Automated solution from Xerox

The Xerox iGen4 together with the Stora EnsoTM module is an automated solution for the digital production of cardboard packaging. For digital color printing is used Xerox iGen4 machine, UV or aqueous coating with varnish is manufactured by a company EPIC and Die cutting is developed by Stora Enso requirements.

Digital – Xerox Igen4

The overall system allows clients producing small runs of printed packaging. Since all modules are connected to a single line, we have maximum productivity when making packaging. For example, at the entrance to the system we insert a piece of paper / cardboard, and at the output we have printed and die- cutted packaging sheet, ready for folding and gluing.

Color printing is in charge of the Xerox iGen4 machine with speed of 110 ppm, and it is a unique solution on the market for making printed packaging with format 364×571 mm, and soon is coming format 364×660 mm. The system is completed with an Epic CTi-635 machine for UV or aqueous coating, Stora Enso unit for collecting and transporting sheets and cutter developed by Kama for Stora Enso. The coating is required for many applications in packaging and gives a quick-drying, UV or based on water protection to package from dirt and scratches. Xerox solution Gallop helps protect the environment because it allows printing small runs on demand, reducing the unnecessary cost of materials, and uses cardboards that are recycled and can be recycled again.

Cost

Steps in the process prior to printing – Digital printing eliminates steps and processes before printing (making films, lighting plates, assembly, and subsequent corrections). Digital printings is ideal for automating the entire procedure, thereby saving time, energy, manpower and reduce steps in production.

Obsolescence of products – in all industries aim is to reduce waste and scrap. It is completely undesirable to have a lot of ready-made storage containers of ambalage that may never be used.

Statistics show that 40-50% of printed material is thrown away because it will not be used or because the statute of limitations.

Taking care of the environment – almost everywhere is present demand of caring for the environment and the use of recycled materials. The digital process reduces waste, saves material and energy, and therefore contributes to environmental conservation.

Flexibility and speed

Faster process – the traditional printing process for packaging can last for days. With digital, you can have finished packing for a few hours.

The sample for testing – as is the cost to produce a single package the same as for a thousand, digital process is very favorable for the production of samples and test prototype packaging. Thus designers can also check how design influences consumers to choose the right product.

Versions of packages – Digital printing is ideal for packaging that needs to be adapted to the local market, due to a specific geographic area of language, demographics, age group or even completely personalized. In the current economic crisis, all the manufacturers are looking for ways to highlight their brand and reach out to their target clientele.

Marketing objectives

Gallop, Xerox iGen4 automated system for the production of cardboard packaging, is unique on the market. It is the only available system for inline digital manufacturing of paper and cardboard packaging.

Approximately 10% of the production of packaging goes to small print runs. As the largest segment of the packaging industry of graphic production, it represents a huge potential. Gallop technology puts Xerox at the top selection of manufacturers for packaging small runs.

Gallop technology

Xerox iGen4 digital system for color printing. It uses a standard iGen4 system with various modifications in order to improve the printed media for packaging. However, these modifications are not only specific to Gallop system, but can be applied to every iGen4 machine.

Xerox with epic

EPIC CTi-635 device for applying of coatings. This module is used to apply UV or aqueous varnish. It is applied to the paper after printing and it dries. It uses Coat-Tech technology similar to Anilox systems used in offset printing machines. With this is achieved coating on the entire paper or only in some selected areas.

Features and benefits:

• UV or aqueous coating
• Fully compatible with the iGen4
• CoatTech Anilox Technology
• Precise Anilox Rolls
• Easy to use
• Glossy or matte coating
• Digital control
• Printed material is ready for further processing
• Stable performance
• Easy installation and handling.

Module for the collection and transport. This module transports the printed sheets of paper / cardboard from EPIC module to die-cutter. In addition, it provides that the printing continues even when the die-cutter is not in use. It also can be used as a sort of final printed sheets.

Features and benefits:

• Stacking of printed sheets (groups of up to 600 mm high)
• High quality components
• Simple user interface
• Precise alignment
• Can operate in online and offline mode
• Merging with Stora Enso DC58A die-cutter
• Flexibility
• Enables continuous printing.

