to establish production schedules to produce approximately 8,800 short tons of paper during mid-summer, and plan the logistics to deliver paper in a timely manner to three different Donnelley printing plants for a fiveweek printing window.
Press considerations: This job ran in three different facilities due to time constraints and reduction of distribution costs. Color was established quickly because we replicated density targets, ink viscosities and temperatures. This methodology and the gravure process created a consistent final product regardless of which facility the catalogs printed. Also, the gravure process allowed us to achieve a full range of color including fine highlights to bright saturated colors. One of the unique challenges was to match the color bars on each of the corresponding pages.
RR Donnelley: Regarding cylinder making, the engraving gradations and set-up was developed through analysis of supplied files and proofs utilizing brown scale analysis (L*a*B* readings). This process allows evaluating print characteristics, color families (ECI charts) and improves graduations based on customer inputs and historical data. Evaluation enabled us to adjust the engraving process to increase weight and color saturation. Weight has previously been a challenge with white-on-white images and fine lines including antennas on remote control cars and puppet stings. Gravure has a huge advantage in reproducing saturated colors due to superior ink trapping conditions on press which allow for detail in shadow areas that can’t be replicated in other processes. Finally, this job was engraved with Hell Klischograph K6 technology—a previous Golden Cylinder Award winner for supplier innovation.
Finishing: The distribution of this catalog included delivery to newspapers, as well as direct mail. Three fourths of the direct mail recipients received a gift card, which was applied to the back cover. This gift card had offerings that corresponded with the coupon barcodes contained in the catalog. The gift cards were Selectronically applied, along with the binding of the coupons, in order to deliver a more personalized offer, which simultaneously optimizing postal savings. Designer: Target Engraver: RR Donnelley Printer: RR Donnelley Press Manufacturer: North American Cerutti Substrate Manufacturer: Myllykoski/UPM Ink Manufacturer: Flint Group
The Gravure Association of America (www.GAA.org) The Gravure Association of America (www.gaa.org) provides information about all the GAA activities at your fingertips, as well as updates on what is going on at the Gravure Education Foundation (GEF). Some of the highlights of this valuable resource include: • Gravure Magazine 2012 Buyers Guide, which contains comprehensive information about companies in all segments of the gravure industry—including packaging, product and publication printers. Equipment and materials suppliers are also listed, as well as gravure training programs and educational institutions. • Current and archived issues of Gravure Magazine, the only technical trade magazine that’s dedicated to the publication, packaging and product gravure process. • A comprehensive search engine with the complete library of all GAA’s whitepapers, and other pertinent technical information • An internal social networking feature that will enable you to connect with GAA members through forums, blogs and classified ads. You'll be able to share ideas, ask and answer questions, and exchange information.
These new online services and GAA social networking capabilities are available only to members. You can obtain information about becoming a member on the website. GRAVURE/Fall 2012
2012 Golden Cylinder Awards TECHNICAL INNOVATON | Image Preparation Prior to Engraving Product: Nescafé Classic Submitted by: UKRPLASTIC URKPLASTIC has developed and patented new software that allows avoiding local moiré in light and dark tones. Due to the use of fuzzy logic elements (fuzzy models) under certain raster filling parameters in each CMYK color, the screening algorithm automatically changes from regular to FM screening and vice-versa without additional intervention of the prepress engineer. Thus, press parameters are automatically considered at regular screening, such as dot gain, corners of rasters, and the parameters are then changed for FM screening. All parameters are received earlier at equipment testing (fingerprint). From previous experience it is known that the situation when, for example, C = 0%, M= 10%-15%-20%, Y= 20%-30%, K- 30%-40%-50%, there is a danger of moiré occurrence. Such and similar situations are called “special.” The program automatically finds “special” situations and transforms color separation file. The method has been tested and has shown positive result.
Oleksandr Galkin from UKRPLASTIC
TECHNICAL INNOVATION | Cylinder Manufacturing Product: Dirol Submitted by: UKRPLASTIC The offered entry has been developed by Kraft Foods Company and prepared for printing by UKRPLASTIC. This sample shows unsurpassed quality of a stochastic screening in rotogravure printing which leads to a completely new use of this method for file processing. Size (line thickness) of the tests, received by stochastic half-toning, is 0.07-0.09 mm. This is, practically, a micro-text, received due to absolutely even line edges as a result of a joint work of stochastic half-toning and laser exposure. Recently, the requirements to the information placed on foodstuff packing have become more stringent. The printers that print in rotogravure on non-absorbing materials experience difficulties because of ink spread, uneven edges of lines, etc. It is due to stochastic halftoning that this complicated problem has been solved.
