Page 1

Summer 2012

The Gaa Packaging Conference

Graph Expo Preview Issue


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ta b l e o f c o n t e n t s

Features 13 Improving the Wettability of Inks and Substrates for Gravure Print

p.13

By Paige Cornelison

Cover Feature 20 Graph Expo is Print Integrated 28 Study of Gravure Printed Nano Silver by Thermal Drying and Intense Pulse Light (IPL)

By Sughosh Satish Bhore

34 Advancements in ESA in Rotogravure

p.28

By Joseph K. Steingraeber

40 2012 GEF Scholarship Winners 42 2012 GEF/Flint Group Technical Writing Competition Winners 43 GAA Member Profile: Steingraeber Company 46 GAA Tour of the Government Office

p.34

Departments 4 Publishers Message: Training and Education 6 Editor’s Desk: Package Printing 10 Industry News 31 GAA 2012 Calendar of Events 44 Product 46 People

p.46 GRAVURE/Summer 2012

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P UB L I S HE R S C O R N E R

Training and Education

O

ne of the major functions of the Gravure Association of America (GAA) is training and education. Some of that is carried out under the auspices of the Gravure Education Foundation (GEF), for example the Flint Group Technical Writing Contest and the Student Scholarship Program. Both of these are highlighted in this issue. The winners of the Flint Group Technical Writing Contest, listed on page 42, will also have their papers published in the Gravure magazine. Two are in this issue—“Study of Gravure Printed Nano Silver by Thermal Drying and Intense Pulse Light (IPL)” by Sughosh Satish Bhore; and “Improving the Wettability of Inks and Substrates for Gravure Print” by Paige Cornelison (page 13 and 32, respectively). The last paper—“The Exploration of Gravure in Photovoltaic Processes” by Rosie Bubb— will be published in the fall issue of Gravure. This year’s scholarship winners are acknowledged on page 40-41. The four corporate scholarships are made possible by Alcoa Foundation, Cerutti Group, Gravure Education Foundation and Gravure Publishing Council. In addition, there are two memorial scholarships: HARRY V. QUADRACCI Memorial Scholarship and Werner B. Thiele Memorial Scholarship.

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GRAVURE/Summer 2012

However, Operator Certification program—which is now available on the GAA website—is handled directly by the Association. Currently, the program offers nine modules: safety, color theory, control inks, print cylinders, impression rollers, doctor blades, troubleshooting on press; press fingerprinting and press characterization; and gravure press dryer. As industry technology evolves and additional needs are identified, modules will be added. These will be available at no charge to those who have already registered for the operator certification program. The program offers significant benefits to your company. It can increase quality, reduce press downtime and increase productivity. More importantly, it will reduce total systems costs in your operation. The certification is valid for five years after completion of the course. I urge you to consider the program for your company. You can log onto the GAA website at www.gaa.org for additional information or contact me directly at bmartin@gaa.org GAA also offers a Basic and an Advanced training seminar at Western Michigan University as well as consulting, technical services, website services, technical materials and in-house training.

–Bill Martin

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: gaa@gaa.org. www.gaa.org


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Copyright Š 2012 R. R. Donnelley & Sons Company. All rights reserved.


E d ito r’ s De s k

F

Package Printing Today

or many years, the packaging segment of the printing industry was thought to be recession proof. Products such as food, personal sundries and other items are usually considered essential. However, the current recession has taken its toll on this marketplace resulting in mergers and acquisitions, plant closings and a general slump in business. In terms of gravure printing, other market factors have also contributed to the decline. While gravure’s strength lies in its repeatability over long print jobs, there is a growing trend towards shorter runs because of product diversification and geographical segmentation in the market. Gravure’s traditional competitor—flexographic printing—has fared better, but both, as well as the offset sector, have seen the emergence of digital printing encroach progressively into their markets. With business slowing, many companies do not want to store excess inventory or print packaging that may become obsolete due to changing government regulations or changes in consumer demands. The result is an increasingly competitive marketplace for gravure printers. Moreover, there are other trends affecting packaging, such as convenience packaging and security functions. When I opened a package of cookies the other day, I noticed a small section that stated “Slit when opened.” It was one of those re-closable cookie packages that open with a pull tab. The note made sense when I opened the cookies, because there was a definitive slit in the printing on the small section. It 6

GRAVURE/Summer 2012

reminded me of the growing problem of brand counterfeiting and tampering along the food chain—an additional challenge for the package printer. How can a gravure printer juggle all the pieces needed to be successful in today’s competitive and evolving market? The GAA is conducting a packaging conference on October 9-11 at McCormick Place in Chicago; its theme—Gravure To Suit Customers’ Expectations. It is a perfect opportunity to become up-to-date on packaging trends; learn about new technology; and understand more about sustainability throughout the packaging supply chain. I’m planning on attending, hope you are too. Speaking of McCormick Place, this issue offers a special preview (page 20) of Graph Expo, which is slated to run Oct 7-10. Its focus is on print integration and will be showcasing many of the technologies introduced at drupa in Germany earlier this year. The issue also features two of the winners of the Flint Technical writing contest: “Improving the Wettability of Inks and Substrates for Gravure Print” by Paige Cornelison and “Study of Gravure Printed Nano Silver by Thermal Drying and Intense Pulse Light (IPL)” by Sughosh Satish Bhore (pages 13 and 28, respectively). On the technology side, is an in-depth look at anti-static systems (page 34). One more note: we are pleased to announce that Gravure Magazine has won an APEX Award in the category of Magazines & Journals- electronic. Hope you enjoy the issue, and what is left of the summer.

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: gaa@gaa.org www.gaa.org

Vol. 26, No. 2 ISSN 08944946 USPS 000-565 Gravure magazine is published online three times a year.


October 7-10, 2012 McCormick Place South • Chicago, IL USA

Print Integrated

Flexible Packaging | Labels: Tape, Tags, Film & Foil Converting | Folding Cartons | Digital Printing Flexographic Printing | Printed Electronics

www.graphexpo.com


2012 GAA Packaging Conference October 9-11 This year, the 2012 GAA Packaging Conference will take place co-located with Graph Expo at McCormick Place on October 9-11. It will be co-chaired by Bob Kikkert, Altria; Rod Sosa, Fres-co System USA, Inc.; and Bob Whitton, Arellton Group. The Theme: Gravure To Suit Customers’ Expectations Some of the highlights of the conference will include: • Innovation in Gravure Press Manufacturing by Achim Kurreck, Chairman, MOOG • Sustainability Innovations Across the Packaging Lifecycle, a panel moderated by Don Carli of The Institute for Sustainable Communication • Intersection of Nanography and Packaging/Product by Gilad Tzori of Landa Digital Printing • drupa highlights panel moderated by Ralph Daetwyler of MC • The Secret Sauce: Converting and Finishing panel moderated by Bob Whitton of Arellton Group, LLC • Gravure Process Panel — Voice of the Customer Panel moderated by Bob Kikkert of Altria

For more information, log onto www.gaa.org. or contact Bill Martin at bmartin@gaa.org.


NEWS

10

Environmental Standard for Printing Inks

Eximpro Mexico installs 3rd KYMC servo Gravure press

UL Environment, a business unit of UL (Underwriters Laboratories) launched its revised third-party environmental standard for printing inks: UL 2801 (Referred to as CCD-040, an EcoLogo® standard, in Canada). This updated multi-attribute standard now includes criteria for certifying eight new subcategories of printing inks, as well as health-based measures to better protect people and the planet from hazardous substances. “Printing inks contain heavy metals, petroleum distillates, and volatile organic compounds (VOCs) that are of health and environmental concern,” says Angela Griffiths, head of operations at UL Environment. “Introducing criteria that reduce the use of toxic chemicals in inks is a positive change to UL Environment’s Printing Inks Standard. The new revisions will help conserve nonrenewable resources, improve indoor air quality for print shop workers, and reduce adverse health effects from exposure to heavy metals.” Health-based provisions are an integral part of the revised Printing Inks Standard. The criteria state that UL Environment-certified printing ink products may not contain hazardous substances in concentrations proven to have carcinogenic, mutagenic, and/or reproductive and developmental effects according to the “European Union Directive 1272 (2008).” See the standard online for further health-based conditions. New subcategories added to the UL 2801 standard include: gravure, flexographic, inkjet, and screen printing solvent-based inks; and inkjet ultra violet (UV) and screen printing UV curable inks. The revised UL 2801 standard also includes three new components, which are present in all recently revised or developed UL Environment standards: packaging; energy management and policy; and socially and environmentally responsible manufacturing. These three components aim to encourage continuous improvement for resource/waste, energy, environmental, and workplace management. To learn more about UL 2801, or to inquire about initiating the certification process, visit www.ul.com/environment. To download a free copy of the standard, visit www.comm-2000.com.

Eximpro S.A. de C.V., a leading flexible packaging converter in Mexico, has installed the latest generation KYMC Gravure press, the GravureJet. It is their 3rd KYMC gravure installation in 12 years. Some of the features of the press include fast set up and change over with touch screen operator control. WIth servo drive technology by Bosch Rexroth and intelligent register control system by Eltromat, Eximpro’s 10 color make ready waste can be reduced to 400m –500m from start up to on register with an infeed to outfeed of 112 meters. KYMC’s GravureJet is available up to 12 colors from web widths in 600mm to 1600mm with shaftless chucking on the print and sleeve type impression roller. The unwind and rewind are fully automatic flying splice at full speed. KYMC’s drying system allows efficient energy use at 350M/min.

GRAVURE/Summer 2012

AGI-Shorewood Consolidates Ownership of Shorewood de Mexico Anticipating growth in Latin America, AGI-Shorewood has purchased the equity interests of the minority stakeholder in its Mexican subsidiary, Shorewood de Mexico. As a result of the equity purchase, Shorewood de Mexico is now a wholly owned subsidiary of AGI-Shorewood international’s operations. Shorewood de Mexico had been a joint venture with Corporativo Cartograf S.A. de C.V., established in 2008 to support Shorewood’s key multinational customers who were seeking high-end packaging solutions in Latin America. Based in the city and state of Aguascalientes, Shorewood de Mexico’s state-of-the-art, ISO-9002certified facility is equipped with offset lithographic and rotogravure presses, as well as finishing equipment. Today the business manufactures packaging for customers in the beauty and personal care, confectionary, health care and tobacco market segments. Prior to this transaction, Corporativo Cartograf owned the building occupied by Shorewood de Mexico. As a result of the transaction, Shorewood de Mexico will acquire the facility and Corporativo Cartograf will move its remaining operations out of the Aguascalientes facility over the next 15 months. Shorewood de Mexico expects to hire almost 400 Corporativo Cartograf employees and will gain additional manufacturing space to expand its operations.


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NEWS

NAPIM’s Bio-Renewable Content Program The National Association of Printing Ink Manufacturers’ (NAPIM) Bio-Renewable Content (BRC) program continues to attract ink manufacturers and suppliers on a global basis. Recently, Premiata Tintas & Verniczes Graficos Ltda, Brazil, Megami Corporation, US and Tianjin, China have received BRC certifications for their ink systems. A complete list of BRC registered ink manufacturers and suppliers is available on the Bio-Renewable Content page on the NAPIM website. The use of BRC materials can be an important component of a printer’s or converter’s sustainability program. The BRC program provides both ink manufacturers and suppliers of printing ink raw materials a mechanism for certifying the biorenewable content in their products. Participants in the program submit formulation information specifying the amount and type of bio-renewable material in their product. After technical review and approval by NAPIM each product is issued a BRC “Index’” based on its biorenewable content. A company specific registration number is issued which can be used to verify the BRC content on the NAPIM website. Artwork for BRC product labels with the appropriate BRC index and BRC “printed with” designation are also provided. If you are interested in registering your products visit the BRC page on the NAPIM website for more information

Color Management Group Signs Distribution Agreement The Color Management Group (CMG) has entered into an exclusive agreement for North America, and a non-exclusive agreement for South America, to distribute Tucanna state-of-the-art solutions, including the tFlow, PrintControl and RapidCheck. The agreement assigns CMG to sell, promote, and service Tucanna products in all markets in the Americas. Introduced earlier this year, tFlow makes complete automation available for graphic arts, prepress, digital, analog, packaging and office printing markets. PrintControl and RapidCheck are tools used to calibrate printing devices in accordance to G7, SWOP and ISO standards.

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GRAVURE/Summer 2012

Health Risk Assessment Clears Shop Towels of Toxicity Claims An initial health risk assessment of laundered reusable shop towels by the international environmental engineering firm ARCADIS indicates that using laundered reusable shop towels creates no health hazard. ARCADIS’s risk assessment indicates that metals that remain on shop towels after laundering are not readily transferred to the hands of workers who use shop towels. As such, they create no health hazard, countering flawed speculation to the contrary. TRSA plans to expand the research beyond the initial sample of shop towels from 10 locations to further verify conclusive evidence that these clean reusable products do not harm workers. Reusable cloth shop towels remain the wiper of choice for industrial applications due to their absorbency and cost benefits. They satisfy EPA’s “reduce, reuse, recycle” hierarchy for effectively managing materials and waste. They are not regulated as solid or hazardous waste as long as launderers use TRSA’s voluntary management practices for handling and transporting them. A new federal rule, expected this summer, will codify these techniques. Compared with disposables, many of which are classified as hazardous waste, reusable cloth shop towels are recognized as the cleaner, greener alternative by users and regulators. While water use is comparable, EPA lifecycle research (measuring a product’s natural resources depletion from harvesting its raw material to manufacturing to industrial use to disposal) shows that compared with reusable cloth shop towels, paper wipers consume 13 times more energy; nonwovens, 7 to 12 times more.


