January 22, 2015
Probably the most compelling reason for choosing LEDs is their longevity in that they can last up to 10 times longer than incandescent lighting ; in many cases up to 50,000 hours or longer.
They are also very rugged and can withstand a significant amount of vibration and impact that is often found in most industrial applications. LEDs are also much cooler and do not as a result suffer from the thermal expansion of the glass cover as found with incandescent lights. LEDs are also much more efficient by converting electrical energy directly to photons and can be manufactured to cope with many different measuring conditions by mixing multiple LEDs together to provide a wide spectrum of coverage. Finally LEDs have much greater stability, turn on very quickly and provide a constant output over along time.
November 20, 2014
One of the most exciting innovations in flexo today is the carbon fiber chamber blade system. Carbon fiber is extremely strong and much stiffer than aluminum by as much as 300%. Not being steel or aluminum, carbon fiber will not corrode and is resistant to all types of inks, solvents and adhesives.
They are generally easier to clean up and require much less water to rinse clean than conventional materials. Newer designs with carbon fiber systems usually mean the chamber does not need removing to replace the doctor and retaining blade. They can be up to 70% lighter than aluminum and even greater when compared with steel. This makes them much easier to handle and can often be lifted in and out of a machine if needed by one operator.
October 20, 2014
Most companies use dyne pens as a method to evaluate the treatment ( dyne ) levels of their materials because they are relatively cheap and easy for most operators to use. This does mean that the results can be very subjective dependent on the interpretation of each peron’s observations and can vary dependent on the application rate and pressure that is applied.
Great care must be taken not to contaminate the substrate to be tested or the pen itself with such elements as dust, wax finger prints, water and plasticizers. Water is a particular problem as every surface will have absorbed some water and like all of the other contaminents mentioned will cause incorrect readings.
All pens have a mix of two liquids to give the different dyne levels so once opened the liquids will begin to evaporate and as one usually evaporates faster
than another if the top is not kept on the pen when not in use it will quickly become inaccurate. On plastic film static electricity can also be a problem as this will also
affect the wettability of the dyne fluid and as a result can result in inaccurate results.
Surface roughness of a material can and will affect the de-wetting of the pen fluids.
The truth is all dyne levels are approximations so at least three test lines should be drawn down on the material with the first two usually being ignored to ensure that any contaminants have been flushed from the prior use of the pen.
September 25, 2014
There is no doubt that choosing the correct blade material to suit your specific print application is very critical. Choose a material that is too soft and you will have to replace it almost every shift, too hard and it may damage your anilox. And if the material is not resistant to the ink or coatings that you are using then it may be chemically attacked and simply corrode.
All that said, if your blade is not rigid enough it will fold over the first time your operator applies too much pressure between the blade and the anilox. Blades that are too thin will also have a tendency to develop a wave in them even with careful installation so will be unable to wipe your anilox evenly across the full face of your roll. This is particularly prevelant in wider web machines. Even when the recommended blade thickness is used many need a back-up material to give it further rigidity and support. If a blade bends to the point that you are no longer wiping with its edge but the back of the blade then you have really lost all control of your wiping action and will potentially cause serious damage to your anilox.
So to some extent blade thickness may initially have it over the material but if you want consistent wiping of your anilox throughout your entire print run you had better make sure you have the right material as well.
August 18, 2014
A quick visual inspection can give you a very good idea of the general condition of any anilox. Look for score lines, dings, chipping around the edge of the roll and of course general contamination.
Any roll with a significant number of score lines, mechanical impact damage or chipping around its edge is likely to need relacement sooner rather than later. In regard to cell condition and current volume capacity this cannot be done with the naked eye and requires some form of magnification in the form of a roll scope or interferometry device.
The roll scope is the most common but is dependent very much on the operator skill and can be very subjective. That said, in the hands of an experienced operator it can be reasonably consistent provided the scope is well maintained and calibrated on a regular basis. It does allow for pictures to be taken of the cells but requires a manual calculation by the operator to determine the cell count and to calculate a theoretical volume.
There are also a number of liquid volume test methods to help determine volume but they again require considerable operator expertise and can have quite a wide range of accuracy. Interferometry is probably the most accurate but again requires significant operator training, regular calibration and is a significant investment but is capable of providing very accurate data and pictures in 3D showing the exact cell structuure, line count and volume. It is up to each printer to determine how much information they require, which will determine the level of investment necessary.
You can of course ask your roll supplier to carry out a regular inspection of your anilox and provide you with the same information but there is always likely to be some bias in regard to the information given so you should always review the data provided and apply some common sense yourself, particularly when it comes time to replacing your rolls.
May 20, 2014
One of the most interesting developments in Flexo is the use of process colors to create spot colors. While not a new concept, it has really only been the relatively recent introduction of new software packages that can convert spot colors into process files that allow for brand spot colors to be reproduced as a process set instead of the conventional
special spot colors.
Of particular interest is that of creating seven instead of four process colors that gives the printer the ability to reproduce a vast number of pantone colors, which reduces the number of colors needed, the number of plates required, the amount of ink required, and the amount of time required to set up and run. All of this makes for a more affordable, quicker way of producing even very short runs, making flexo just as competitive if not more competitive than digitally printed short runs.