Stora Enso Gallop DC58A die-cutter. This is compact die-cutter which the company Kama specially produced for the Stora Enso Gallop system. Because of adaptable design the tool changes is simple and it is therefore better than traditional die-cutter. It has a vacuum gripper for optimal handling with all media.

DC58A from printed sheets creates the desired format that is ready for folding and gluing. Die-cutter also has the option of cutting, perforating, and cold embossing and use of Braille. Option is that the system can be upgraded for hot foil stamping, combination of hot foil stamping and embossing and stamping holograms.

The biggest advantage is that the change of tools and preparation between applications is tremendously quick and short: it takes only ten minutes!

BOBST – for complete customer service

During the last Drupa, Bobst with the number of visitors confirmed that with plans for the development of equipment and services, including equipment for digital printing and finishing are on the right track to meet the production challenges that customers expect in the future.Emilio Corti, Director of Sales in Bobst pointed out that the last Drupa for the company was a huge success.

Bobst – Die cutting machine

It was introduced advanced technology for die cutting, hot stamping and folding-gluing with new service packs.

Customer reaction was excellent, as was reflected in a number of generated orders. Opportunity to talk with customers of Bobst’s equipment, their expectations in terms of quality, productivity and the availability of the machine, were the most important part of participating in the fair, and the received information were disclosed in Bobst’s research and development department. At the same time, it was confirmed that the programs developed from Bobst conform to their expectations, and finally the green light was obtained for both conventional and digital equipment.

Emilio Corti said: “We presented the results of studies for the digital press to many customers and received positive responses. They think that we are on the right track and that the solutions we develop are exactly what they need in the future. “

Large numbers of visitors to the Bobst’s stand were the printers from emerging markets (one of four visitors came from the BRIC countries – Brazil, Russia, India, and China).

Bobst at Drupa 2012

Corti said that technological development unveiled at these printing fair meets the needs of Bobst’s customers especially in these emerging markets, where there is a clear trend towards high quality packaging.

“Despite the problems in the world economy, two thirds of customers had projects that they would like to discuss with us, and these conversations results with new orders,” says Corti.

Service for the happy customer

With the launch of the new equipment at Drupa printing fair, Bobst was unveiled and new maintenance services – new remote service applications Mobile Portal Monitoring machines using smart phones and tablets, as well as boost my Bobst program that provides a web portal for users who want to upgrade older generation machines.

Visitors to the fair are truly appreciated our approach to service, Corti said, adding that they really wanted to hear about the problems that customers encounter.

Bobst so once again confirmed its status as a reference supplier when it comes to service.

Fillers for printing inks

One of the important components for formulating of inks is fillers or additional pigments. Basically it is important that ink is not too concentrated with pigments because too much pigment will give negative impact on printability of ink.

Market for fillers to grow

Fillers do not affect the tone of ink, but they have changed rheological properties of printing inks.

Among other things, enhance the colors consistency, so they become more suitable for printing.

Fillers are actually fine-grained white or transparent inorganic powders. As pigments, and they are insoluble in the binder. Fillers added to the binder give transparent dispersion.

Filler task is to replace a certain percentage of expensive pigments and to have positive influence on the properties of printability of inks. In use today there are cheap, mineral fillers, and artificial fillers that are somewhat more expensive.

Artificial fillers are fine-grain white powders, and usually they are received with deposition of hardly soluble salts. These fillers have lower hardness and higher dispersion from natural and so their use is greater.

Because they can change the rheological properties of printing inks, fillers must not chemically react with the binder, or dissolved in it.

cmyk printing

Aqueous dispersions of fillers are opaque, and oil filler dispersion was partially transparent.

Fillers can differ in chemical composition and fineness of grind. Central particle size is between 0.01 and 1 micron.

Specific gravity of fillers ranges between 1.5 and 4.5 g/cm3. Depending on the color, fillers must be white or transparent and should not affect the tone of the pigment. Fillers must be resistant to binder in long term strategy, and must not chemically react.

Filler China Klej is widespread in nature aluminum silicate. It is obtained by digging, washing, precipitation, drying and calcination. This filler is white fine-grain powder, with soft structures. It is used for deep and screen printing.