Oleksandr Galkin from UKRPLASTIC
2012 Golden Cylinder Awards TECHNICAL INNOVATION | Inks and Substrates Product: Solid Gold-Barking at the Moon 28.5 Submitted by: Fres-co System USA Solid Gold selects ingredients from around the world to provide premium sustenance for our canine and feline family members. The expectation of excellence is met by the features of this package and by the superiority of the gravure printing process. Separations accommodate the combination of clean bright solids for banners and text along with the soft features of the painted process illustrations amid fading stippled shadows to create warmth and engage the consumer. “Barking at the Moon” sparkles like the night sky even in the light of day through the utilization of transparent inks and a holographic substrate. This item reverse prints on a clear poly in seven tightly registered colors and laminates to three additional structures along with a registered water-based, solventless, glossy anti-skid which is surface printed in gravure on the outside. This process is completed in-line in a single pass. The valve on the finished package allows compression to stack and palletize which allows for a space reduction in shipping while the nearly invisible anti-skid feature keeps the packages from slipping off one another. Gravure printing lets Solid Gold’s “Barking at the Moon”…shine. Designer: Visual Solutions Separator: Fres-co System USA, Inc. Engraver: Southern Gravure Printer: Fres-co- System USA, Inc. Press Manufacturer: Cerutti Substrate Manufacturer: Fres-co System USA, Inc. (printed poly) Ink Manufacturer: Siegwerk Ink/Sun Chemical Corporation
Trish Goffredo accepted the award for Fres-Co System USA, Inc.
TECHNICAL INNOVATION | PRESS Product: Sears Canada-Soft Proofing Submitted by: RR Donnelley-Warsaw Sears Canada, PI Media and RR Donnelley have expanded the soft proof workflow from a prepress proofing process to press proofing with no workflow changes for either Sears Canada or PI Media. PDFx1A files are supplied to RR Donnelley as final files and used for soft proofing. Sears Canada gradations were developed through press fingerprinting before production, to minimize variations between the file and production press. In addition, an eight-step brown scale is incorporated into press color bar on every press form to allow mini fingerprint tests. Additional color management includes a color software program. The majority of Sears Canada forms run on the three-meter presses capable of delivering up to 144 pages at once or three 48-page signatures. Because gravure is a stable and predictable process, the soft proof workstations are â€œnear pressâ€? rather than on press. This allows the company to optimize the availability to more presses and ensure color stability by providing a more consistent temperature and color controlled environment. While soft proofing is not new to the industry, this use has an unexpected twist. Soft proofing allows moving the printing from Canada to the US, expanding international markets. This eliminates a two-day delay in US customs for hard copy proofs. Using the system, the company ran 114 gravure press forms totaling 18,144 pages and saved approximately 228 days from the production cycle because of the elimination of hard copy proofs. It also saves materials and energy, which went into making hard copy proofs. Designer: Sears Canada Separator: PI Media Engraver: RR Donnelley Printer: RR Donnelley Press Manufacturer: North American Cerutti Substrate Manufacturer: UPM-Kymmene Inc. (Primary supplier, due to volume of paper needed, some supplied by Verso and NewPage Corporation Ink Manufacturer: Flint Group
2012 Golden Cylinder Awards TECHNICAL INNOVATION | Packaging Product: Overprint on Already Printed Packaging Submitted by: Rotoprint Sovrastampa SRL The company specializes in modifying already printed packages (allowing the recycling of the same) either in tetrarex, elopak, combibloc, cluster, cases, blisters, microwave boxes or in any kind of reels, single or multi-layered. Our specialization enables us to create personalized mock-up, change EAN codes, prices, weights, expire dates… modify ingredients, names of product inside packaging, corporate names, add the product tracing, EEC labels, PaO, promotional advertising, “Scratch & Win,” transform the basic image of the packaging and so on. Its customers include Alcan, Amcor, Chiquita, Coca-Cola, Henkel, Masterfoods, Danone, Del Monte, Kraft Food, Nestlé, Royal Canin, Parmalat, Procter & Gamble, Unilever, Reckitt & Colman, Manetti & Roberts, Tetrapak. This overprinting offers a wide range of benefits: reuse updated stock material; update packaging graphics, law inscriptions or product ingredients; postpone purchase of new materials; avoid further weight on the ecosystem; save transport; and save disposal costs.
Giancarlo Arici (left) and his son Giovanni Luca Arici from Rotoprint Sovrastampa SRL.