INKS

Improving the

Wettability of Inks and Substrates

for Gravure Print By Paige Cornelison

G

ravure print is known for its abilities to perform well on a wide variety of substrates. However, wih such a great advantage comes a greater responsibility to account for possible issues—including wettability factors. Wettability is the ability of a liquid to adhere to a solid—in this case, the ability of ink to adhere to a piece of paper. Failure to comply with the scientific “laws” of wettability can result in failed print jobs and therefore a loss in time as well as profits. This research paper examines what encompasses wettability and the various ways to maximize the benefits of surface energy and surface tension through tests (contact-angle, dyne pens, du Noüy ring method) and treatments (corona, plasma, flame) for ink, substrates, and substrate coatings alike. Rotogravure printing, or gravure, is widely known as a high quality process in many respects. Take one look at a gravure printed magazine and you will immediately notice its rich, vibrant color and amazing shadow details. Such high quality comes from the fact that the gravure process uses small, recessed cells of ink on a large cylinder and transfers ink smoothly, as well as the fact that it allows for quick drying time in between print units so dry trapping can occur,

resulting in rich, deep colors. It’s no wonder most upscale publications look to gravure to print their jobs. Besides its high quality printing, another positive factor about the gravure process is its allowance for a wide range of substrate possibilities, and various ink types. Gravure commonly prints well on non-paper substrates, such as polyethylene, polypropylene, polyvinyl chloride, polyester, and polystyrene, as well as paper substrates such as newsprint, supercalendered stock, coated book stock, and paperboard (Special Papers). Gravure also implements both solvent-based inks and water-based inks. This generally means that gravure’s highest product markets are for publications, products, and packaging. Of course, this substrate/ink versatility is always an important factor when it comes to any printing process. However there is another factor involved in gravure printing, which seems to be often overlooked: the compatibility between the substrate and the ink. The ability for a specific ink to work well with another specific substrate is called their “wettability.” The behavior between the two is key when it comes to the quality of a print job. But the question is: what is the best way for a gravure plant to ensure that its substrate/ink wettability is at its absolute best? Research shows that there are two key steps to maintaining the best and most accurate wettability. The first is

to have accurate test methods of both the ink and the substrate, so as to know exactly what you are working with before you even begin to print. The second is to use these test methods to be able to treat your substrates to an accurate level, so as to maximize the ability of your substrate and ink to cooperate together and produce a highquality product. There are many methods for both testing and treatment of substrates and inks; the goal of this paper is to use secondary research, which was built upon past classroom experience with this subject, in an analysis of each method to determine which ones are best for the gravure printing process.

Understanding Wettability

Wettability is loosely defined as the ability of a liquid to hold contact with a solid surface. AccuDyne describes it as “the ability of a substrate to anchor inks, coatings, or adhesives.” Within this definition are two key terms: surface energy and surface tension. Surface energy applies to the substrate. Surface tension strictly applies to the liquid, or in this case the ink. The Sabreen Group defines surface tension as “a measurement of surface energy… the property (due to molecular forces) by which all liquids through contraction of the surface tend to bring the contained volume onto a shape having the least surface area.” This means that the higher the substrate’s surface energy is than the ink’s surface tension, the better its “wettability” will be. Or, in simpler terms, you want the energy of the paper to be significantly higher than the ink. The more spreadable the ink is, the better—but only to a certain degree. TEGO®, in an article entitled “Substrate Wetting Additives,” outlines three general rules for wettability: 1) a substrate with high surface energy is easily wetted, 2) a liquid with low surface energy is good at wetting, and 3) wetting is ideal if the surface energy of the liquid is significantly less than the surface energy of the substrate. GRAVURE/Summer 2012

13


INKS It is relatively easy to visibly observe the difference between different inks with substantially different wettabilities (Figure 1). Inks with higher wettability appear much more spread out as opposed to those with lower wettabilities, which bead up on any given substrate. You can similarly tell the difference between two substrates’ wettabilities by observing the behavior of the

Figure 1. Low surface tension (right) vs. high surface tension (left) (Eisby 2)

same ink on each one. What gets a bit more complicated is measuring their wettabilities in scientific terms. Wettability is measured in dynes per centimeter, or dyn/cm. Technically, a dyne is “a centimeter-gram-second unit of force, equal to the force required to impart an acceleration of one centimeter per second per second to a mass of one gram” (thefreedictionary.com). It is a unit specifically used to measure surface tension/energy. You can use dynes to compare a substrates surface energy vs. ink’s surface tension. For example, some plastics need to be at 36 to 40 dynes/cm to have successful wettability; water based inks 40 to 44, coating applications 50 or more, and so on (“Substrate Surface Energy Testing”). The TEGO® article features a mathematical formula that can accurately measure surface tension. This formula (Figure 2) uses derivatives (the rate of change of a function), where y indicates the surface tension, W indicates surface energy, and A indicates surface area. This shows that tension and energy and directly proportional in relation to the surface energy of the substrate. According to TEGO®, “The work required to extend an

Figure 2. Formula for surface tension (TEGO® 69)

14

GRAVURE/Summer 2012

interfacial area A by unit amount is termed interfacial energy W. It is proportional to the size of an additional unit and can be formulated as differential. The quotient Y is defined as interfacial surface tension”. (Interfacial means the two objects share a common boundary, or in this case where the ink is touching the paper). This formula is, in effect, used in all of the tests that are used to evaluate wettability, as will be discussed further on. Even after this seemingly complicated definition and formula, the question then becomes relatively simple: how does wettability affect my print quality? The straight answer is that the “wetter” an ink is and the more “wettable” a substrate is, the better outcome of quality your print job is going to have. This has to do with ink lay-down, sometimes referred to as “wet-out”, of ink. If an ink had no wetting (it was too thick) or it was “spreading” (too thin), or a substrate has too much (or not enough) absorption, it can lead to murky inks and blurred images. This is obviously far from ideal. It takes a perfect balance of ink and substrate to create the perfect images. Another important factor to consider in regards to wettability is that the amount of wettability needed is going to vary greatly between different inks and different substrates. For example, water has at least twice the amount of surface tension as most other liquids (TEGO® 70). This means that water-based inks are going to require substrates with a much different surface energy levels than that of solventbased inks. In relation, the substrate is usually the only factor you can change – that is, treatment is only available to the substrate. Ink is not what is typically altered to reach the desired wettability levels, as it would most likely affect the image quality.

Methodology

After understanding what wettability is and what affects it has on the quality of print, it is important as a printer to take the initiative to also understand what the next steps are in the process of achieving optimal wettability. There are several options as to the method-

ology for both testing and treatment of the wettability of both ink and substrates, and discovering how the derived numbers applies to the gravure print process.

Wettability Test Methods

When it comes to testing the compatibility of both substrates and ink, there is a wide variety of methods that both have seen improvement within the past decade, as well as many methods that have a lot of room for improvement within the future. These methods include one that tests the wettability of both the ink and the substrate, one test that looks at only the substrate itself in terms of surface energy, as well as one that only tests the surface tension of the coating on a substrate. Looking at these different methods and comparing them will give some insight as to which is best for the whole of the printing process; specifically for gravure. The contact angle method is used to determine the wettability factor between the ink and substrate. It is a widely used criterion and is well suited to evaluate how compatible the two are. As shown in the diagram in Figure 3, each individual drop of liquid/ink is measured in relation

Figure 3. Wettability in terms of the contact angle of the ink on a substrate. (Sabreen 1).

to how it sits on the substrate. An angle is measured proportionately. In general, an ideal contact angle is less than 60˚. This signifies good surface wettability, and high surface energy. The contact angle is measured by a drop projection instrument that is attached to an angle-measuring device with a microscope and screen. (ASTM 1-2).


INKS In regard to the contact-angle method (Figure 4), TEGO® explains in their referred article that the contact angle method applies and expands upon the formula that was previously explained. It incorporates what is called the Wenzel ratio, f, which is a correction factor for the equation. The article explains “it is defined as the quotient of the area A which the droplet would occupy on a smooth surface and the area A’, which it really occupies.” Simply put, this ratio compares the ideal surface conditions with its

Figure 4. Wenzel ratio (TEGO® 72)

true surface conditions, helping a printer to understand how they need to adjust for the substrate at hand. The article also explains that, understandably, the higher the Wenzel ratio turns out to be, the greater the roughness of the substrate is. Also, the rougher the substrate is, the better the wettability. (This is an especially important consideration for gravure, because this process has a harder time printing well on rougher substrates, since it needs a very flat and even surface to transfer ink from its recessed cells.) The next method for testing wettability was designed to examine only the substrate for its surface energy levels. The Dyne pen method (Figure 5) is a very simple test method that consists of exactly what it sounds like; it is a pen used to find the dyne level of the substrate. There are generally a certain number of pens available that will

Figure 5. Dyne pen test method

give you positive results for a specific dyne level, usually ranging from about 30 to 60 dynes (Sabreen 2). The pen is used to draw a few parallel lines across the substrate. If the solution drawn beads up within a couple of seconds, it is assumed that the surface energy is approximately the number of dynes as assigned to that specific pen. If not, you use the next dyne level and repeat the test, until you get the desired results (Sabreen 2). As it may be already clear, this test method entails a few potential issues. First of all, it is not the most precise way to go about finding dyne levels. Every measurement will be rounded off to the nearest number. Also, the results are solely from the observations of the naked eye. It would be relatively easy to get different results, especially with different testers. This is made obvious in The Sabreen Group’s “Surface Wetting and Pretreatment” article, where their Dyne Test procedure states that “Excessive solution will result in misreading.” Another problem is that the substrate cannot be at all contaminated before testing. Any particles of dirt, dust, or even fingerprints will invalidate results. The substrate must be perfectly pure as well. There is also the possibility of a chemical reaction occurring between the pen solution and the substrate, which would also invalidate results. The solution is hazardous, and needs to be at room temperature with a specific and consistent humidity for it to work accurately. In addition, it has about a 6-12 month shelf life, which is not very long if a printer uses a less broad variety of substrates and doesn’t test them very often. The last method of wettability testing is one that seems to be a bit less common in the industry. The du Noüy Ring Method (Figure 6) is used to measure the surface tension of the coating that is applied to a substrate. It is detailed in TEGO®’s article and is a unique way of predicting the way an ink will interact with a substrate’s surface. This method uses a ring made out of platinum-iridium, with handles, that is placed into a bucket of the liquid coating. As it is slowly withdrawn, a

Figure 6. The du Noüy Ring Method (“Du Nouy Ring”)

“lamella” is formed which “constitutes an increase in the surface area of the liquid.” They measure the surface tension of the liquid by determining the amount of force needed to pull the lamella up from the surface. It is performed and calculated by a machine. (It is important to note that this method only works with non-pigmented liquids; a pigment impairs the stability of a lamella so the surface tension values seem too low. Therefore, this test method would not work on inks themselves, only the coatings.) One flaw that may be presumed with this process is that it does not consider the substrate that is going to have the coating applied to it, and the specific substrate may have an influence on the wettability of the ink/coating combination. But, it does seem to derive results that can otherwise be relied upon when looking at which type of coating to choose for your desired print job.

Treating Substrates for Improved Wettability

The most direct and effective way of improving wettability is to make a change to the substrate. This is done through what are called surface pretreatments, or simply treatments. There are three main types of surface treatments, that each chemically alters the substrate, and each with a variety of differences that can be compared by a list of criterion. GRAVURE/Summer 2012

15


INKS The first treatment is what has been described by Elise M. Sanders as an “old favorite” of pressmen of the past several decades (Sanders 9). The corona treatment uses oxidation to energize a substrate, or to raise its surface energy. An article written by the son of the inventor of the corona treatment, Verner Eisby, describes the treatment as “a high frequency electric discharge towards a surface… the result from this is an improvement of the chemical connection (dyne/cm) between the molecules in the [substrate] and the applied media/liquid [ink]” (Eisby 2). This type of test is used on a variety of materials to improve wettability, and works just as effectively on paper and other substrates (Figure 7). Sander’s describes the corona treatment as a relatively low-cost process and one that is very common (and therefore may be classified as an easier process). There are some problems though, which include the creation of an

uniform layer of plasma bonded to the surface of the substrate, also via oxidation. It is meant to reduce the contact angle of the liquid on the substrate. There are three subtypes of plasma treatments: cold gas, atmospheric, and grafting. Cold gas uses a vacuum to apply the treatment, atmospheric is the same process without using a vacuum, and grafting plasma deposits a coating onto the substrate and changes the surface via polymerization.

ing substrate wettability is called the flame treatment. Sanders also explains this treatment in her article. It is very similar to corona treatment in that it encourages oxidation of the substrate. The main difference is that it uses an open flame as opposed to a corona discharge. It has the lowest cost of all three treatments, and can lead to very high dyne levels in any substrate. It also has a high shelf life, is ozone free, and has no blocking/ picking, or pinholing aftereffects. But flame treatments are not very popular; the reason mainly being that the process is very difficult to set up and control, and the open flame is simply not something most pressmen believe to be smart to have in a pressroom full of paper (Marc Nolan of Sherman’s Treaters describes this treatment as corona’s “Poor Cousin”). In addition, whenever the flame treatment is used, it seems to be most effective on paperboard and thicker stocks, which are not generally the main substrates that gravure tends to print.