Filler Aluminum hydroxide is one of the most important filler in the industry of graphic colors. It is obtained by deposition of aluminum sulfate. It is characterized with the low specific gravity, high dispersion and is very transparent.

It is resistant to light, alkali and water, but not resistant to high temperatures.

It is used to create multicolored and transparent inks.

The most famous fillers used in the manufacture of printing inks are:

– Barium Sulfate

– Aluminum hydroxide

– Magnesium carbonate

– Calcium Carbonate

– Talk

– clay

– Silica

Drupa 2012 – Innovations and Novelties

In this article we wanted to evoke the atmosphere and show some of the novelties that were presented by short at Drupa, for all those who have not had a chance to come and a reminder to those who were.

Kodak

NexPress-SX3900

At the Kodak booth an absolute hit was a digital printing machine Kodak NexPress SX 3900. For this, in practice, proven machine, Kodak has introduced a new option – an optional tray that allows printing on substrates up to size 356 x 914 mm (356 x 660 mm in automatic duplex mode), and gold, pearl and neon-pink toner as an option for the fifth printing unit. With the previously launched option for a fifth printing unit such as Clear, Red Fluorescing, Dimensional Clear, Black or Light RGB toners, gold, pearl and neon-pink toner bring an unprecedented range of options that adds to standard CMYK print a new value, thus enabling the expansion of business and increase revenue to the owners of Kodak NexPress digital printing press. These three options will be available on the market early next year.

Furthermore, Kodak introduced the Kodak Flexcel Direct, a machine for direct engraving of flexo printing forms. With laser engraving of elastomer is obtained a printed form with great endurance. The machine is capable of producing sleeves and panels. It is technology that many flexography printers eagerly await.

MGI Digital Graphic Technology

Great interest of visitors to the booth of French company MGI Digital Graphic Technology has caused a new MGI JetVarnish 3D, machine for digital partially coatink with digital inkjet coating technology, which in the latest version, first presented at Drupa, can now be made, and dimensionally, ie partial relief coating at a speed of 3000 sheets per hour for format 52 x 105 cm.

Konica Minolta

Konica Minolta – KM1

Konica Minolta is at its booth presented a prototype of a new digital ink jet printing machine KM-1 inkjet technology that can print up to B2 format sheets stacked at a speed of 3300 sheets per hour.

Resolution of 1200 x 1200 dpi provides exceptional printing quality. In addition to the proven digital production presses bizhub PRESS Series C 6000/7000 and C8000, Konica Minolta has introduced a new model and prototype bizhub PRESS 1100 C, which will allow printing of high quality prints at a speed of 100 A4 / min, regardless of the grammage of the paper. The launch of this machine on the market is expected over the next year.

Epson

Epson Sure press

Epson has introduced a new generation of ink jet printing machine for labels from the roll to roll with printing capability of white ink Epson SurePress L-4033AW. This is a digital printing machine for printing labels on all materials commonly used in the production of labels, from paper to foil. With six printing units, CMYK + orange and green, now there is and white ink for printing on transparent and metallic materials. Most manufacturers of labels showed interest in this machine because of the quality of prints and affordable prices.

Techkon

Techkon SpectroDens fogra

Techkon this year had a larger booth than usual and a large attendance. Of the many innovations the biggest attention was on new model of spectrophotometer SpectroDens Premium, who was redesigned, with color display and plenty of new features. What is interesting to the younger generation is applications for the iPhone, whit which we can control the registry on the print.

Morgan

From novelty on boot of British company Morgan, a leader in the manufacture of machinery for processing plants for digital printing, we single out a new range of polyurethane binder (machine PUR adhesive binding): DigiBook 150, 300 and DigiBook 450. By its very reasonable price, along with the proven quality of the Morgan processing plants machines, these machines for PUR binding will certainly find its place in a number of digital printing factories, as well as conventional printers that have a need for quality binding.