IN MEMO RIA M
Warren Robert Daum 1914- 2012
Warren Daum, former President of the Gravure Technical Association and founding president emeritus of the Gravure Education Foundation served the Gravure industry for more than 45 years. He established alliances and partnerships between corporate leaders and educational institutions leading to International conferences, educational seminars, industry textbooks, and the publishing of Gravure Magazine. Honorary appointments included: Industry Advisory Council for Rochester Institute of Technology’s School of Printing Management and Sciences, where he was advisor to the Dean of the College of Graphic Arts and Photography and Director of the School of Printing; Drexel University, College of Media Arts and Design; and Fairleigh Dickinson University. Warren’s love of learning began at Columbia Grammar Preparatory School in NYC; he earned a Bachelor of Science in 1936 from Brown University, a Master’s in Psychology in 1940 from Columbia University and attended the Harvard Business School for leadership training. Together with Barbara Birkett and Miles Southworth of Graphic Arts Publishing, Inc., Warren co-wrote “Leadership: A Quick and Easy Guide” for the printing industry. Warren proudly served his country in World War II as a U.S. Navy Lt. Commander from 1941 to 1945. He was last commissioned as a Supply Officer aboard the U.S.S. Makin Island in the Pacific Theatre. Warren volunteered for many civic organizations starting with the Lawrence Public Library and The Peninsula Counseling Center. In the 25 years he lived in Concordia, he volunteered for many committees which reflected his hobbies: Cribbage, Gardening/Grounds, Library, and Astronomy. He held memberships at Congregation Etz Chaim in New Jersey and Temple Emanuel of New York City. He supported numerous religious, veteran, health, and educational organizations. As a life-long avid swimmer, his last swim was at the Concordia olympic pool just a year ago. Warren loved animals including his many dogs: Buddy, his childhood Airdale; Sindy and Magoo in a long line of Beagles; and his adoring cats Kaji-San and Lucky Lady. His devoted family and friends wish him well on his next adventure, sending him off with love in their hearts. His daughters JoAnna Daum and Leslie Daum, his grandchildren Geremy Rheinwald (Brittany) and Aleesha Rheinwald, (Matt); his cousins Stephen and Ellyn Kravette and their families, the Fritschi Family, his companion Ellen Sonnenfeldt, and John Pancisin, his special “ buddy,” who cared for him these last few years. He joins his beloved wife Joan Daum with whom he shared a 53 year marriage, prior to her death in 2001
The following is from Flavio D’Andria, who joined the Cerutti Company in 1976 where he remained until retirement at the end of 2007. He notes that he visited the United States extensively, initially as Sales Area Manager and then as personal assistant to Mrs. Tere Cerutti, Chair Person of the Company and Trustee Emeritus and European Delegate of the GEF. He had been consistently exposed to the U.S. Gravure industry and developed excellent business and friendship relations. Among the persons he really enjoyed to be related with, a special one is Warren Daum and therefore he relates this memory.
In memory of Warren Daum
It is difficult for me to put down in writing and in a language which is not my original one, feelings that originate from the deepest of my heart. But Warren deserves this effort. I probably met him for the first time in 1978, two years after joining the Cerutti Company, when I started to assist Madame Tere Cerutti in her frequent and well-liked visits to the States. That was the time of the G.R.I. and G.T.A. Meetings when Warren’s vision of promoting the gravure process and supporting its education was very close to become a reality. An endless mission he pursued with all of his strength and across his nation’s borders. I always admired in this charismatic person his determination, passion and respect for people. He taught leadership but has been a bright example of humility. Dear Warren, somewhere Joan and many of your friends including Tere are waiting for you to join them! You have managed to create the Gravure Person of the Year award but for me, besides our unquestionable and unlimited friendship, you have been and remain the Gravure Person of the World. For ever! Peace be with you!
E-Boss By Gary White
new development for embossing of film, foil, paper, and plastics has been introduced by Pamarco Global Graphics, Palmyra Division utilizing the company’s proprietary electronic micro-embossing technology. This unique method is ideal for light embossing applications achieving textures of 0.0045” or less. Traditionally, mill fabrication and subsequent mechanical engravings were required to emboss designs. This specialized method of creating embossing designs, eliminates these steps, which in turn can save cost and dramatically reducing lead times. Traditional engraving tool development requires an expert craftsman to hand cut a new pattern into steel. From his “skeleton” tool, several transfers are required before the final engraving mill is completed. This procedure takes several weeks, and it is quite expensive. A bigger problem is that the sheer number of trained die cutters in this country has been reduced to a dimin-
Image showing positive and negative areas.
ished few. Apprenticeships and training for these skilled positions virtually stopped replenishing in the late 60’s and 70’s, so the level available and the actual number leaving the industry are significant. Development of new embossing designs primarily turned to laser technology. With its inherent ceramic surface roughness limitations and the aggressive nature of that surface against certain substrates, laser technology has restrictions for embossing. While less expensive and faster than die cutting, this technology is slower and generally more costly than the new electronically cut generation of engravings.
Sample card embossed via the new EBOSS method.
The technology is geared specifically for labels, decals, diaper film, food and medical packaging products, cigarette packaging, vinyl table coverings, book covers, and a multitude of other items requiring decorative or personalized surfaces. The high cost of traditional embossing and the exceptionally long lead times discouraged many companies from considering embossing as a means of product differentiation in the marketplace.
The new technology enables product customization, which was never before obtainable in the industry. Images and type can be incorporated in textured patterns for the first time utilizing this technology. Logos and product names in positive or negative lettering, in raised or lowered patterns are also available for the first time on an embossing roll. That makes this technology ideal for anti-counterfeit efforts as well as for customization of confectionary, distilled spirit, and pharmaceutical packaging. The company developed the technology because it believed that potential users of this new technology will realize an increased marketplace competitive advantage, incorporating specific label branding, anti-counterfeiting methodology, and a unique approach to texturing their product. Can you imagine for example, a beer label that not only turns
Image of a plate for a cigarette package, and detail image of that plate
Detail of an embossing plate
the mountains blue when it’s cold, but the tactile experience of feeling the raised mountains on the label as well? This technology is highly adaptable to existing manufacturing operations, and in some cases, Pamarco has been able to form matched base products.