Results Figure 8. Plasma treatment (smartgarmentpeople.com)

Figure 7. Plastic material being treated with the corona method (tantec.com)

ozone gas that is often emitted, as well as sometimes causing picking and blocking on the substrate when it is printed. It may also be considered a problem that the treatment affects the entire substrate as opposed to just the surface. It also cannot be used on any metallic-like material as well as other substrates like fluoropolymers or polypropylenes (PillarTech.com). The humidity can also have a negative effect on the treatment abilities.

All three eliminate unstable molecules and clean the substrate surface (something corona treatments fail to do). The plasma has a long shelf life and works well on a very large gamut of substrates. It also works well with papers that are going to be run at high press speeds, something that the gravure process is very familiar to. There is usually no picking or blocking that occurs, and there are limited ozone emissions. It is also good at limiting pinholing, which is something else that gravure is used to experiencing. It is also a much faster process than corona. The one very limiting factor of this process is that it is far more expensive than the corona treatment ever was, and ever will be—such great technology comes with very high cost. Despite this, the plasma treatment seems to be the future of most substrate treatment types.

The second treatment is a newer concept that is rapidly causing the decline in use of the corona process. As described in Sanders’ article, “Plasma Substrate Treatment,” the plasma treatment (Figure 8) forms a The third and final treatment for improv16

GRAVURE/Summer 2012

There is no way to improve wettability of an ink and substrate combination without having methods to test them. It is very important to be able to decide conclusively what the best options are when you are choosing your consumables. In addition, accuracy and ease of use are both essential to determining which test method is best suited for the needs of a printing plant. Testing is also an important avenue for being able to closely treat your substrates to the best of your ability. After reviewing both the gravure process and the many different testing and treatment methods, it is feasible to come to a relative conclusion about which methods would be more successful in the gravure industry.

Test methods

When it comes to the dyne pen method, it is relatively obvious that the dyne pen is a much less complicated way of testing a substrate’s surface energy. It requires a very low amount of skill, as well as materials, to perform. However, it brings a wide range of variables that can easily influence


INKS the outcome of the test. When you are working with such a consistently highquality process such as gravure, it is important to derive the most accurate results as possible, and be able to rely on more than just an “eye-ball” estimate of whether or not your substrate is at the level it is supposed to be. Additionally, this test does not determine the ink’s interaction with the substrate; it simply gives a general energy level of the substrate on its own. Overall, this method can be dismissed based on its inability to achieve consistent, applicable, or reliable results. The du Noüy Ring Method sounds like a more fail-proof method to testing the coating of a substrate. However, because this is the only thing it tests, it would be easy to receive results that are later influenced by other factors, such as the substrate itself and how that interacts with the ink. It may be argued that the coating serves as a barrier between the substrate and the ink and there would be no problems here, but if you consider the fact that different substrates have different amounts of roughness that the coatings are contoured to (roughness’ effect on wettability and gravure was discussed), it is easy to see how this test method cannot guarantee the best outcome for the whole printing process. The contact angle method is a relatively simple method to understand and test. It is also very scientifically and mathematically sound when it comes to comparing its results accurately and closely. It proves to be very useful specifically when it comes to testing both the substrate and ink for compatibility in a uniform and precise way. Although the price is moderately expensive since this method requires machine use, the precise accuracy along with its ability to measure both the ink and substrate together gives it good reason to be the best option for measuring wettability, perhaps for any print process.

Surface treatments

Conclusion

The corona treatment is a close second to the plasma treatment, but just has too many factors that give it reason to fall short. It is true that it has a low cost, and that it is a method that people have been comfortable with for decades, but there are too many benefits from the plasma treatment to give corona another glimpse. Not to mention that gravure implements many non-paper substrates that corona cannot accommodate for. It is true that there is a steep learning curve for the plasma treatment, but in a side-by-side comparison of the two, it is evident that plasma is overall the best investment a pressman can make in order to ensure higher quality press runs and quicker turnaround time to follow.

Paige Cornelison, a student at California Polytechnic State University – San Luis Obispo, is one of the winners of the Flint Technical Writing Contest.

The flame treatment has some positive attributes that make it seem like it would be a reputable surface treatment method. However, because it is such a hazardous process, and not many people know how (or are willing to try) to use it, it brings this method low on the list. Especially for gravure, where the type of substrates that are used are not going to benefit greatly from the method that is primarily thick paperboard stocks, the flame treatment is a good solution in hindsight but does not quite fit the standard.

It is always essential for a printer to ensure the absolute highest quality in their products that they can achieve. And wettability is just as important as any other factors in the process. Although it seems there should be an obvious choice in both testing and treatment, it is true that the choice needs to be made specifically for the printing process at hand. Gravure’s process and substrates are going to be much different from that of flexography or lithography printing. For example, these various substrates, such as foil, film, plastics, etc., are different from paper in surface energy, absorption and ink laydown, and in turn there are different methods that need to be used to accommodate for them. It is also important to remember that these results are not at all absolute; there are always variables that every production plant needs to consider in order to pick the methods that cater to their needs and specifications, such as budgets and time factors. But it always starts with that simple concept of how a single drop of ink interacts with the surface of a sheet of paper.

References • ASTM International. “Standard Test Method for Surface Wettability of Paper (Angle-of-Contact Method). ” Shanghai Polymer Materials R&D Center. ASTM International, 2003. Web. 31 Jan. 2012. <http://www.polymercenter.org/admin/upfile/20097101347550.pdf>. • “Corona, Plasma, Flame ... How Do You Determine What’s Right for You?” Pillar Technologies, Inc. Pillar Technologies, 2010. Web. 05 Mar. 2012. <http://www.pillartech.com/SurfaceTreatment/InTheNews/tabid/137/ articleType/ArticleView/articleId/35/Corona-Plasma-Flame-How-do-you-determine-whats-right-for-you.aspx>. • Du Noüy ring. Digital image. Attension. Biolin Scientific. Web. 4 Mar. 2012. <http://www.attension.com/surface-tension>. • Eisby, Frank. “Corona Treatment: Why Is It Necessary?” The Plastic’s Network. WordPress. Web. 31 Jan. 2012. <http://plasticsnetwork.files.wordpress.com/2007/12/corona-treatment.pdf>. • Harris, James D., comp. “Chapter 16 - Gravure Nonpaper Substrates.” Gravure: Process and Technology. Rochester, NY: Gravure Education Foundation, 2003. 479-518. Print. • Nolan, Marc. “Flame Treatment - Corona’s Poor Cousin?” Sherman Treaters. Pillar Technologies. Web. 1 Mar. 2012. <http://shermantreaters.co.uk/acrobat/flame.pdf>. • Rong, Xioyang. Special Papers and Other Substrates. San Luis Obispo: Cal Poly State University, 2011. PPT. • Sabreen, Scott. “Surface Wetting & Pretreatment Methods.” Sabreen - Secondary Plastics Manufacturing. The Sabreen Group, Inc. Web. 31 Jan. 2012. <http://www.sabreen.com/surface_wetting_pretreatment_methods. pdf>. • Sanders, Elise M. “Plasma Substrate Treatment.” GravurExchange. PLGA Global, May 2009. Web. 31 Jan. 2012. <http://www.gravurexchange.com/pdfs/GravurEzine-0904.pdf>. • “Substrate Surface Energy Testing - Accu Dyne Test Procedure.” ACCU DYNE TEST. Diversified Enterprises. Web. 1 Mar. 2012. <http://www.accudynetest.com/qctest.html>. • TEGO. “Substrate Wetting Additives.” Technical Background. Evonik Industries. Web. 31 Jan. 2012. <http://www.tego.de/sites/dc/Downloadcenter/Evonik/Product/Tego/en/Technical-Background/substratewetting-additives.pdf>.

GRAVURE/Summer 2012

17


2012 GPC Conference November 11- 14

Planning is underway for the 2012 Gravure Publishing & Premedia Conference, co-chaired by Scott VanLieu and Matt Huber with assistance from GPC Council chair Mike Schilaci and vice Chair Peggy Regan. This year brings several notable changes. • Conference dates are Sunday, Nov. 11 thru Wednesday, November 14. • Conference venue is the Waldorf Astoria Hotel, Naples, Florida. • The GAA Premedia Conference will join the GPC Conference, now known as the GPPC Conference.

Conference Highlights • Keynote: The People’s Politics—speaker Mara Liasson, political contributor, FOX news Channel and national political correspondent, National Public Radio (NPR) • Energy and the Prospects for Economic Growth in the U.S: A Post Election Perspective—speaker Bud Weinstein • Next Generation Workflows—speaker Matt Huber • The Environmental and Social Perceptions of Print and Paper— speaker Phil Riebel • How Technology is Transforming Marketing—speaker Suresh Palliparambil • Trends in Digital Publishing—speaker Rebecca McPheters

Check out the GAA website: gaa.org for updates.


2012

is

“Print Integrated” Slated to run from October 7-10 at McCormick Place in Chicago, IL, GRAPH EXPO 2012—now spanning the realm of print, online and mobile—is expected to be the year’s largest and most exciting display of “live” running equipment in the Americas. More than 400 exhibitors will fill McCormick Place South with demonstrations of new presses, the latest innovations in related equipment, unique new applications and new product introductions—many that debuted in Düsseldorf but to be seen here for the first time in North America. Adapting and evolving every year, GRAPH EXPO promises to have something for all areas of the printing industry, including conferences and seminars, more than 45 different co-located conferences, user-groups, meetings and events. 20

GRAVURE/Summer 2012


GRAPH EXPO Conferences and Seminars

An excellent way to begin the GRAPH EXPO experience is by attending the EXECUTIVE OUTLOOK. After 16 years of a predominant technology focus, the program has been enhanced to provide a more blended analysis of key marketing trends with new technology enhancements. With the theme, “Using Marketing and Technology to Innovate and Thrive,” this year’s EXECUTIVE OUTLOOK promises a dynamic conference that will provide attendees with indispensable information on how to use technology to propel their marketing initiatives to gain a competitive advantage in today’s economy. It will be held in McCormick Place from 12:00 noon to 6:00 p.m. on Saturday, October 6, the day before the show opens. The keynote address features Jeff Hayzlett, best-selling author and President of the Hayzlett Group, who will share the essential business lessons to lead, drive change, and grow profits. It will also offer fast-paced but detailed vignettes about technologies with future growth potential such as printed electronics. One of the highlights of the program will be the announcement of the “Best in Category” MUST SEE ‘EMS winners, which essentially provide a “road map” to the most innovative technologies and products exhibited at the show. It will also feature the Positively Print awardee—representing the best-of-the-best campaigns that promote the enduring power of print. In its third year, the Positively Print program is intended to spotlight the variety of ways in which the effectiveness of print is being promoted. Nominated candidates will be evaluated on their originality and perceived effectiveness in delivering the message of print as an integral-and effective-component of today’s integrated marketing campaigns.

GRAPH EXPO Conference Program

The GRAPH EXPO conference program will run the gamut from “hands-on” skill-building to top level business management sessions presented by experts in their field. The program of 50 seminars, that will debut a new In-Plant Track, will also span a variety of hot-topic subject categories, including: • Cloud Computing Management • Color Management • Interactive Media • Design • Lean Management • Digital & Manufacturing • Entrepreneurship • Mailing & Fulfill• Executive ment 22

GRAVURE/Summer 2012

• Pre-media • Print Buying • Printed Electronics • Production • Sales & Marketing • Social Networking

• Transactional • Trends & Opportunities • Workflow • Emerging Technologies

Co-Located Events

In addition to the seminar program, GRAPH EXPO 2012 will also be an epicenter of the graphic communications industry for 45 co-located conferences, user groups and special events. The GAA (Gravure Association of America) Packaging & Products Technology Conference and Person of the Year Event is one such conference. Others include: NPTA Alliance Meetings for Package Printing & Converting; Idealliance and IPA G7 Summit to cover Workflow/ Color. Visit www.graphexpo.com for an updated listing.

Other Highlights

Another highlight of the show will be is the free International Days Program. “The Latin American Opportunity—Status and Future Prospects” is a perfect way to explore the fast growing markets in Latin America. Listen to experienced business development experts and already established printers and network with prospective customers and partners. Scheduled for Tuesday, October 9, 4:00 pm - 6:00 pm, McCormick Place South, Room S102. In addition, there will be free presentations— for all registered attendees, with no reservations required—by exhibitors and also on industry segments.