Psychophysical color characteristics

Colorful inks except wavelength are also characterized by three properties:

1. Tone of ink or tonality of color of inks quality is determined by the wavelength of light rays, which cause the sensation in the eye and color. That is, quality property from which a colorful ink varies from gray. The color of tone indicates type of ink or ink itself.
2. The degree of saturation or the amount of white is a measure of color saturation or ink purity. The degree of saturation is talking about the absence of white in a colorful ink. A small degree of saturation is said that the color is pale.
3. The degree of darkness, brightness, or luminance is content of black in a
   colorful ink. In the degree of darkness in which black gives the greatest degree of darkness, means that the tone of ink is equal to zero.

The color that is determined by three characteristics of tone, brightness and saturation can be described in the diagram with 3 color coordinates or in cylindrical coordinate system.

hsv space

– Saturation is the color distance to the radius vector from the achromatic axis.
As much as the distance from the achromatic color axis is greater, the greater is the saturation of colors.

The color that is determined with these three characteristics of tone, brightness and saturation can be described in a diagram with three color coordinates and the cylindrical coordinate system.

On the psychophysical characteristics of inks are coming adjacent to the physical quantities:

• Tone of ink represents the dominant wavelength.
• Saturation is the purity.
• Brightness is the physical size of illumination.

HSL color cylinder

The tone and saturation together are producers of chromaticity of ink.

Ecological development of ctp plates

CTP plate Agfa Thermo Fuse

Most printing houses is faced with the problem of working with organic chemicals and their disposal. Meeting increasingly stringent standards and the care of the environment is an additional motive for crossing to the no chemical technology. Agfa offers a range of innovative solutions for working with no chemical plates grouped together under the patented name AGFA ThermoFuse.

Agfa plates

By applying this technology with ease of operation, lower costs and reduced environmental impact can be achieved better stability and durability of the entire print production process.

The principle of thermo-technology AGFA Fuse

For standard, chemical CTP systems under the influence of light or temperature-sensitive laser illuminates the surface of the plate. The resulting image is not mechanically resistant and is necessary to develop a chemical process by which the board is prepared for printing. The final result (plate ready for printing) is dependent on a range of analog values such as: the state of chemistry and temperature, rate of passage of the plate through the developer, washing method, grommets and more.

No matter how the elements are controlled and kept within the standard values, final plates are reproducible only within certain tolerances.

AGFA ThermoFuse technology uses the power of lasers to melt extremely small thermoplastic elements that are found in the surface layer of the plate. During illumination thermoplastic particles absorb heat and melt, joined together and formed solid areas which are firmly glued to the aluminum substrate. Dark areas remain in the initial state, and subsequently washed from the plate. With this process in one step we are getting stable and mechanically resistant plates ready for printing. In other words, the plate is fully formed in the process of illumination, and the whole process is 100% binary and dependent only on the laser settings. The only thing left after the illumination is to wash or rinse unexposed particles in areas where there are no pictures.

At the plates: Azura TS rinsing is carried out using water-based solution that includes a means for the grommets, which also serves to protect the plate, while the plates: Amigo TS uses a mild “Clean Out” liquid.

The benefits of technology ThermoFuse

Plates: Azura technology ThermoFuse does not require chemical process, but it is necessary to rinse them after illumination so it is not possible to say that the process is fully processles. Despite this, process brings many advantages over conventional chemical CTP technology and also the processles technology that is applied from other manufacturers:

• 100% binary process (eliminated the influence of chemical variables in development)
• Aluminum plate surface is mechanically resistant and suitable for a large number of prints
• Ease of Use
• The visible image of the finished plates (measuring wedge plates and checks before placing the printing press)
• Speed of lighting is almost identical like to the chemical CTP plates
• A large number of prints (Amigo TS plates without firing can provide up to 200,000 impressions, and with the baking much more)
• Environmentally friendly technologies
• Lower cost (less water and energy consumption)
• Possibility of archival records and reprints (rinsing is carried out with the aid of liquid containing means for grommets)

ThermoFuse technology was developed with the aim of saving and reducing the negative impact on the environment. Aluminum plates use very thin surface layer which is washed in an aqueous solution. Thermoplastic components (latex) are chemically inert. The chemical for rinse the rubber coating is pH neutral (pH value is very similar to the value of tap water) and does not contain alkaline and corrosive agents, and undesirable solvent.

Using ThermoFuse technology significantly reduces water consumption, probably one of the most important and most threatened resources.