Welcome to the Electronic Age
While traditional embossing cylinders have always been associated with considerable expense and long processing delays because of both the initial tooling development and subsequent engraving process - the new Pamarco emboss procedure greatly reduces both items. Design creation now has become a function of pure electronic programming and development – each phase of that development customized as required through a highly developed computer program thereby eliminating the need for hard tooling, manufacture, and subsequent rework—a huge time and cost saving to each order processed. After the initial embossing concept is close to finalization, a series of test engravings can be performed for approval prior to creating the final embossing cylinder again, time well spent before press trials or production. Test engraving can normally be accomplished within 5-7 working days per test which allows for timely development and an overall comfort factor not seen in the normal embossing world. Once final approval is gained, a production cylinder can normally be engraved and shipped 7-10 days after authorization to proceed. In addition, the new method is a highly repeatable process, easily duplicated from cylinder to cylinder; there is no hand creation and back-and-forth from master mill to casting— all of which is subject to human variance. Repeat engravings are a one-to-one exact replica of the original. This is an advantage of the electronic era and one realized for all our cylinders. Re-engravings can be processed in 7-10 working days in most cases”. In essence, the company has brought to market an embossing process that offers light weight manufacturers entry into a market they may not have been able to consider due to cost and time constraints. In general, Pamarco is able to customize a package with an embossing cylinder that will run in register, in-line if desired with the print cylinders using the original design file that created those gravure cylinders. Imagine each label or wrap specially made with a very imaginative embossing feature or anti-counterfeit device tailored to a specific request. Gary White is Plant Manager of Pamarco Global Graphics, Palmyra Division.
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Putting an End to Patchwork Prepress By Carol Werlé
rinovis was founded in 2005 with the merging of three gravure printing arms of Bertelsmann’s Arvato, Gruner + Jahr AG and Axel Springer AG. It is now Europe’s largest printing enterprise and delivers magazine, direct mail and home shopping catalogs, and custom-made communication solutions. Prinovis’ 3,800 employees operate out of four facilities in Germany (Ahrensburg, Dresden, Itzehoe and Nuremberg) and one in England (Liverpool).
ES provides an extremely realistic and accurate view of a magazine.
Prinovis is hoping that its customers will give them an approval with a soft proof—a ‘certification’ to go ahead; that if Prinovis adjusts the press to the ES soft proof, the customer will certify that Prinovis can continue without further approval. It would be a big benefit in the consumption of time and eliminating costs during the production process.
When Prinovis was formed, the company’s prepress process was like a patchwork quilt, with each facility having its own system, explains Roger Schwarz, Chief Information Officer, Prinovis. “The imperative was to find the “one innovative, modern system that will give us a standardized environment, letting us centralize prepress and IT support for the company,” notes Schwarz. “We were using TWIST, as well as other systems, modules, and our own written programs. We want to reduce the number of components we use, reduce the number of providers we deal with and thus, reduce costs.”
A plan for prepress
The prepress plan is to use Hell Gravure Systems’ software to drive engravings for the gravure cylinders and Dalim Software’s TWIST Engine and ES for everything else. Prinovis is looking to upgrade its older version of TWIST to the newer TWIST Engine 3.0, and
extend its use of the system—which will continue to initiate jobs internally out of the workflow, converting customers’ data into the TIFF file format used to engrave gravure cylinders--with ES, allowing color-accurate virtual and remote soft proofing and realtime collaborative project management via a standard web browser. ES and TWIST combine to bring sophisticated and fast approval cycles to a fully automated prepress process. At press time, Prinovis was about to go live in Dresden with the ES/TWIST Engine server. The plan is then to go live in Itzehoe within two months, and then onto to Liverpool and Nuremberg. “Our target is to implement a consistent, centralized prepress system based on ES TWIST 3.0,” says Schwarz. “The Dresden workflow will be our role model of the system we want to implement companywide—a system that is standard, harmonized, and centralized.” Currently, Prinovis is using ES and the DIALOGUE Engine in magazine approval cycles. Although ES TWIST system is not yet in full production, Schwarz is seeing productivity improvements already. “Our file processing is about 20-30% faster, but it is the amount of resources we’re expending for the same production volume that is important,” says Schwarz. “The number of full-time employees that are needed in the prepress environment has already decreased— about three-to-four per site. It is essential that we are able to build a well-automated system with fully configurable customer job structures and the ability to easily
Prinovis’ target is to implement a consistent, centralized prepress system based on the Dalim Software and TWIST solutions to drive TIFF data to all of its gravure presses, including Liverpool (gravure cylinder engraver in Liverpool pictured here).
PREPRESS view job status. Only with this system, utilizing TWIST Engine and ES, have we been able to free up a good amount of manpower for other prepress tasks within our plants.”