Special Show Floor Features

Complementing the extensive seminar and conference program are special show floor sections, pavilions, areas and features to help make your visit to GRAPH EXPO a unique experience. These include the following: • The CPP Zone—A GRAPH EXPO 2012 debut, this new converting area compliments the growth of package printing exhibitors, technologies and offerings that are expanding across the show floor. • The Marketing Pavilion—is a complete one-stop destination for marketing education, resources and networking, as well as all the latest marketing and graphic communications tools and techniques. It is designed to meet the needs of highly experienced marketers and graphic communications pros that are, or want to learn how-to become marketing service providers. • News Print— in response to the demand voiced by newspaper production pros for a dedicated section of


GRAPH EXPO their own at GRAPH EXPO, the News Print pavilion returns to engage both newspaper and commercial printers and present the latest technologies, unique new applications and workflow solutions. • GREENspace is a timely and specialized show-floor feature dedicated to educating attendees about what sustainability is—and what “going green” really means to their industry, their business and their customers. This section is devoted solely to exhibitors of eco-friendly products and services focused on sustainability. • Mailing & Fulfillment Center— will feature all the latest production technologies, systems and applications to add value to clients’ projects. For a complete listing of all show floor pavilions, sections and areas visit: www.graphexpo.com.

The Numbers Buyer attendance—real attendance—at any exhibition is an important metric. So, too, is the number of companies represented by buyers/attendees on the show floor. Tradeshow producers report attendance in many ways. Some count an attendee each day they come to the show. Others count the same attendee each time they enter the hall, regardless of how many times, and some even count people that register and don’t attend the show at all!

GRAPH EXPO Attendance Numbers

Buyers Educators/Students Press Total Attendees Exhibitors GRAND TOTAL

Graph Expo 2011 Verified 13,426 301 192 13,919 6,532 20,451

Graph Expo 2010 Verified 12,552 792 208 13,552 6,409 19,961

For quality products and quick deliveries direct from the manufacturer you can count on Allison Systems’ 44 years of experience for your doctor blade needs.

- A large variety of edge configurations and metal blade material choices from carbon steel to long-wearing and cylinder-friendly tool steel. A coating can be added to provide additional lubrication, life, and corrosion-resistance. - Plastic and composite materials are available for specialty applications.

- Blade holders and heavy-duty blade systems custom engineered to provide appropriate and repeatable blade contact angles for all of your gravure cylinder sizes. - On-site technical assistance, troubleshooting, and operator training services.

- Out of Blades? Don’t panic, we can provide same day emergency blade shipments in most cases.

Call, email, or visit our website today to put the Allison advantage to work for you!

220 Adams Street Riverside, NJ 08075 856-461-9111 sales@allisonblades.com www.allisonblades.com

GRAVURE/Summer 2012

23


ESCALATORS TO/FROM LEVELS 4 & 5 MEETING RMS.

Printers

Master

Stratis Plastic Multifeeder Technology Software Magnetics Inc Pallets 101 105 106 107

Doyle Systems

Superior Paper Handling Solutions

110

Coast to Coast Label, Inc

122

121

ImpoProof

123

Automatan

StopStatic.com div of Alpha Innovation

125

129

Epicor Software Printer's Plan Corporation

132

130

Metafix Inc

Compart North America Inc

133

Balemaster Enterprise

Group

144

136

145

100/200 AISLE 201

207

Prisco-Prisco Digital

R E G I S T R A T I O N

212

217

224

Vits America, Inc.

ATS-Tanner

GBC

227

229

234

Nitta Corporation of America

Dalim Software GmbH

Solimar Systems

237

235 Kallima Paper

246

240 Mohawk Fine Papers

Rochester Software Associates

GTI Graphic Technology Inc

Rollem International

Rampage Systems

340

334

249 IT Supplies

Enfocus

Prestige Scheduler from Pivotal Z

JUST Normlicht Inc

342

349

300/400 AISLE 427

300/400 AISLE

414

400

421

432

EskoArtwork

436

500/600 AISLE

627

E N T R A N C E

Glunz & Jensen, Inc

448 Digital Information Ltd

DigiTech Solutions

PREPRESS/SOFTWARE/DESIGN

636

641

646

644

GMG Americas

649

LithoTechnics, Inc. dba colorHQ.com/A Div. Of Metrix Software The Board Room

Burgess Industries, Inc

Konica Minolta Business Solutions USA Inc

FUJIFILM

Canon U.S.A., Inc.

444

441

Lasermax Roll Systems

CGS

PACUR Techkon USA

DynamicsPrint

744

747

749

700/800 AISLE Agfa Graphics

845

841

Epson

Mitsubishi Imaging (MPM) Inc

Goss International

1100/1200 AISLE

1200

1214

1227

1221

1238

1244

Standard Finishing Syste

Xerox Corporation

Eastman Kodak Company

Heidelberg

HP

Pitney Bowes

1646 xpedx

1900/2000 AISLE

2000

2010

PRESS/FINISHING/PACKPRINT/PHOTO IMAGING

2017

2027

MBO America

2034

G&K-Vijuk International

Muller Martini

2038

2100/2200 AISLE

2227

EFI

2210

2216

2238

2236

KBA North America

205

2047

Adphos North America

GPA, Specialty Substrate Solutions

Lam

2244

225

Printin

ILF Technologies

2221

Spiral Binding James Burn USA

manroland Inc.

2044

Delphax Technologies

MBM Corporation

Xeikon America, Inc.

I-Web

Duplo USA Corp.

2444

2449

Best Graphics Inc.

2500/2600 AISLE

2600

2610

2617

2623

J.A. Flesher Company

2625 2626 Becker Pumps Corp

Graphic Whizard Inc

2635

2627

Graphic Whizard Inc.

2639

WCJ Pilgrim Wire

Tec Lighting Inc.

2641

2645

KDX America, LLC

Kongskilde Industries

Xante

2648 CRC Information Systems

C.P. Bourg Inc.

2839

2835

Ricoh

2841

Crawford Pamarco Global Technologies Inc Graphics

Harris & Bruno International

Bell and Howell LLC

FloClear LLC

Consultants Corner

2935 2936

2939

Green-e

HOP Industries Corp

2844

2848

DHP Mfg. Bindery Equipment

OKI Data Americas

2941 2942

2850 UNICORServices Business Group

Sentry Insurance

Air Systems Design Inc

2948 2949

GREENspace 3035

3039

3037

WEIMA America, Monigraf, Inc Inc

3117

3100/3200 AISLE

3200

3211

3208

Great Atlantic Capital Corporation

Creative Banner

Tippmann Die Cutting Solutions

American Ultraviolet

3135 3136

3217

3235

Octopus MES (Genisys Consulting Group)

3237

Kern Inc.

B&R Moll

Folex Coating GmbH

3239

3241

Verso Paper Corp

Inc

Sajo Technologies Inc

3141 3142

Bordeaux Digital Inc

Anew Green Inc

Oxytech EZturner Ascentium Capital Systems,

3041 3042

3139

3335 3336 3337

3339 3340

3435

3439

ACTEGA Kelstar Inc

3044

3048

Hohner Stitching Products, Inc

Dorstener Wire Tech

Cooper Enterprises, Inc

3050

AccuraMIS

Advantage Sign Supply

3148 3149

3244

3248

Sealed Air Corporation

3250

Deluxe Stitcher Company

Kirinuki Japa (Dairoku Insatsu)

Magnum Magnetics

Pressline Technologie

3348

3350

BAUM

3423

Colter & Peterson Inc

3427

The Challenge Machinery Company

Brandtjen & Kluge, Inc.

3445

Press Solutions / Albo System

Mimaki USA, Inc.

3448

Jorson & Carlson

3

3500/3600 AISLE

3601

3605

3609

W+D North America

3614

Gunther International

3616

MCS

3623

3619

3627

MGI

NPI

3632

Thiele Technologies (Streamfeeder)

3832

3900/4000 AISLE 4006

4012

4015

Buskro USA Ltd

NAPL

Neopost USA Lake Image Systems, Inc

4315

4407

Longford International Ltd

Sefas Innovation, Inc

Sensible Technologies/Transformations

Flex Systems Postmark

4603

4611

4over, Inc.

4032

4027 4028

4030

4127

4128

4130

4135

4136

4227

4228

4230

4235

4236

4327 4328

Document Data Solutions

4422

Collins Ink Corp

4424

Gluing Machinery & Systems, Inc

4427

Therm-O-Type Corp

4330

4429

4035 4036

4332 4333

4335 4336

4432 4433 4434 4435 Impress Ihara U.S., Pro-Bind Systems Inc

Duraco Inc.

4514

4613

Postmatic Inc. Nordson Corp.

Formax

Label Source Ltd

4711

Beta Industries

Clear Image Technologies

Redi-Data: Reseller Division

4713 4714

4617 4618 4619 4620 4616 Tompkins Mailing

Printing Equipment Company

DOCUMENT Systems Media Technology

B&W Press

Think Ink Robatech USA, Inc

RST Marketing

Lorton Data

4716 4717 4718 4719

4622

Walco Systems LLC Whittier Mailing Products

4722

4625

Controls Engineering, LLC

4627

4632

Straight Shooter Equipment Co

Garrido

Printware LLC

Printer Repair Parts

Gordon Brush Mfg. Co. Inc

Schmid Rhyner USA Inc

Cook Receipt Book

4634

American International Machinery-Signature Folder Gluers

Foil & Specialty Effects Association

The Binding Edge Magazine

4811

Thompson Direct

4813 Spedo U.S.

4816 4817

Precision Inline Finishing Solutions Systems Inc Window Magnets 4 Book, Media Inc

4819

GRAVURE/Summer 2012

3848

Absolute Printing Equipment/Perfecta USA

4045 Printing Industries of America

4338

4341

4438

4441

AdTech Graphic Service

4444

4446

Flexmag Industries MABEG Inc

Feeders

American Express Open

4544

Graphic Arts Magazine

4546

4448 4449 4450 Coda, Inc

Dealer Communicator/Trade Show Times

ImageOn Impact

Unibind Inc

4548 4549 4550

Straub Design Company

5008

5012

Domino North America

5016 5017 Fannon Products, LLC

4644

Millennium Wire & Steel

ML System Inc

4738 4838

4744

GAERF 2012 Student Design Competition

5019

5127 5128 5129 5130

5223 5224 5225 5226

5227

Chowan University

4841 New York City College of Technology

4938 4939

4844

4648 4649 4650

Financial Transaction Two Sides U.S Services

NPTA Alliance

Digital Digital Output Publishing Magazine Magazine

Sunraise Inc

4748 4749 4750

4848

University of Houston ILT Dept

4941 4942

EDUCATION MAIN STREET 5034 5035 5036 Print & Graphics Scholarship Foundation

5123 5124 5125

Tomorrow's Ferris State Workforce University

4934 4935 4936

4646

4746

International Graphic Arts Education Association

Harper College

5134 5135 5136

5038 5039 Cal Poly State University

University of WisconsinStout

5138 5139

5041 5042

5045 5046 5047

5049 5050

5141 5142

5145 5146 5147

5149 5150

Pittsburg State University

5100/5200 AISLE

S

5209

5212

5216

5219

5230 5231 5232

5234 5235 5236

5238 5239 5240 5241 5242

5244 5245 5246 5247

5249 5250

5323 5324 5325 5326

5330 5331 5332

5334 5335 5336

5338 5339 5340 5341 5342

5344 5345 5346 5347

5349 5350

5423 5424 5425 5426

5427 5428 5429 5430 5431 5432

5434 5435 5436

5438 5439 5440 5441 5442

5444 5445 5446 5447

5449 5450

5300/5400 AISLE

W

24

3844

4041

Adhesives & Packaging Corp

4834 4835 4836

ESCALATORS TO/FROM LEVEL 1 LOBBY

4900/5000 AISLE

Floor plan as of July 11, 2012

4038

Tecre Co., Inc

Satori Software Inc

5116 5117

N

Akiles Products, Inc

4636 Capital

4732 4733 4734 4735 4736

4725

4916 4917

5005

3841

4534 4535 4536

4532

4700/4800 AISLE 4805

E

WPM

MAILING & FULFILLMENT CENTER

4608

Kirk-Rudy

Anchor Software LLC

Specialty Equipment Services

4511 4512

4507

4500/4600 AISLE

United Business Mail

4318

4417

4414 4415

4411

Uluro-by Transformations

3648

Videojet Technologies Inc

4300/4400 AISLE 4402

Mutoh America, Inc.

CPP

4023

4018

EAM-Mosca Corp

3644

Morgana Systems

3838 D&K

4002

3638

BOWE SYSTEC GmbH

5409 5410 5411 5412 5413 5414

5416 5417 5418 5419 5420 5421

TO/FROM LEVEL ONE WEST LOBBY OF SOUTH BUILDING

UP

TO McCORMICK WEST BUILDING

UP

UP


Eizo Nanao Technologies Inc

152

253

252 Estimator Corp

CADlink Technology Corporation

254

Fastbind SoftSolutions, Recosoft Inc Corporation

354

358

353

451 GMC Software Technology

459

Convertible Solutions

Color Management Group

461

652

462

463

464

465

Printflow

Virtual Systems

Aero Rubber Company, Inc

561

Printing Impressions

563

565

PMC

556 656

653

Cyrious Software Doxim

Datatech SmartSoft

PrintGuard Inc.

M-Photo LumaPix Ltd

751

753

661

658

PTI Marketing Technologies

PressAccess

754

664

662

PrintPointLEADER

Lucid Dream Software Inc

Aleyant Systems

Amicon Technologies

761

762

700/800 AISLE 864

PrinterPresence by Firespring

858

667

668

767

768

Online Print Solutions

861

851

867

Avanti

871

872

CHILI Publish

Durst Image Technology US

KIP

873

Pageflex

971

973

MARKETING PAVILION 1061

1064

Gateway Bookbinding Systems

1067

OnPrintShop Web2Print Store (Radixweb)

MindFire Inc.