Tested and proven technology

Agfa ThermoFuse is a proven technology. Agfa first introduced procesless plates for printing in 2000th: Thermolite, which have been used successfully in more than 100 different models of direct printing machines and excellent are accepted in the market.

Plates: Azura presented at Drupa 2004 are intended for use in standard thermal CtP devices with a laser wavelength of 830 nm.

In the middle of 2010 the new, improved generation of plates are introduced ThermoFuse (Azura TS and: Amigo TS). These plates provide an even greater number of prints, and improved lighting speed.

Existing users of chemical thermal CTP solutions relatively easily and with little investment can go on the boards of technology AGFA ThermoFuse. CTP device is not necessary to change (it is necessary to check the list of supported devices for the desired CTP plate type), or the necessary changes apply only to the process of developing. To work with the plates: Azura TS is necessary to buy a unit for washing while working with the plates: Amigo TS is possible with installation of appropriate brushes to use existing developer for CTP or conventional plates.

Special applications

Great quality print products are getting increasingly popular in the printing industry. A constantly developing requirement for surface finishing techniques has become noticeable over the past few years. You will need an appealing design and top-quality printing and finishing to distinguish yourself out of your competition! Gorgeous print products generate a winning impression, deeply influencing the choices buyers make.

Upgrades in the technological options backed up by presses, including inline surface finishing in a single pass, are also fuelling this development. Advancement has been significantly evident in the section of coatings. There are now a large number of special, user-friendly coatings with new features. They deliver all manner of effects, giving designers ever better liberty of expression.

Cold Foil Finishing

cold foil finishing

Cold foil is an magnificent innovative print technology that enables you to apply metallic foil, in-line, at press speed, in an endless spectrum of colors. Cold Foil Finishing can be applied using two conventional offset printing units. The first unit uses its inking unit and also an offset printing plate to apply glue either as a spot application or to the complete sheet.

The second, actual cold foil unit incorporates take-up and take-off units for putting on the foil. Along with the sheet, the foil is fed into the nip between the blanket and the impression cylinders and applied by pressure to the regions of the printing stock covered with glue. Right after the backing is taken away, the metal layer remains on the sheet. The remaining printing units are used to overprint the sheet. CMYK and spot colors can be printed to the sheet and over the foil. The result is a fantastic foil effect.

Drip-off and Hybrid Coatings

Drip-off

drip-off

Standard inks are used for the process colors. A special-effect print varnish is applied in the final printing unit to the sections that are to have a matt appearance. Then, the coating unit is used to apply a conventional full-area high-gloss coating that drips off the spots previously given a matt coating. This maintains the matt effect of these parts and offers the remaining spots a gloss surface.

Hybrid

Hybrid or UV inks are utilized for the process colors. A further printing unit is used to utilize a UV special-effect print varnish to the areas of the picture that will have to have a matt visual appeal. Next, the coating unit is used to implement a full-area UV high-gloss coating. Because a UV high-gloss coating is used for hybrid applications, a greater gloss intensity may be achieved compared to a drip-off application produced by using a conventional, water-based high-gloss coating. With hybrid applications, however, the structure of the matt effect is much stronger than with drip-off applications.

Hybrid and UV Spot Coatings

hibrid

Hybrid

UV inks are being used for the process colors. An extra printing unit applies a hybrid special-effect print varnish to the regions of the picture that will have to have a matt appearance. After that, the coating unit is used to apply a full-area UV high-gloss coating. The matt effect is produced exactly where the gloss coating \”sinks\” into the special-effect print varnish.

UV

UV inks spot-coated with a UV matt varnish in a additional printing unit are used for the process colors. Next, the coating unit is used to put a UV high-gloss coating as a second spot coating. This evidently separates the matt and gloss sections. As a UV high-gloss coating is utilized for the hybrid application, the gloss level is comparable to that accomplished with the UV application. The matt effect in the hybrid application, nonetheless, has a surface which is less smooth compared to the UV application, recognized as a hybrid effect.