Driving soft-proofing use
One of the goals is to use ES to drive the use of soft proofs for color adjustment of their presses instead of hard copy proofs. So, customers won’t have to pay for the more expensive hard copies, and they are able to approve the pages directly in the Prinovis system. Prinovis can use this exact data for engraving, printing and color corrections. “We are hoping that our customers will give us an approval with the soft proof—a ‘certification’ to go ahead; that the feeling is ‘if you adjust the press to the ES soft proof, we certify that you can continue without further approval or notice,’” says Schwarz. “For us, that is a big benefit in the consumption of time and eliminating costs during the production process. Especially with periodicals, that time-savings is important.”
Prinovis is already finding targets where the new Dalim Software system will be of considerable assistance. “There is a high demand for exceptionally accurate, true-life colors in advertising for fashion magazines,” comments Schwarz. “Two publishers, Bauer (10 magazines per year) and Klingel (79 magazines per year) require two million copies per issue. Given the number of hard copy proofs we created for all of these issues, we see softproofs reducing costs.” “We also produce all issues from the publishing house Wort und Bild,” adds Schwarz. “With our remote softproofing and online approval system, producing 64 issues comprising of 170 million since last spring, we have been able to eliminate our need for press proofs.” For Schwarz, who comes from the banking industry, the experience of trying to harmonize a workflow that was so disparate has been unlike anything he had envisioned.
Connect. Collaborate. Innovate.
Working directly with Dalim Software was one of the high points. “They were responsive, and they’re open to new and different ideas without losing sight of the need to produce a product,” he says. When Schwarz began working at Prinovis a little over a year ago, he was given the mandate to not “do anything but finish the project—and we did it!” he asserts. “When we started, there were some target goals for efficiency, which we’ve surpassed—that is why we are taking it to the other sites.”
Dr. Carol Werlé has directed DALIM SOFTWARE GmbH since the company’s capitalization as a software manufacturing company in 1999. Obtaining a doctorate in Physics from the University of Strasbourg in 1985, Carol joined the company, then known as DALiM GmbH, in 1987 as its first Support Engineer. His first contact to the Graphic Industry was through Siemens Medical Imaging in Erlangen, Germany and goes back to 1984.
Graphic Communications continues to invest at a time when many companies are cutting back. As one of the world’s largest independent paper and print media consultants, we’ve expanded our specialties and adapted innovative technologies with our parent company, Unisource Worldwide, Inc. We work with the industry’s finest suppliers to create customized paper and print platforms, environmental paper, printing and packaging solutions, and branding programs that elevate the image of our national and global clients. And that’s just part of our story. We’ve spent millions on world-class systems that help our partners drive compliance and success companywide. In a way no other marketing communications expert can, GC delivers the knowledge and data essential to optimum paper and print media management.
Graphic Communications is a Proud Continuing Sponsor of the GPC I 866-650-5522 I www.graphiccommunications.com GRAVURE/Fall 2012
European Publication Gravure Award 2012
nce again this year the European Rotogravure Association held the European Publication Gravure Award in conjunction with the Eurographic Press, the leading printing trade magazines in sixteen European countries. The judges were Jürgen Fischer - retired gravure print manager; Eddy Hagen - Vlaams Innovatiecentrum voor Grafische Communicatie (VIGC), the Flemish Innovation Center for Graphic Communication; Bernhard Niemela - Editor-in-Chief, Deutscher Drucker (for Eurographic Press); Brian Reynolds - former Managing Director, Sun Printers. The awards were presented at the ERA Annual Conference, held in Turin, Sept. 24-25. According to Fischer, a long-time judge, the standard of entries was increasing, and this made the job of the judges ever more difficult. Three awards and five commendations were given in the four different paper classes plus the Innovation Prize category: IMPROVED NEWSPRINT (News-Std, News-Plus, Directory) Two commendations • COMMENDATION NewsPlus paper SuperBest wk 8ROTO SMEETS DEVENTER • COMMENDATION NewsPlus paper Praxis nr. 18 ROTO SMEETS DEVENTER UNCOATED/SC PAPER (SC-B, SC-Std, SC-Plus etc). One Award • WINNER SC paper Quattroruote 6/2012 EUROGRAVURE SpA LWC PAPER (less than 70 g/m²) One Commendation • COMMENDATION LWC Paper Bunte 16 BURDA DRUCK GmbH
COATED PAPER (70 g/m² and over) One Award • WINNER: MWC paper Vermögensberater 2/12 BURDA DRUCK GmbH INNOVATION PRIZE for new techniques or fields of application. One Commendation, one Emerging Technology Award • COMMENDATION Innovation Prize Thin Parts Fixer ESKO • WINNER Emerging Technology Prize; Helio Brushing hsa HELIO SERVICE AHAUS
Burda won the category Coated Paper: Christophe Barth of Burda received the Trophy from ERA Secretary General James Siever (l).