1071 1072 1073 1074 interlinkONE

Advertising Specialty Institute

Grow Socially

1171 1172 1173 1174

1255

1261

ems

1266

Mitsubishi Lithographic Presses

Oct. 7 - 10, 2012

McCormick Place South Chicago, IL

Komori

1461

1464 1465 1466 1467 Kunshan Huawei Purification Equipment Co. LTD

NELA

Gammtech Corp

1564

1566 1567

NEWS PRINT 1653

1658

1661

1664 1665 1666 1667 Press Tech Co

alfaQuest Technologies Inc

Grafix, L.P.

ABB

RISO, Inc.

1764 1765 1766 1767

SCODIX

1700/1800 AISLE

1861

1864

Dynaric Inc./DYC Supply Co

TKS

50

2054 Van Son Holland Ink Corp

mina System AB

50

2254

ng Research Inc.

2057 Colordyne Technologies

2059 Baumer hhs Corp

2061

Prime UV Systems

ProImage America Inc

2257

2259

Diversified Graphic Machinery

LasX Industries, Inc

2063

Pressline Services

PVC Spiral Supply

2457

2459

2657

2659

Technifold USA

Kasper Consumables, Inc

2066

News & Tech

Technotrans America Inc

2161

2163

2261

2263 2264

Harland Simon

Print2Finish LLC

This nearly 40,000 sq. ft. show floor hub is now recognized as the industry’s largest mailing event—anywhere in the Americas! And it’s the one-stop destination where 34% of attendees who are seeking to expand their services will come to find the tools and technologies they need to automate their work.

2266 2267 Plumtree Company

Kansa Technology LLC

EAE-Ewert America Electronics

2461

2466 2467

2361 2362 2363 2364

2454

e Corp.

2366 2367

2566 2567

2651

EyeC-America

Spiel Associates, Inc.

2661 2662 2663

Brackett, Inc.

Manugraph DGM, Inc

Impressions Worldwide

2852 2853

MGF Services Innolutions, Inc LLC

DG press WEKO MachineS

Introducing the new home for the newspaper publishing industry! Responding to the call from newspaper production pros from throughout the Americas, this pavilion provides 9,000 sq. ft. of exhibit space devoted to the needs of newspaper publishers and printers who will come seeking ways to cut costs, boost profits—and make informed buying decisions.

2952 2953

3052 3053 Meaden Precision Machined Products

-

n

AmeriWater

People's Capital & Leasing Corp

3152

3252

Habasit America

an

Print & Finishing Equipment

es

Brodie System, Inc

3352 3353

3451

ne

359

456

551 651

258

Hybrid Software

Metamation

ECRM

352

ES CA TO LAT LE /FR ORS ME VELS OM ETIN 4 & GR 5 MS .

Alwan Color Expertise

154

3457

3461

3657

3661

Future Print Sponsored By FlexTech Alliance

Roland DGA

3651 Update Ltd

3851

MultiCam Inc.

3654

Tamerica Products, Inc

3854 3855

3857

U.S. Paper Masterpiece Counters Graphix

Pack-All, Inc

3954 3955

4051

Zund America

3859

Grimco Inc. FASTSIGNS International, Inc

3957

4054

3666 3667

3761 3762 3763 3764

3766 3767

3959

PRINT MEDIA CENTER

The Marketing Pavilion

4357

4456

4461

d

GLOBAL CHANNEL PARTNER SUMMIT

G-7 ZONE

GREENspace is a timely, specialized and multi-faceted show floor feature dedicated to sustainability—what 'going green' really means to your industry…to your business…and to your customers.

3861

4057

4354 4452

Reprographic Technology

3663 3664

AnaJet LLC

For highly experienced marketers — and graphic communications pros that are, or want to learn how to become `marketing service providers’ — the popular Marketing Pavilion is here! This one-stop destination is `prime real estate’ for exhibitors seeking the most captivating location to reveal their latest marketing and graphic communications tools and technologies.

e

e,

4752 4852

4866 4867

ESCALATORS TO/FROM LEVEL 1 LOBBY 5051 5052 5053 5054

5151 5152 5153 5154

5251 5252 5253 5254

5157 5158 5159 5160 5161

5167

5260

5263 5264 5265 5266 5267

5456 5457 5458

5460 5461 5462

5463 5464 5465 5466 5467

5351 5352 5353 5354

5451 5452 5453 5454

5163 5164 5165

5256

5363 5364 5365 5366 5367

GRAVURE/Summer 2012

25


GRAPH EXPO Exhibitor List Following is a selected list of exhibitors from Graph Expo that may be of interest to those in the gravure industry.

Bobst North America Inc. Booth # 4030 

Esko Booth 427

Esko will be exhibiting a variety of products including Esko Studio and Esko WebCenter. Esko Studio is a unique set of tools for packaging artwork.

Bobst is a leading supplier of high quality printing and converting equipment to the web-fed flexible and folding carton packaging production markets.  The company offers innovative solutions for a broad range of applications and needs.

Dalim Software GmbH Booth 229

Dalim will be showing the DALM SOFTWARE ES 3 customer-facing environment, which combines prepress workflow tasks with the business logic of project planning, with milestones and sophisticated approval processes. Sharing joint projects is easy, through any standard web browser. Users are automatically involved at appropriate production stages, including reviews and approvals. The ES FTP server can

Operators can virtually hold the 3D pack in their hands. It is viewed in the designer’s preferred editor (e.g., Adobe Illustrator), helping to show how it fits together. Esko Studio is available in different versions for flexibles, boxes, labels and shrink sleeves and multipacks. Esko WebCenter is a powerful webbased Packaging Management platform to manage business processes, approval cycles and digital assets.

GrafikAmerica Booth 4336

upload files, and production parameters can be passed at file delivery through the web interface. For travelers without web browser access, ES soft-proof, annotation and approval features are available in an Apple App. Part of ES, Digital Virtual Library (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.

26

GRAVURE/Summer 2012

GrafikAmerica is the distributor for the Grafikontrol product line to include the Grafikscan 3000 100% inspection system and CR33 register control system; Eltex ESA systems and NIRA LEL. Its sister company, IMC America, distributes Recmi fully automatic log stackers and overhead conveyors; roll handling systems, and Penn Graphics semi-automatic stackers, and CAMotion automatic vision-guided palletizing/ depalletizing systems.

GMG Americas Booth 641

Several products will be shown at the GMG booth. GMG CoZone is a new, modular cloud-based tool for companies across the entire print supply chain. Its flexible modular-based business model appeals to small agencies as well as

larger corporations. CoZone also offers the essential advantages of soft proofing. GMG OpenColor is designed to target the continuing trend in package printing for the increasing use of multicolor printing. Multicolor printing typically uses spot colors in place of CMY or K.. The lack of core technology to accurately proof this press behavior poses one of the biggest challenges for packaging printers. CPCs have very high color accuracy expectations across printing processes and different converters. GMG Open Color is designed to address this complex and error prone problem in package production.

Pamarco Booth 2841

Company will have a variety of products, many for offset on exhibit at the booth.

StopStatic.com Booth number 129.  

StopStatic.com, a Division of Alpha innovation, is offering a show special kit for Static Elimination. The StopStatic™ Cords Kit, containing all three rolls of unique antistatic cords that the company

makes, gives enough products to solve all the static issues. 1 - roll of Static String™ - This is the most successful antistatic cord in the world. It can be placed in contact with feeding sheets and winding rolls. 10 meters (33’); 1 - roll of ionWire™ ionizing wire. This is the smallest diameter static eliminator in the world. ionWire™ can get in very small gaps in the machine to do the job. 7.62 meters (25’) and; 1- Roll of Static


GRAPH EXPO Exhibitor List Elastic™ - This is the first bungee cord static eliminator which stretches across for simple placement and bounces back if moved 5 meters (18’).

Two Sides US Booth 4649.

Two Sides U.S., Inc. is an independent, non-profit organization created to provide members of the Graphic Communications

Supply Chain a forum to promote the responsible production and use of print and paper, improve sustainability standards and practices, share

experiences and maximize customer confidence in our products. Two Sides Mission Statement-Two Sides is an initiative by companies from the Graphic Communications Supply Chain including forestry, pulp, paper, inks and chemicals, pre press, press, finishing, publishing and printing. Our common goals are to promote the responsible production and use of print and paper, and dispel common environmental misconceptions by providing users with verifiable information on why print on paper is an attractive, practical and sustainable communications medium. Two Sides Vision-By uniting with common purpose behind ‘Two Sides’, the Graphic Communications Supply Chain, led by sustainable and responsible forestry, paper production

and printing, aspires to ensure that, in a world of scarce resources, Print and Paper’s unique recyclable and renewable qualities can be enjoyed for generations to come.

Verso Paper Corp. Booth 3339

Verso Paper Corp. is a leading North American producer of coated papers, including coated groundwood and coated freesheet, and specialty products. Verso’s paper products are used primarily in media and marketing applications, including magazines, catalogs and commercial printing applications such as high-end advertising brochures, annual reports and direct-mail advertising. Additional information about Verso is available on the company’s website at www.versopaper.com.

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27


PRINTED ELECTRONICS

Gravure Printed Nano Silver By Sughosh Satish Bhore

I

n this study, the conductivity of a gravure printed nanosilver ink was compared after thermal drying and sintering treatment with Intense Pulse Light (IPL). The samples were printed on K Proofer on two different substrates; Polyethylene Terephthalate (Melinex, Dupont Teijin films, Delaware) and MG coated Paper (DunCote, Port Huron, MI). Thermal drying studies were performed using a hot air oven at 320 0F for paper and 2600F for PET at various times ranging from2 to 20 minutes. IPL was performed using a Xenon Sinteron 2000 unit. The use of the Sinteron 2000 enabled the nano silver (Ag) ink in to be sintered in extremely short time intervals under ambient conditions without damage to the substrate. The voltage and duration of pulse required to sinter the ink was found to be dependent on the substrate. The minimum resistivity obtained on the DunCote paper was 10.6 M Ώ/sq by thermal treatment and 6.2 Ώ/sqby IPL treatment. For the PET film, the minimum resistivity obtained was 2.4 Ώ/sq for the thermal treatment and 3.2 Ώ/sq for IPL treatment. The quality of the printed images was quantified with the ImageXpert (KDY Inc.) image analyzer. Due to the higher smoothness and low porosity of the PET, the print quality of the nanosilver ink was better on the PET than the paper.

Introduction

In the 21st century Printed Electronics (PE) can create electrically functional devices by printing on variety of substrates. When compared to conventional manufacturing methods, PE is more cost effective and easier to produce. Printing processes used for PE include Inkjet, Flexography and Gravure depending upon the requirement and available inventory. Gravure is an Intaglio printing process and has the advantage over other printing processes in that it can change Ink Film Thickness (IFT). By altering the cell depth ink film thickness can be changed and that plays a major role in deciding resistivity. Other key components 28

GRAVURE/Summer 2012

in PE are the substrate and conductive ink use for printing. Physical properties of the substrate such as roughness, porosity, and surface energy greatly influence the results. [1] Therefore, the substrate has been selected in such a way that it should be

smooth, have less porosity and high surface energy. All materials have basic physical and chemical properties; these include melting point, color and reactive characteristics which are traditionally considered independent of volume. [4] However, when materials are converted to nanoparticles these characteristics start to change [4]. The “Melting Depression” is a term used to explain that their melting point decreases as their particle size decreases. Therefore, ovens with a low temperature can be used to cure nano inks. Because of the low melting point, after heating nano ink melts and forms a homogenous conductive layer of ink on the substrate. However, this is a time consuming process and thus the heating process is not preferable in actual high-speed, roll-to-roll production. [4] Photonic sintering is new technique of sintering material by using Intense Pulse Light (IPL). As the particle size of the ma-

Figure 1: Spectral Distribution of Xenon Flash lamp (a).Energy generation using shorter wavelength (b).


PRINTED ELECTRONICS

Figure 3: Magnified images of the uncured (Extreme Left) and Sintered by Oven (From left to right) on DunCote paper at different time intervals from 2 to 20 Minutes in descending order at 1600C. Red circle indicate blow off Ink film due to excess sintering treatment.