Requirements for the Printing Inks

custom printing inks

Printing inks must be transported from a reservoir and then in a printing-process-specific manner onto the substrate. The ink transfer can take place through:

1. ink splitting (offset, gravure, and letterpress printing): inking rollers, printing plate, and blanket (in offset) transfer/transport the ink film;
2. direct ink film transfer from a base foil onto the substrate (hot embossing, thermo transfer);
3. pressing the ink through openings (screen printing);
4. spraying on the ink in the form of droplets without making direct contact with the substrate (ink jet).

The inks must dry or cure on the substrate. Here, differentiation is basically made between physical (absorption, evaporation) and chemical drying (oxidation, radiation curing) procedures. Very often a combination of the drying processes is applied. Solidification drying represents a special characteristic whereby inks are fluid in a hot state and then solid after cooling, for instance, hot embossing The ink must have good adhesion to the substrate.

Several methods are common (also combinations):

1. The ink anchors mechanically to the substrate surface (penetrating into pores, encasing paper fibers); here, a certain pressure between ink carrier (e.g., blanket for offset printing processes) and substrate is required and/or
2. The ink penetrates into the substrate surface by capillary action (e.g., ink jet).
3. In the case of extremely smooth surfaces, the ink is held by means of polar interaction (chemical/physical effects) between the ink and substrate.

Foil stamping – perfect result

Ideally shiny surface elements in gold, silver, copper, aluminum and metallic colors can be transferred to the substrate by hot-foil stamping. A base film is covered with a layer giving the color and a hot-melt glue (adhesive coating layer). The image can be transferred under pressure and heat with a heated block (letterpress block). Ideal presses are letterpress machines and flat-bed die-cutters. Hot-foil stamping is primarily utilized for goods such as packaging for cosmetics, candies, and drinks as well as for catalog covers.

hot foil stamping

In narrow-web flexo-graphic presses embossing is often done in-line. Holograms can be transferred similarly with conventional hot foil stamping machines. The holograms are first embossed into the foil and then utilized with a coating. This foil can then be applied like a gold foil, for example, using the hot-foil stamping technique with a repeat length control.

Resource: Hot foil stamping

Color in Graphic Design

CMYK color printing

Utilization of color in graphic design – prepress really is a effective tool to generate an emotional response by consumers. When applied adequately, color has a mighty impact on how consumers can accept the product, service or company. To determine the correct color selection, graphic designer should do cautiously observation.

TYPES OF COLOR –  In graphic design you can find three main color types:

1.  CMYK
2.  RGB
3. Pantone CMYK

CMYK – means (cyan, magenta, yellow, carbon (black)). With combination of these four colors in theory we can easily make all other colors.

RGB – refers to red, green, and blue. This variety of colors is used for what we see on display of computer monitor or TV.

PANTONE – Pantone colors are employed in a process of printing where we want to have exact color matching, so when we want uniformity of colors it is the best to make use of Pantone colors.For example, if somebody intends to print catalog about his firm he will do it applying CMYK model yet he’ll use Pantone color ( known as spot color) for his company’s logo simply to be sure that logo will appears exactly as he wants to be. Use of Pantone (spot) colors will escalate expenses of printing but it is vital when we need to accomplish uniform look of printed material.The only restrict of Pantone colors (however it is the same to all other colors) is their dependence of the type of paper or cardboard on which they will be printed.

DIRECTIONS WHILE USING COLORS

Colors could have different interpretation in different nations. In China white is the color of death. Softer and stronger colors interests consumer with modest incomes despite the fact that clients with highest salaries commonly use more delicate colors.

Color Rainbow Strips

MEANING OF COLORS

When doing design designer must have argument for selecting the color he’s going to work with, if not how he is going to convince the contracting authority that the color he select will be the right one for his project?Here are a few of definitions linked with color:

• Blue: – sky – sea – water – trust – wisdom – trust – loyalty – stability – faith – peace
• Red: – fire – love – energy – passion – power – danger – heat – warning
• Green:  -money – growth – envy – loyalty – stability – fertility – environmentally
• Yellow: -energy – sun – creativity – happiness
• Orange: – sunlight – joy – success – encouragement – autumn
• Purple: – power – luxury – nobleness – nobility – spirituality
• Brown: – earth – stability – organic – open space