SPECIAL COMMENDATION for wide web. One commendation • COMMENDATION Wide Web (over 3,6 m) Saturday Telegraph 28.04 POLESTAR UK PRINT Ltd
Next opportunities for participation in the Gravure Award (open to both members and non-members of ERA): • ERA Packaging Gravure Award 2013 (in cooperation with G&K TechMedia) • European Publication Gravure Award 2014 (in cooperation with the Eurographic Press) Since its foundation in 1956, the European Rotogravure Association (E.R.A.) has developed into the leading international organisation of the gravure industry. It currently has some 90 members worldwide, from the publication, packaging and decorative printing sectors, as well as associated industries such as paper and ink makers,
Mauro Cosani (center) of Eurogravure received the Trophy as winner in the category Uncoated/SC Paper
Alfred Schley of hsa Helio Service Ahaus, winner of the Innovation Prize.
printing and finishing equipment manufacturers, the leading cylinder engravers, and some major print buyers.
P R O DUCT S CATALYSTPAPER.COM
Madern Offers Revo-Line Rotary Die-cutter
TODAY’S PAPER HAS IT COVERED. Catalyst manufactures the very paper that is most in demand today. Our top quality, lighter basis weights make us a one-stop paper supplier for printers, publishers and major retailers the world over. Our products range from book grades and newsprint, to prestige grades for glossy brochures, catalogues, retail flyers, magazines and everything in between. We manufacture smart, sustainably and economically. It remains a paper world – and Catalyst is a paper company of today – meeting your needs now and in the future.
Madern USA has introduced the Revo-Line, a new versatile rotary die-cutting concept. The base frame is manufactured from a special stone cast material, which is less sensitive to temperature changes, and will reduce vibrations compared to cast steel or iron. While the modular design enables flexible options, the Revo-Line is also available as a single converting station using combined rotary cutting and creasing converting tools. The upper and lower converting tools are mechanically coupled and can be completely adjusted or set off-line with a special make ready set. The Revo-Line calls for top loading with a dedicated installed overhead crane. Whilst the alternative, the Revo-Line Pro, makes use of an additional top frame quick change-over feature, to enable changeover from the top or sliding the complete module out, eliminating the need for a dedicated overhead crane. The Revo-Line Diecutter combined with the Value Series cutting tools will be one of the most competitive rotary die-cutting solutions.
K. Walter Offers Helio®Zinc Alkaline zincplating processes that are currently available on the market only offer low currentdensities of 8 A/ dm2. They are difficult to handle as well as to set up. With Helio® Zinc, K.Walter presents an acid zinc-plating process free from ammonia. The process offers high plating performance and a much simpler system. The process works on current densities from 10 – 30 A/ dm² with 50% immersion. Helio® Zinc dissolves the metal in the anode basket and does not require an external dissolving unit like common alkaline processes. The system is much like a conventional copper plating tank. The anode material has to be added to the basket on a regular basis. Helio® Zinc does not require an external freez-
P R O DUCT S ing unit for carbonates. The electrolyte works free from sodium hydroxide and ammonia. The process requires only one additive to maintain the electrolyte. The additive contains both hardener and brightener components. Common alkaline zinc-plating processes require 3 to 4 different additives to achieve stability in zinc-plating. The plated layers have much better corrosion resistance and higher Vickers readings than alkaline zinc products. Helio® Zinc is ideal for direct structuring. Digilas, DLS and Cellaxy have been successfully tested on acid zinc layers. Zinc as a material offers higher material removal rates with lower laser power compared to copper. Helio® Zinc assures smooth chrome plating on engraving depth of up to 1500µm.
Dalim Software Highlights ES 3 and DVL During Graph Expo 2012, D A L I M SOFTWARE highlighted the latest release of its online production management, ES (Enterprise Solution), which includes a redesigned user interface, making it easier to access, manage, control, organize, and sort projects and files. Some of the features include: A check in/check out tool that takes the worry out of managing multiple versions; and Project Data Management, which creates subdirectories that organize project content—such as text and pictures— into meaningful, descriptive folders. This latest version of the ES platform also includes a PDF-enriching option, and an API for easy connectivity with third-party applications. Combined with the Virtual Library (DVL), the solution lets users turn print-ready Pdfs into interactive, browser-based HTML 5 flipbooks. Part of ES, DVL is a page-turning application providing real-time access to a realistic publication ‘look and feel’, even simulating paper grades, for softproofing review and approval before a job is printed. Dalim Software also showed TWIST and DIALOGUE engine enhancements. TWIST is as much as four times faster, bringing higher levels of workflow productivity. A new feature allows users to automatically compare versions of a document with the control to stop the workflow process if a problem or difference is found. DIALOGUE Engine supports the Just Normlicht viewing booth, for better control when soft proofing during a press check. When the user opens a file in DIALOGUE Engine, the system will control the brightness of the viewing cabinet and match the image on the monitor with the one on the cabinet.