Figure 2: Basic Set up for Xenon Sinetron 2000

Figure 4: Magnified images of the uncured (Extreme Left) and Sintered with Xenon® IPL (From left to right) on DunCote paper at different voltages from 3500 to 3100 in descending order. Red circle indicate ink blow off due to excess sintering treatment.

terial changes it also changes the ability of the material to interact with light. When particle sizes become smaller than the wavelength of light, the electromagnetic field of light can modulate the electrons of the atom. This changes the absorption characteristics of the material. [4]As the absorption characteristic changes it will cause the mobility of atoms resulting in sintering of an ink.

to 1000 nm with adjustable pulse energy up to 1500 Joules/pulse.[3] The Sinetron 2000 offers the flexibility to adjust both the energy delivered to the flash lamp and the pulse width. The pulse width can be adjusted to four different preset values by changing PFN setting. The energy to the flash lamp can be controlled by setting the voltage on the system. [3]

Sinetron 2000, is an IPL flash lamp by Xenon is used to sinter nano inks using the combination of Melting Depression and Absorption Characteristics at low temperature. These flash lamps are capable of generating high peak power pulses in short time. The spectral distribution for the lamps is shown in Figure 1 (a) [5]. High energy can be generated from these pulses in short time as shown in Figure 1 (b) [5], with very small rise in temperature of substrate to sinter the ink. The Sinteron 2000 system primarily consists of modules: Controller includes power supply and Pulse Forming Network (PFN) units mounted in a single rack and a Flash Lamp [3] The fundamental set up for IPL Sinetron 2000 is shown in Figure 2. Xenon arc lamps generate light by using high voltage to breakdown the inert gas within the lamp envelope creating a conductive discharge path where the flash exists.[4] After the lamp is triggered it emits an optical spectrum of broadband from 240 nm

The water-based nanosilver ink used to study in this experiment was made by Inktac Co. having particle size 2-10 µm. Samples were printed on a K-Proffer (RK Print-Coat Instrument Ltd.). Prints were taken on both the substrates for comparison. Selection of substrates has been done on the basis of printability & electrical properties. Oven sintering took place in variable time interval . Temperature was set at 320°F for paper and 260°F in an oven for thermal. Resistance of the sample was measured by using a Keithley 2400 digital multimeter in the 4-wire sensing mode. Finally, the sheet resistivity was calculated using the following equation [1] for both substrates. Ω/sq = R(L/W) Where: R is Resistance [Ω] L is Length [mm] W is Width [mm]

Experimental Procedure

In present work, other parameters like

PFN setting, distance of the sample from the lamp, position and pulse duration were kept constant—only the voltage required for IPL changed. For paper, voltage varies from 3100 to 3500V, and for PET it varies from 3400 to 3000V. To improve the conductivity, samples are presintered by using RC 847 lamp. It is same kind of lamp used in sintering; the only difference is it applies only single pulse for few seconds as selected. For RC 847, voltage was set at 3600V and pulse duration is 3seconds. Total time required for sintering a sample is 7 seconds including sintering timing of Sinetron 2000. Print quality was evaluated using an ImageXpert (KDY Inc.) image analysis system comprised of a motion table for sample positioning, two calibrated cameras for image capture and ImageXpert image analysis software (IX 10.0b63).

Results and Discussion

The samples were cured in an oven at different time intervals whereas specimens were cured by IPL at different voltages; results are shown in Table 1, 2, 3 and 4. Initially after printing on a paper there was no conduction of current. After first sample was cured at 2 minutes in an oven some conductivity can be seen, but resistance measured was very high it showed 26.7MΏ/sq, high resistance means less conductivity. As there is an increase in curing time, resistance decreases, but only to GRAVURE/Summer 2012

29


PRINTED ELECTRONICS Table 2: IPL Sintering at different voltages onDunCote Paper

Figure 5. Change in resistivity versus the sample number.

some extent. Minimum resistance found at 10 minutes, it was 10.6 MΏ/sq. In actual production it is very high. To get a good conductivity sample should have properly cured good Ink Film Thickness (IFT) and should be a continuous film. Due to the porosity of paper, absorption of ink on the surface is uneven. After curing where the IFT is less, ink will blow off as shown in Figure 1. In first few samples, ink tries to cure itself and become conductive, but with an increase in time, the ink will blow off more and create an “Open Circuits” that results in increase in resistance. On the other hand, in IPL sample sintered at different voltages. In the trial, one voltage was set at highest level and the resistivity was found to decrease significantly (measured to be 6.5 Ώ/sq). The lowest resistivity was found at 3400 V, because in the

30

GRAVURE/Summer 2012

first trial at highest level some part of the ink burnt out and creates an obstacle for conduction. Thus resistance found is little higher than second as shown in Figure 4. As voltages decrease from 3400 to 3000, resistance increases step-wise because of uncured ink. Table 1: Thermal Drying at different time intervals on DunCote Paper

Sample No

Voltage (V)

Time (Seconds)

Resistance ’Ω/sq

1

3500

7

6.5

2

3400

7

6.2

3

3300

7

20.5

4

3200

7

23.8

5

3100

7

71.6

The results for IPL and Oven sintering for PET are shown in Table 3 & 4, respectively. Initially after printing, PET showed high resistivity about 22 MΏ/ sq. After oven curing of 2 minutes, it decreased up to 4.2 Ώ/ sq. Minimum resistivity acquired at 15 minutes it is found to be 2.4 Ώ/sq. For further study some samples were sintered for 20 minutes, but there was no change in the value It remained constant. Sintering results by IPL showed that resistivity decreases with decrease in voltage, but only to some extent, then it again starts increasing. The minimum resistivity found at 3200 V it is 3.2 Ώ/ sq. At higher voltage samples have higher resistivity because of cracks and some burn spot developed on the Ink film as shown in Figure 6. If the voltage drops from 3200 V there will some ink remain uncured that results in higher resistivity. Graphical presentation of change in resistivity against sample no is shown in Figure 5. Table 3: Thermal Drying at different time intervals on PET Sample No

Temperature (°F)

Time (Minutes)

Resistance ’Ω/sq

1

260

2

4.2

2

260

5

3.1

Sample No

Temperature (°F)

Time (Minutes)

Resistance M ’Ω/sq

1

320

2

26.7

3

260

10

2.9

2

320

5

21.7

4

260

15

2.4

3

320

10

10.6

5

260

20

2.4

4

320

15

21.3

5

320

20

22.9

Table 4: Sintering by IPL at different


PRINTED ELECTRONICS

Figure 6: Magnified images of the uncured (Extreme Left) and Sintered with Xenon® IPL (From left to right) on PET at different voltages from 3400 to 3000 in descending order. Red circle indicate cracks on Ink film due to excess sintering treatment.

Figure 7: Magnified images of the uncured (Extreme Left) and Sintered by Oven (From left to right) on PET at different time intervals from 2 to 20 Minutes in descending order at 1300C

Voltages on PET Sample No

Voltage (V)

Time (Seconds)

Resistance ’Ω/sq

1

3400

7

5.8

2

3300

7

4.0

3

3200

7

3.2

4

3100

7

5.4

5

3000

7

5.8

Conclusion

From the results it can be concluded that an IPL sintering system can very useful in high speed production process like roll-toroll. Resistivity obtained on PET by IPL is almost equal to that obtained by oven curing, and for paper; resistivity obtained by

IPL is far less than the oven curing. Saving of time is the biggest advantage of IPL over the oven heating. Another important advantage of IPL is it doesn’t change the color of the sample as sintering in an oven can. During the experiment, the color of the paper sample altered while heated at high temperature consistently. It turned from white to yellow. The important aspect to remember while working with IPL is that it is very sensitive to voltage change. As seen from the results, a small change in voltage greatly impacts the output. There are some burning issues also because of the higher voltage. But this problem can be fixed by changing the other parameter such as distance of the sample from lamp or by using PFN settings which can be used to change

the output power from the lamp. For further work, other nano ink such Nano copper which are cheap in cost and readily available can be used. These nano copper inks can be used on a variety of substrates by using different printing process such as inkjet or screen to find the compatibility with the process. Sughosh Satish Bhore, a student at Western Michigan University, is one of the winners of the 2012 Flint Technical Writing Contest. References: 1. Dr. Joyce, M. 2008. Printed RFID Tags on Packaging Materials, Kalamazoo, Progress Report No.3, Western Michigan University. 2. Kim, Hak-Sung; Dhage, Sanjay R.; Shim, Dong-Eun; Hahn, H. Thomas, .2009. Intense pulsed light sintering of copper nanoink for printed electronics, California, University of California.3. 2011. Xenon Sinteron 2000-L Manual, Wilmington, Xenon. 3. 2010. SINTERON 2000 Photonic Curing R&D System, Literature Available: http:// uv-curing.xenoncorp.com/Literature/PDF/ SINTERON_2000.pdf 4. Xenon Corporation. Available: http:// www.xenoncorp.com/sintering.html 5. Carter, M. Seras, J. 2007, Photonic Curing For Sintering Of Nano-Particulate Material, Rapid City, South Dakota School of Mines and Technology.

2012 GAA Calendar of Events September 17-21

GAA Basic Gravure Seminar

Western Michigan University/Staybridge Suites, Kalamazoo, MI

October 7-10

Graph Expo

McCormick Place, Chicago, IL

October 8-9

GAA/GEF Fall Board Meetings

October 9-11

GAA Packaging & Products Conference Golden Cylinder Awards Luncheon for Pkg & Product Categories Cylinder Society Induction for Product & Packaging Sectors

McCormick Place, Chicago, IL

November 11-14

Gravure Publishing & Premedia Conference (GPPC) Golden Cylinder Awards Luncheon for Publication Categories Cylinder Society Induction for Publication Sector

Waldorf Astoria Naples, Naples, FL

2013 GAA Calendar of Events March

Printed Electronics Symposium GRAVURE/Summer 2012

31


te a D e h t e Sav

March 2013

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 in March of 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


TECHNOLOGY

Advancements in ESA in Rotogravure By Joseph K. Steingraeber

E

lectrostatic Printing Assist (ESA) has contributed more to improve the quality of rotogravure printing than any other innovation. ESA systems optimize ink transfer from the gravure cylinder to the printing substrate. Over the past 30 years ESA power supplies and application mechanisms have undergone many changes. Such technical developments, particularly those from ENULEC, have since raised the bar for ESA.

ESA Eliminates Dot Skip

ESA systems facilitate ink transfer in the rotogravure process to ensure that each engraved cell filled with ink can make contact to the substrate for optimal ink transfer. In the absence of ESA, gravure print is prone to missing print; this is known as dot skip. Dot skip is a common problem seen in the half tones and below. When printing paper, cartons and films ESA is an effective solution to complete vignettes, improve ink density and eliminate dot skip. When the objective is to produce consistent quality high standard

Left with Enulec ESA, Right without ESA

34

GRAVURE/Summer 2012

gravure print, ESA is an important tool that can help achieve quality standards. Dot Skip occurs when ink in the image cells do not make contact to the substrate. The physical cut of the doctor blade used to clear ink from the surface of a gravure image cylinder can leave behind a concave meniscus of ink in the cell, thus ink is in position beneath the surface of the image cylinder. When a separation inhibits contact between ink and substrate, poor print quality with missing dots will occur. Ink contact to the substrate is the fundamental requirement essential for quality gravure printing. The transfer of ink in the gravure process is a phenomenon of inter-molecular attractive forces that occur between the ink and substrate called capillary action. (Concept: think of a water leak in a house where the water

path climbs up a wall.) Molecules of liquid media will move in any direction of molecules of a solid. In relative terms, the rotogravure process draws ink out of the image cell by means of contact-adhesion relationship resulting in a form of capillary action that enables evacuation of the gravure cell.

How ESA Systems Work

Simply put, ESA elevates ink to the surface to achieve contact with the substrate. How does that happen? ESA Systems work by means of 300-1500 Volt DC electrostatic force between a semi-

Top sample is with ESA; bottom is without ESA.

The latest presses coming from Italy are equipped with Enulec ESA

ESA 1000 installed onto latest cigarette packaging press.


TECHNOLOGY

conductive impression roll, the substrate and the grounded gravure cylinder. The electrostatic force produces a downward force into the grounded gravure cells which creates pressure that disturbs ink cell contents resulting in a wave that elevates the ink to the surface. When ink is available at the surface of the cell, it will make contact with the Substrate. This enables capillary action to transfer ink to complete the rotogravure printing process. Advantages of ESA include: • Optimum ink transfer to paper and film substrates • Longer running time for impression rollers • Reduced impression roll line pressure • Optimal print results on low quality papers, board and plastic materials • Faster production speed and best print results • Consistent control of print quality • Built in antistatic safety bars before and after each print station

There are basically two types of electrostatic printing assist systems—contact and non-contact types.

There are basically two types of electrostatic printing assist systems—contact and non-contact types. ESA can be applied directly to the surface of the roll or through the core via the impression roll shaft. Top load systems types have a charge bar electrode, conductive roller and direct contact plates/brushes Damaged Surface of the Roller

...or the Surface of the rubber can be Damaged

Single layer semi-conductive impression roll shaft insulated from Ground (left). Semi-conductive impression roll insulated from ground (right).

that require a 2 layer impression roller having layer one with insulation and layer two with semi-conductive material. Core charge systems require single layer impression covered in semiconductive material. The bearing housings need to be insulated from ground. Insulation is normally done by milling out the press frame and inserting non-conductive phenolic bearing shells a task normally completed by the OEM for new presses. ESA systems have one thing in common; they all depend upon this 300-1500 volt field between the ESA impression roller, substrate and grounded gravure cylinder in order to create ESA. The methods of design used to transfer ESA energy varies greatly in terms of high voltage generators, ESA applicators, reliability, safety and performance. Conductive roller applicators charge through metal rollers through direct contact against the ESA impression roll. Conductive rollers span the impression roller and are typically small diameter (e.g. small metal roller skate wheel.) Due to the small bearings in the metal rollers, they are quick to wear out mainly due to heat related to the speed difference of the impression roller. In addition, they can bounce, bend and arc. Hence, in the 70s and 80s the industry began using direct contact brushes or metal plates which mount in a static position

Damaged Surface of the Roller

...this results in Stripes of damaged Areas

Dirty System can lift Contacts

Sparks can occur ...