Hybrid Software Showcases Lifecycle Print Management Products At Graph Expo 2012, Hybrid Software showcased its range of Order Lifecycle Management (OLM) software solutions. Developed to provide easy, comprehensive connectivity between web-to-print, MIS, and production systems, OLM software solutions can help streamline production and improve production efficiencies. Hybrid Software’s OLM products address the entire production workflow, from online ordering to delivery, integrating with most popular MIS systems, databases, and production systems. Rather than requiring extensive, customized software development from IT consultants, Hybrid Software solutions provide “integration as a product”—all the tools to make the process easier for in-house IT departments to map data and implement cohesive production systems. One of the new applications was Pipeline v2.0, an integration application that allows users to easily share job information from a wide range of otherwise disparate and disconnected graphic arts production systems, such as web-to-print portals, MIS/ERP systems, and premedia workflows. Pipeline v2.0 connects directly to third-party applications that use databases and makes it possible for users to share data from each system to avoid duplication data entry. Hybrid Software also demonstrated its new Taskforce Scheduler, a highly configurable scheduling system for prepress and graphics production that integrates with MIS and ERP systems to download a feed of jobs and due dates. It then maps available resources to ensure that the jobs are produced on time with the available manpower and equipment.
GMG Americas Offers Color Management Solutions During Graph Expo 2012, GMG Americas showcased solutions for the color management and proofopenColor ing of a wide array of print. On display were two solutions introduced at drupa: GMG OpenColor, a revolutionary spot color tool for labels and packaging, which greatly extends color control and repeatability; and GMG CoZone a comprehensive cloud solution for professional media and color management users. GMG OpenColor creates high-quality multicolor profiles that simulate the printing behavior of diverse print-
P R O DUCT S ing technologies, media types, and screens—if necessary, without use of “proprietary chart based” press fingerprinting. While the increasing use of multicolor printing reduces the amount of press units used by assuring accuracy to the necessary spot colors, there must be the ability to simulate spot color overprints, a big challenge for printers. GMG OpenColor addresses this complex problem, resolving CPC color accuracy expectations across different printing processes and numerous converters. It analyzes each ink color and substrate, applying them to a specific printing process (flexo, offset, digital, gravure). Then process-specific information is added (ink rotation, trapping, etc.), and the final press condition is simulated. If needed, OpenColor can create a profile with very few color wedges automatically on the fly—step scales of spot colors on the substrate. Adding additional overprint readings increases accuracy. OpenColor supports up to 15 colors, is offered with standard targets, and is compatible with Equinox, Hexachrome, and other multicolor technologies. CoZone is GMG’s new, modular cloud-based tool for companies across the entire print supply chain. It’s a flexible, modular-based business model, without the need to use expensive local hardware or software, appeals to small agencies as well as large corporations. With CoZone customers can let people collaborate on files without additional investment in infrastructure and support. In its first release CoZone.Collaborate is available for collaboration and approval of PDF or image documents.
Dow Corning Offers PS Solutions The pressure sensitive products are designed to help label, tape and non-stick packaging manufacturers improve performance, increase productivity, control costs and oper-
ate more sustainably. These include: Syl-Off® brand water-based solutions for coating films and non-stick packaging; and low-adhesion PSAs for protective films and tapes. Syl-Off® emulsion coatings for non-stick packaging provide a tough, durable and water-repellent surface for foodgrade release and packaging paper applications. Thermal-cure silicone Syl-Off® emulsion coatings for films are unique emulsions with low and stable release profiles that can add value to finished products. They also offer the potential for low coat weights and can be applied to PET either in-line or off-line. Dow Corning® brand hard-coating solutions give surface-protection films greater durability and hardness while maintaining high transmittance. Designed for use on PET films, these innovative solutions offer superior anti-graffiti performance and ink repellency, plus better grease-removal capability.
THE PATH YOU CHOOSE IS AS IMPORTANT AS YOUR DESTINATION
TOWARDS A SUSTAINABLE FUTURE
At Resolute Forest Products, we have chosen the path that leads to a sustainable future. And with all of our managed woodlands certified to internationally recognized forest management standards, we have a big head start. We are also one of the world’s leading recyclers of old newspapers and magazines, and have made significant strides forward in reducing our greenhouse gas emissions, as well as in the development of environmentally friendly products. But we know we can do even better. We have stepped up the pace, identifying ambitious new objectives for responsible fiber sourcing, action on climate change, product stewardship and stakeholder relations. Resolute is proud to sponsor the GPC Conference in November.