GRAVURE/Summer 2012

35


TECHNOLOGY

Typical Direct Contact Charge Contacts riding directly on the face of the impression roller.

directly upon the ESA impression roller. The metal paddles/ brushes also make direct physical contact to the rotation of rubber impression roll. This condition brought forth another set of challenges that effected impression rolls, including rapid increase in shore hardness as the constant rubbing of metal to the pressure roller will polish the roller surface. Moreover, dust particles can accumulate under the plate/brushes, which can lift the contacts paddles (a spark hazard) and eventually the dust particles will fall into the ink tray directly further affecting the quality of the print.

ESA power consistently to the impression roll. This advancement also allows the charge bar to be positioned 1-6 mm air gap which is a 50% improvement in proximately of the bar to impression roll, eliminating air gap (air is resistance to the transfer of ESA current.) The combination of having twice as many pins and half the air gap compared to older technology allows for safer voltage levels that more efficiently deliver ESA power. The safety of the non-contact electrode systems are further enhanced with integrated static eliminators leading into and out of each print station which eliminates static from accumulating on the substrate and also provides for static elimination when ESA is not in use.

Cleanliness Counts

ESA performance can be hindered by the cleanliness of systems when they become contaminated with ink and dust particles. In order to overcome this problem, ENULEC designed a virtually

Today non-contact top load systems are the practical ESA solution due to technological advancements in charge bar design, safety and ease of installation onto existing presses. This type of ESA system operates with no contact to the impression roll which eliminates the physical abrasion problem and the life of Open Body ESA Electrode Bar Top Load Non-Contact ESA Example

Non-Contact ESA Example

Enulec ESA 1000 Dot Skip Eliminator with integrated static eliminators on entry and exit of print station.

maintenance free air-assisted impression roller charge bar. In contrast with conventional charge bars with exposed charging pins, the advantage of the ENULEC air-assisted ESA charge bar is that it does not require regular cleaning. By virtue of its special electrode construction, the charging pins in this bar are completely embedded into a small tube and this, together with a small air pressure in the area of the ionization points enable the air-assisted electrode cells to prevent contact with ink par-

the impression roller is significantly longer. Top load electrode bars in standard form have exposed pins and that provide optimal ESA performance in the majority of pressroom environments. ENULEC has further improved the electrical safety characteristics of its ESA1000 charge bar electrode by providing safety resistors on every pin within their bar and by increasing the number of pins on the charge bars having pin pitch of 5mm providing 2-4 times more energy points for the ESA to transfer 36

GRAVURE/Summer 2012

Air-Assisted ESA 1000EX Charge Bar.


TECHNOLOGY ticles and dust particles thus eliminating contamination. The advantage of being able to run ESA on press without contamination, performance loss or cleaning interruptions has earned ESA 1000 Air-Assisted Charge Bar

Gravure Pilot Plant with Enulec ESA 1000

this ENULEC air-assisted ESA bar a respected position in the rotogravure technological advancements of this millennium. Direct Charging (Core Charging) systems deliver a charge to the impression roll shaft; the charge flows from inside out through a single layer semi-conductive impression roll. Typical methods used to apply the charge have been through carbon brush contact assemblies that contact the shaft. The physical

Enulec fluid coupling and Top Load ESA systems are integrated into new presses available from your leading Italian gravure press OEMS

contact of brushes to the rotating shaft is known to wear and create downtime issues. In order to overcome these maintenance issues ENULEC designed a special charge applicator having no moving parts to transfer the current to the core of the impression roller (sleeve mandrel.) Using a specially developed fluid transmission coupling which does not have any brushes or bearings has made it possible for gravure printers to run for years without maintenance issues related to ESA. Core charge systems require the shaft/bearing housing to be isolated from the press. Fitting for an insulation shell is done by milling out of the machine frames in order to expand the bearing sockets to open the area to hold isolation shell. This work can be a daunting task on existing presses and is most efficiently accomplished at the time of press manufacture. Today

ENULEC Fluid Coupling Core Charge

GRAVURE/Summer 2012

37


TECHNOLOGY

ESA 1000 Touch Screen Interface with Quality Management Software

ENULEC EST Antistatic Bar.

ESA 1000 Capacitance Free Power Supply integrated into a new rotogravure press

the ENULEC fluid coupling ESA is now an integrated feature built into the new presses available from leading Italian gravure press OEMs.

Factors Affecting Performance

Successful ESA performance relies upon an effective method of application, a properly specified ESA impression roll in range for the system used, and a reliable power supply to bring forward the energy necessary to create ESA. Conventional ESA power supplies employ cascade-based generators for high voltage generation. Although they provide ESA power, safety can be an issue in circumstances such as when the impression roll is raised. When this occurs, the safety release contacts shut off the generator. However, the older power supplies have capacitors that release the residual internal charge remaining in process of generation to the ESA applicator. A concern is that the ESA impression roll may still be receiving a charge for several seconds after the power supply is shut off. This can become a problem when the impression is raised. When a charge continues to be applied onto the impression roll while it is raised, it will discharge to the gravure cylinder resulting in a arc. (Concept: If you ever worked on an unplugged microwave oven, opened the back reached in and got shocked you made contact with a capacitor) ENULEC designs and builds only capacitance-free high voltage generators having high internal resistance that enable optimum power transfer to the ESA impression roller and increases the performance of the ESA system considerably. With capacitance free technology, the ESA charge bars can be guaranteed

38

GRAVURE/Summer 2012

safe and current-free immediately after the system is switched off as there is no residual charge in the system. Alternatively, when the ESA is switched on, high voltage is available immediately and the system can be used straight away without delay. This specially developed capacitance-free high voltage generator enables the system to be used in conjunction with ESA impression rollers having high surface resistances, including resistances outside the range normally specified. This results in a substantial increase in impression roller life related to electrical specification. ENULEC速, a Germany manufacturer located near Hamburg, has introduced developments in the field of Electrostatic Assist and static elimination in terms of safety, performance and reliability. The company specializes in optimum charge and discharge systems for the printing, converting and packaging industries. ENULEC is best known for their ENULEC ESA1000 Dot Skip Eliminator system utilized by the leading OEM rotogravure press manufactures and high quality gravure printers worldwide. Founded in 1981 by Hubertus and Christa Dettke, the company has been owned and managed by the Dettke family for more than 30 years. Since the 1980s, ENULEC has concentrated on the design and supply of electrostatic printing assist systems and discharging systems, developing expertise in this area. All parts of the system are manufactured in-house. The company supplies parts for the (unlimited) life of any ENULEC product sold. Where component parts cease to be commercially available, the company maintains that any newly sourced or designed parts or assemblies will be compatible with existing systems and capable of being retrofitted.


We want to see your company in the 2013 Buyers’ Guide! f ciation o o s s A e r Gravu America ’ Guide ure Buyers v ra G 3 1 0 2 A.org

www.GA e: ories includ ide Categ Buyers’ Gu cies an ult ns Industry Co lies ces & Supp rkflow Servi Digital Wo ces rvi Se ed lat Gravure Re nt & Equipme Machinery lies ols & Supp Blades, To nts ngs & Pigme Inks, Coati tes er Substra Paper & Fib bstrates & Plastic Su Film, Foil Printers g gin cka Pa nters corative Pri Product/De nters Pri n tio ca Publi & 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. We’ll soon be sending out information on how your company can be listed in the 2013 Buyers’ Guide, which will be published in January 2013.

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 sschippits@gaa.org.


EDUCATION EDUCATION

2012

GEF Scholarships Winners Corporate Leadership Scholarships

Four Corporate Leadership Scholarships were awarded for the 2012 academic year in the amount of $1,500 each, made possible by sponsorship of companies in the gravure industry, including Alcoa, Cerutti, Gravure Publishing Council (GPC), Gravure Education Foundation (GEF). This year’s winners are Chen Zhang, RIT; Nicholas, Gawreluk, RIT; Greg DeGross, Western Michigan University; and Bonnie Hanna, Clemson University, respectively. Chen Zhang is a student at Rochester Institute of Technology. He has a passion for Interaction Design, Branding and Art Direction. He especially likes minimal design which is functional, structured, visually attractive and elegant. He is now a MFA (Master of Fine Arts) candidate majoring in Computer Graphic Design from RIT. His undergraduate background is New Media Design from Beijing Institute of Fashion Technology. He had a summer internship working as Information Architect in Ogilvy & Mather in New York. He has also worked with Prof. Chung on the redesign and rebranding of the RIT Gravure Day 2012 program. Nick Gawreluk is a student at the Rochester Institute of Technology (RIT) entering his senior year with a major in Print Media and minor in Business Administration. At RIT, Nick is heavily involved in the School of Print Media and has international experience in the printing industry. Within the past two years, Nick has worked in Germany and Brazil for Heidelberg and is looking to continue his global adventures. With the support of a GEF scholarship he will be able to continue working hard in school and pursue his dream of one day becoming a leader in the printing industry. Expected graduation is spring 2013. Greg DeGross is from Grayslake, IL. He is a senior at Western Michigan University, working on a major in Graphic and Printing Science and minor in Business. He intends to pursue a career in the printing and packaging industry. This is his second summer interning at Nosco, Inc., Gurnee, IL, a company specializing in printing for pharmaceutical packaging, RFID and serialization. Greg is working as a Quality Assurance Specialist and says he is having a fantastic experience learning the intricacies of the printing business. Last summer he worked in the Digital Printing Department, operating an HP Indigo 4000 series digital press. He notes that this scholarship will allow him to concentrate on classes and experience more of the industry. He is active in Western Michigan University’s Graphic Arts Society, and for nine years have been volunteering in his community.

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GRAVURE/Summer 2012

Bonnie Hanna is a Senior, Graphic Communications major at Clemson University from Statesboro, Georgia. She hopes to graduate in May 2013 and pursue a career in the vast field her major encompasses. Bonnie has held leadership positions in campus organizations that utilized her communicative skills including the Fellowship of Christian Athletes, Reformed University Fellowship, and the Residence Hall Association. In addition, some of her most rewarding contributions to campus life resulted from the two years she served as a Resident Assistant. Bonnie participated in the Corporate Internship Program at Quad/Graphics in the summer of 2011, and worked as a designer for Printing Solutions in Walhalla, SC, in the spring of 2012. This scholarship from the Gravure Education Foundation will allow Bonnie to be a full-time student this year as she focuses on wrapping up her undergraduate degree and pursuing exciting, new opportunities in the graphics field!

Memorial Scholarships

In addition, two Memorial Scholarships were awarded to honor the memory of former leaders and supporters of Gravure Education— Harry V. Quadracci Memorial Scholarship and Werner B. Thiele Memorial Scholarship. These were won by Alexandria Powers from Cal Poly; and Lisa Car from Clemson University, respectively. Alexandria Powers is a senior at California Polytechnic State University studying Graphic Communication with a double emphasis in Web and Business Management. She grew up in Los Altos California with her younger brothers, Luke and John, and her two loving parents. She is currently working at Adobe Systems Inc. as an intern and hopes to peruse a career that encompasses her creative talent. Alexandria enjoys swimming, kayaking, going to the beach and painting on her free time. Lisa Carr is currently a sophomore Graphic Communications major at Clemson University. In high school, Lisa completed all levels of Digital Art classes and with the recommendation from a high school teacher, decided to channel her creative tendencies and pursue a degree in Graphic Communications. Lisa is the Vice President of the Graphic Communications honors fraternity Gamma Epsilon Tau – CU Chapter. She is very honored to be the recipient of 2012 Werner B. Thiele Memorial Scholarship and says it will allow her to continue to be tremendously involved in the Graphic Communications community at Clemson University and graduate Spring 2015.


GRAVURE Magazine 2012 Subscription Form GRAVURE is an online magazine. Please enter my online subscription for GRAVURE Magazine United States/International:

 1 Year/ $67.00

 2 Years/ $130.00

Type or print clearly the following information: Name _______________________________________________________________________________________ Title ________________________________________________________________________________________ Company Name ______________________________________________________________________________ Address ____________________________________________________________________________________ City, State, Zip Code, Country & Postal Code _______________________________________________________ ____________________________________________________________________________________________ Phone Number _________________________ Fax __________________________________________________ Email Address __________________________Website _______________________________________________

If a Printer:

We print: We use the following processes: In-house, we have:

If a Print Buyer: We purchase printing for: We purchase using the following processes: In-house, we have: We purchase substrates directly: We purchase image carriers directly:

 Publications  Packaging  Products  Gravure  Flexography  Lithography (offset)  Prepress  Engraving/plating  Bindery  Converting Operations  Publications

 Packaging

 Products

 Gravure  Design  Yes

 Flexography  Prepress  No

 Lithography (Offset)

 Yes

 No

If a Supplier: We support: Our primary business is:

 Publications  Packaging  Products  Paper  Ink  Manufacturing  Other, please explain _____________________________ _________________________________________________ _________________________________________________

Payment Information:  Check or money order enclosed (U.S. funds only) Amount $ ___________  Credit Card amount $ __________________________________________ Credit Card:  VISA  MasterCard  American Express Account Number __________________________Exp. Date ___________________ Name Printed on Card _______________________________________ Signature __________________________________________________

Return this form with payment to: GRAVURE Magazine P.O. Box 25617 Rochester, NY 14625 Phone: (201) 523-6042 Fax: (201) 523-6048 web: www.gaa.org Rev. 09/11


EDUCATION FEATURE

2012

GEF/Flint Group Technical Writing Competition Winners E ach year Flint Group, Plymouth, MI in conjunction with the Gravure Education Foundation sponsors a Technical Writing Competition to encourage scholarly inquiry into technical subjects related to the gravure printing process. The contest is open to all full-time college students in either an undergraduate or graduate program. Congratulations to this year’s winners: Sughosh Bhore, 1st place Graduate for “Study of Gravure Printed Nano Silver by Thermal Drying and Intense Pulse Light (PIL)”; Roseanne Bubb, 1st Place Undergraduate for “The Exploration of Gravure in Photovoltaic Processes”; and Paige Cornelison, 2nd Pace Undergraduate for “Improving the Wettability of Inks and Substrates for Gravure Print.”