Learn more about our commitment to sustainability at resolutefp.com
C O NF ERENC E
ERA Annual Conference in Turin
he European Rotogravure Association’s Annual Conference took place in September in Turin, Italy with more than 100 representatives from publication gravure printers, the supply industry and print buyers attending. The conference included a visit to OMG Cerutti in Casale Monferrato and Vercelli where the latest gravure press technology such as the newly developed Aurora press was explained. On the occasion of the conference the ERA members also elected a new president: José María Camacho, CEO of CirclePrinters will lead the organization of the European gravure industry for the coming three years. Some of the highlights are outlined below. The conference started with a keynote address by Stefano De Alessandri of Mondadori, Italy’s leading media house. Under the headline “Print vs. online in publishing – will the printed magazine disappear?” De Alessandri described how the media market has changed and hit the traditional print media. Whereas magazine and newspaper circulations have dropped during the last four years, internet access through new devices such as smart phones and tablets have increased, and thus online audiences have grown by almost 10 % in 2011 alone. The advertising market also shows a strong inclination towards internet-based media to the cost of traditional print. However, he is convinced that magazines will not disappear as their growth potential particularly in the emerging markets is not exhausted. Next was Stefan Svensson of IKEA who talked about the new role of the IKEA catalogue. From an initial print run of half a million, the catalogue is now delivered to over 200 million households and is read by more than 500 million potential customers. Whereas the catalogue is still IKEA’s main tool to drive traffic into their stores, the number of visits to their web site has grown to over 900 million per year. This has led to a redesign of the catalogue which has developed from a mere illustrated list of products towards a lifestyle magazine with a changed format and higher paper quality to give it a more glossy appearance. The high print run of their catalogue will further grow when markets such as Brazil, Mexico and India open IKEA stores, which will continue to favor gravure. The potential of gravure printing in emerging markets was shown by Christophe Barth of Burda Druck who presented Burda’s joint venture in publication gravure with Hindustan Times in Noida, India. After a challenging beginning due to the
Former Italian finance minister Prof Domenico Siniscalo gave a fascinating insight on the current euro crisis.
Stefano De Alessandri of Mondadori, keynote speaker of the conference.
different cultural background in India their plant is now in operation and fully loaded. The Indian market is rather interesting for gravure: main segments are business magazines, annual reports, newspaper supplements, catalogues and school books. A yearly growth of the print market by more than 10 % is expected. Three speakers discussed different aspects of the printed catalogue in distance selling and retail trade, where online is increasingly challenging print. Dr Bernd Vogt explained the benefits of the printed catalogue for the mail order industry. Former ERA President Giorgio Ferraris described the central role of the catalogue in communication. He showed the example of the Italian furniture company Modo Convenienza which has launched a gravure printed catalogue: altogether eight catalogues with in total 80 million copies per year are distributed to the Italian households. Dr Kai Hudetz showed examples of side-effects of the online revolution. One is that social networks lead to loss of control over brand presentation. ERA’s Annual Conference 2013 will take place September 30- October 1 in Germany in the Frankfurt region
We want to see YOUR company in the 2013 BUYERS’ GUIDE! iation of c o s s A e Gravur America uide Buyers’ G re u v ra G 3 201 A.org
www.GA e: ories includ ide Categ Buyers’ Gu s cie an nsult Industry Co lies ces & Supp rkflow Servi Digital Wo ces rvi lated Se Gravure Re nt & Equipme Machinery lies ols & Supp To s, de Bla nts ngs & Pigme Inks, Coati Substrates er Fib & r Pape bstrates & Plastic Su Film, Foil rs nte Pri g Packagin nters corative Pri Product/De rs nte Pri n Publicatio & Training Education
The only uide Buyers’ G for the Gravure Industry!
A diverse spectrum of companies helped us compile the 2012 Buyers’ Guide, the only gravure-specific directory of its kind. In this guide you’ll find information about companies in all segments of the GRAVURE industry — including packaging, product, publication and specialty printers. Equipment and materials suppliers also make a strong showing, and we’ve included a section on gravure training programs and educational institutions. The 2013 Buyers’ Guide will be published in January 2013. CLICK HERE to obtain a form, and return it as soon as possible to Sue Schippits at SSCHIPPITS@GAA.ORG or via fax to 201-523-6048.
Buyers’ Guide Categories include: • • • • • •
Industry Consultancies Digital Workflow Services & Supplies Gravure Related Services Machinery & Equipment Blades, Tools & Supplies Inks, Coatings & Pigments
• Paper & Fiber Substrates • Film, Foil & Plastic Substrates • Packaging Printers • Product/Decorative Printers • Publication Printers • Education & Training
To access the 2012 Buyers’ Guide, go to www.gaa.org. For Questions or suggestions regarding the Buyers’ Guide, please contact Sue Schippits at 920-495-4969 or firstname.lastname@example.org.
GAA PRESS OPERATOR CERTIFICATION PROGRAM F E AT UR E
GAA Press Operator Certification Program is the first nationally recognized gravure press operator skill certification training course. Having certified press operators in your organization demonstrates to your customers and employees the level of commitment your company places on insuring excellent manufacturing practices to produce the highest quality printing. The significance you attach to guarantee these manufacturing and quality practices exist in the operation is a definite employee morale booster and it is an excellent method to evaluate, recognize, retain, reward, and advance talent. Certified press operators will help increase quality, reduce press downtime, increase productivity and factor heavily in your efforts to reduce total systems cost in the operation. We believe that is a very powerful sales tool.
There are currently nine modules completed. These initial courses cover:
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Pressroom Safety The Impression Roll Doctor Blades Cylinders Inks Color Theory for Press Operators Pressroom Troubleshooting Gravure Press Fingerprinting Gravure Press Dryers
We anticipate that certification will provide a distinct competitive advantage to those companies that participate, and we want everyone to have an opportunity to get involved at its inception. Go to http://gaa.org/operator-certification for more information and a link to a program presentation that summarizes the Operator Certification Program content, training options, and the economics. 62 GRAVURE/April 2011
GRAVURE Fall 2012