Sughosh Bhore is a first year graduate student at Western Michigan University. He has completed his Bachelors degree from PVGs COET, Pune University, India. He has worked for OMNOVA Sol. as a Research Assistant as well as at a Publishing and Printing firm in India for 2 years. He has been honored with several prestigious scholarships such as: Print Graphics Scholarship Foundation (2011), J N Tata Endowment (2011), Tata Chemical Golden Jubilee Foundation (2011), Jamsetji Tata (2012). For the curricular research, he is working with Dr. Margaret Joyce in Printed Electronics. Currently, he is working as summer intern in R&D at Sun Chemical, Carlstadt, NJ.

42

GRAVURE/Summer 2012

Rosie Bubb, California Polytechnic State University third-year student and Minnesota native, is pursuing her bachelor of science in Graphic Communication with a minor in Packaging. Having a fascination with print design and new applications for print, she is concentrating in Design Reproduction Technology and Graphics for Packaging. In addition to exploring print applications, she loves to explore the Central Coast via hiking, running, and sailing. This summer, she plans to merge her interests in travel with her knowledge of Graphic Communication through her graphic design internship with Southwest Airlines in Dallas.

Paige Cornelison is from Susanville, California, where she lived with her parents, brother, and sister. She is now a 2nd year Graphic Communication major at Cal Poly State University, San Luis Obispo (and loves every minute of it!). She holds a concentration in Management, and is expected to graduate in June of 2013. Upon graduation, she would like to enter into the printing world, and is interested in a career related to quality control. Paige spends her extra time with her local church family, and likes to explore the beautiful Central Coast area with her boyfriend and friends.

In addition to a cash prize, the students will have the winning papers published in Gravure magazine throughout the year.


GAA MEMBER PROFILE

Steingraeber Company Steingraeber is a St. Louis-based company, who specializes in Electrostatics and Ink Management systems. It is the North American partner of ENULEC Electrostatics GmbH and Opt-Color Viscosity controls. In addition, the company recently released their own line of automated ink dispensers. Today, Steingraeber provides systems to blend ink, control ink on press, Electrostatic Assist for complete ink transfer from the gravure cells and static eliminators to bring safe levels of voltage to substrates used in the printing and converting processes. A leader in electrostatic assist systems, the company’s ENULEC ESA1000 Dot Skip Eliminator with unique “air assisted” electrode bar technology is a low maintenance electrostatic assist solution. The company is a partner supplier of ENULEC headquartered near Hamburg Germany; there are 3400 ENULEC ESA systems installed throughout the global gravure markets. ENULEC is the ESA system utilized by many major gravure press manufactures in Italy. Their Opti-Color Viscosity Controls and on-press ink blending systems enable Steingraeber to complete on-press ink management controls for their customers. The Opti-Color OBD rotational viscosity sensors and ViscoStar falling ball viscosity sensors are standard ancillary equipment installed on presses throughout North America and around the world. Steingraeber automated ink dispense systems are gravimetric based custom configured systems for 10-76 liquid media components for dispensing solvent, water, UV inks and coatings products. They provide dispensing solutions for applications from lab to ink room to pressroom The com-

Solvent Based Ink Dispenser Model SL53/S

ENULEC ESA1000 Dot Skip Eliminator installed by Steingraeber onto a Rotogravure press

pany is also able to retrofit select older ink dispensers to new technology with new dispenser heads and software solutions. To complete their portfolio of solutions, they supply Powerwise ink sumps, pumps and mixers. With 20 years of expertise in providing electrostatic, viscosity and ink

management solutions to the printing and converting industry, Steingraeber is a valuable resource to the industry and GAA is pleased to have them as a new member. For further information, visit the company’s website: www.steingraeber-corp.com GRAVURE/Summer 2012

43


NEW PRODUCTS Gallus Introduces Press with Gravure Printing Unit The Gallus ICS 670 shown at Drupa was equipped with a great number of innovations, such as the new gravure printing unit and the cold foil module.. According to the company, the new gravure printing unit sets new standards in view of operation, operating costs and flexibility. In addition the combination with the platform concept of the Gallus ICS 670 it opens up highest flexibility and efficiency in production. Another innovation— the new 100% quality control in combination with the automatic single blank ejection on the Gallus flat-bed cut-line FCL—helps increase inline efficiency. The Gallus ICS 670 was demonstrated live at Drupa.

Flint Group Introduces PluriTech™ Shrink-U Flint Group has introduced PluriTechÔShrink-U, the next generation of solvent-based packaging inks for the North American Gravure Shrink Sleeve Market. Over the last five years the Shrink Sleeve market has become more complex and new film technologies have driven printers to acquire multiple ink systems to compete. High fidelity graphics are also pushing the limits of the conventional shrink ink systems. With PluriTech™ Shrink-U Flint Group responds to these challenges. PluriTech™ Shrink-U provides excellent adhesion to a wide range of substrates making it truly “Universal.” This new ink

system further delivers the peace of mind that comes with zero blocking, flexcrack free, and zero ink pick.

GMG Introduces OpenColor Another innovation unveiled at Drupa was the GMG OpenColor, its new proofing solution for the packaging market. GMG OpenColor has the ability to allow for color-accurate reproductions of print processes that use spot colors and multicolor separations with more than the traditional four process colors (CMYK). Until now, the overprinting behavior and color interplay between CMYK and spot colors could only be reproduced by combining a CMYK profile with spot color libraries. The major drawback of this method was the inaccurate simulation of spot color overprints. With the increasing use of multicolor printing, the simulation of spot color overprints currently poses one of the biggest challenges for packaging printers. GMG OpenColor is the first profiling tool on the market that provides this capability. Offering an accurate prediction of overprints, GMG OpenColor creates high-quality multicolor profiles simulating the printing behavior of diverse printing technologies, media types, and screenings. GMG OpenColor comes in different versions tailored to fit different printing technologies and customer requirements.

Value Series Rotary Cutting Tools Madern USA has introduced a new range of solid cutting tools, called the Value Series. Value Series rotary tools are a stripped down design to allow lower cost than traditional fully segmented Madern tools. The Value Series tools are solid hardened cylinders that are manufactured for high quality cuts at the highest speeds and for countless products. They can be made based on the crush cut or scissor cut (MP) cutting principles, depending on the carton

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. 44

GRAVURE/Summer 2012


NEW PRODUCTS shape and type of paperboard to be used. MadernUSA also has the capability to combine cutting and creasing in the same station, depending on carton intricacy and die-station availability. The Value Series cutting tools combined with the Revo-Line Die-cutter (more info next issue) will be one of the most competitive Rotary Die-cutting solutions.

Schober Unveils Automated Robotic Stacking System At Drupa, Schober introduced the high velocity Twin Spider Automated Robotic stacking system for their RSM Rotary Die Cutting Machines. Specifically designed for precise stacking and counting of products up to 40” in length (1000 mm), this new delivery technology is ideal for IML and other labels as well as nested product configurations and different profile jobs that have been ganged together into one print repeat. The Twin Spider Robotic system is used in line with the proven Schober RSM rotary die cutting technology. Speeds of up to 195 f/min (60 m/min) are attainable with a maximum cycle rate of 50 cycles per minute. Schober USA is the North American representative of Schobertechnologies GmbH, a leader in rotary web converting technologies for the label, packaging and converting industries.

Sun Chemical Launches SunUno Solimax Ink System

Sun Chemical, the world’s leading manufacturer of printing inks and pigments, has launched the SunUno Solimax multi-purpose ink system. Suitable for both surface and reverse print applications on a number of the commonly used flexible packaging substrates, Solimax is designed to maximize press

room efficiency while simplifying the overall print production process. Suitable for both flexo and rotogravure, the SunUno Solimax ink system is the latest generation of inks providing a single platform that can cover multiple end use applications. Intended for surface printing and adhesive lamination for various end-use applications such as lidding materials, medical laminates and food packaging for confectionery and snack food, Solimax is compatible with both solvent-free and solvent-based lamination technologies.

Multifunctional moisture meters from DomoSystem The multifunctional Humitest® moisture meters from DomoSystem enables measuring the water content and the temperature of pile paper and liner paper as well as the ambient humidity of the paper. Measuring the water content and the temperature of paper and liner paper as well as ambient humidity ensures quality monitoring at different stages of the transformation and the use of these materials. Designed for reliable measurements on site, the new moisture meters for paper are fitted with a 0.3 meter long sword-sensor. They measure: paper water content and temperature; ambient humidity and ambient temperature; and dew point. In addition, with the Humitest for paper expert, they can measure wood equilibrium moisture content and kraftliner paper and test-liner absolute moisture.

GAA 2012 Basic Gravure Seminar Looking o t w e N

the Gravur!e Industry

SEPT. 17, 2012 Basic Gravure Seminar

to Hone Your Skills?

Western Michigan University Kalamazoo, Michigan The Basic Gravure Seminar teaches state of the art technologies and the latest industry challenges on 26 topics covering the entire gravure printing process. It gives you a solid foundation in all areas of the gravure process, as well as filling knowledge gaps for experienced practitioners who have not been formally trained.

The basic gravure seminar is valuable to pressroom supervisors, press operators, print buyers, designers, ink suppliers, paper suppliers, engravers, and management. For more information, log onto the GAA website at www.gaa.org or contact Bill Martin at @gaa.org. GRAVURE/Summer 2012

45


PEOPLE N EWS

GMG Announces Appointments/Promotions As a result of expanding growth and greater activity, GMG Latin America, the regional business arm of GMG, a leading developer and supplier of high-end color management software solutions, is pleased to announce the appointment of Enrique Amigo to the position of Regional Sales Representative. In addition, GMG recently promoted Paulo Monteiro to Business Director, GMG Latin America. Enrique brings a wealth of color management expertise — including in-depth GMG knowledge — with over 20 years’ experience as a color management consultant in Latin America. Most recently, he was Latin America Director for GMG Consulting, an organization that cooperates with GMG, to develop consulting services and specialized technical assistance for color management. Concurrently, he has been Web Editor-in-Chief at Red Gráfica Latinoamérica, developing and managing research content (notes, articles, interviews and audiovisual materi-

als) for the graphic arts industry in Latin America. Previously, he was Technical Advisor for Quebecor World/Worldcolor/Quad Graphics Colombia.. Enrique, based in Bogota, Colombia, will be responsible for supporting distribution channels along with Saul Arana, who joined GMG early this year as Technical Support Manager, GMG Latin America. They both report to Paulo Monteiro. Paulo Monteiro has been promoted to Business Director, GMG Latin America. Now in his sixth year at GMG, Paulo Monteiro will maintain GMG’s growing Latin American presence as Business Director. In this role, he will continue to build and manage distribution channels for GMG color management solutions throughout Central and South America. Paulo has specific responsibilities for sales, support, service and distribution and will also be the liaison to key industry associations and standards committees.

CONFERENCE

GAA Tour of the Government Printing Office Part of the GAA Environmental Workshop, which was held in June was a tour of the Government Printing Office in Washington. The tour included a walk through the pressroom and a demonstration of some old craft skills. A 150th Anniversary exhibit was on display in the museum area. The individual in the photos is the master marbler at Government Printing Office. He has been doing this job for 50 years. He showed the visitors how he makes various marble designs, colors, etc. On the side of the walls in his working space, you can see samples. According to him, there are only a handful of marblers in the US. In addition, he showed the visitors the congressional records and other government books that are marbled. He also showed samples of embossing on books, menus and an embossing on the carrier that the president is given to sign bills. 46

GRAVURE/Summer 2012


Engaged readers. Enthusiastic customers. Increased circulation. Increased store traffic & sales. Let Quad/Graphics show you how to make the connection and extend brand experience across all channels and devices to enhance the overall value of your print. www.QG.com/redefining-gravure 1.877.310.9557 redefining-gravure@qg.com

FOLLOW QUAD/GRAPHICS ON

Innovative People Redefining Print

SM

Š 2012 Quad/Graphics, Inc. All rights reserved. | 07.12 | 12-0115


GAA Press Operator Certification Program F E AT U R 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 Pressroom Safety ➋ The Impression Roll ➌ Doctor Blades ➍ Cylinders ➎ Inks ➏ Color Theory for Press Operators ➐ Pressroom Troubleshooting ➑ Gravure Press Fingerprinting ➒ 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. 48 GRAVURE/April 2011

GRAVURE Summer 2012  

GRAVURE Summer 2012

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