Gravure pad printing UV ink printing To obtain successful pad printing when printing gravure printing UV ink, it is necessary to control two key factors in the process: printing ink film thickness and curing environment.
Printing ink film thickness: Gravure printing has excellent ink film thickness control method, which is favorable for UV ink printing. The gravure printing plate has a precise etching depth, and the printing ink film thickness provided by the gravure plate can be precisely controlled. Many printers can precisely control the thickness. Many printers use a technique with a depth of 15 to 25 μm on the steel plate. Photopolymer resins are also suitable for printing with UV inks, but they require more care during exposure and development. They need more care during exposure and development to control the depth of image corrosion.
As a general principle, the greater the specific gravity of the colorant contained in the UV ink layer, the greater the blocking effect of the ink layer on UV light, and it takes more time to fully cure the ink layer. The thicker the printed ink film, the stronger the abrasion resistance and solvent resistance of the print. Note that if the proportion of the pigment component in the UV ink is too large, and the printed ink layer is thick, only the surface of the ink layer is cured when the UV light is cured, and the entire layer of the ink is not completely cured. Therefore, the UV ink used for gravure pad printing must accurately control the specific gravity of the colorant during deployment.
Controlling the curing environment: In order to consistently deliver durable, high quality prints to the printing customer, it is necessary to maintain the appropriate curing conditions for each batch of printing jobs. This means that it is necessary to extend the quality control measures to the maintenance of regular measurement and control curing systems and curing systems.
We mentioned radiometers earlier in the article. Such instruments are necessary. It allows you to ensure that the energy emitted by the curing system remains consistent and that it meets the curing requirements of the ink used. There are now two types of radiation negotiation: one is to measure the real-time UV intensity; the other is to measure the intensity after UV light output. There are several types of radiometers that record the UV light energy output from a UV light curing system. Moreover, some UV light curing systems inherently have built-in radiometers that continuously monitor the UV energy of the curing system.
If the lamp power, conveyor belt, and other curing system settings remain the same, the attenuation of the UV energy output as the lamp head ages is also recorded. Over time, the output energy of the lamp head will gradually decrease, and slowly it will not be able to reach the energy required for proper curing. It is for this reason that daily or weekly measurements of UV energy output are part of the print production process using UV ink printing. The value should be recorded after each measurement. Set a lower limit (we recommend a 30% reduction in output energy), after which the lamp head should be replaced. The recorded data can also help predict how long the lamp can last. The lamp's general service life is 1,000 to 2,000 hours.
Multi-color printing UV inks can be used to print monochrome and multi-color printing jobs. In a multi-color printing job, if the print job involves three primary colors, the ink is often wet-overprinted, and the color is completely dried after printing. Under such working conditions, it is important that the printing color sequence be correct. In general, yellow and magenta inks have higher UV light transmittance than blue, violet, and green inks, and therefore print less transparent colors first.
However, some print jobs contain multi-color printing, each of which requires separate curing. For current gravure pad printing and curing systems, such curing requirements mean that after a color is printed, the printing job must be It is removed on a gravure pad printer, dried on a UV gravure system, and then printed on the gravure pad printing machine to print the next color. So this will create production time and the challenges of possible alignment issues. With the increasing use of UV inks, gravure pad printer manufacturers may develop multicolor intaglio pad printers that have a UV light curing unit for each pad, just like multicolor screen printing machines. Each printing unit has a UV curing unit.
The advantages of the UV ink gravure printing process include: fast drying, reduced solvent specific gravity, less VOC (organic volatiles) release (UV ink solvent volume accounts for 30% of the ink, and solvent inks reach 60% to 70 %); Reduced curing energy; Reduced number of sites required for printing production; Effective cross-linking reaction with very low energy (especially suitable for substrates with poor heat resistance); Single-component ink formulation makes ink useable Longer; excellent solvent resistance and abrasion resistance make the print very durable; in the closed ink hole, the ink's activation period (without cross-linking reaction) is unlimited; due to the ink cleaning easier and more automated, Labor is saved; the choice of ink color is very wide.
Where to start Do not rush to invest in UV ink gravure printing process. We recommend using a more cautious approach to consider whether UV inks are really suitable for your main printing job.
1. First, the used substrate is sent to the gravure pad printing UV ink supplier for ink compatibility printing test. The objectives of the test are stated in written form, including the expected abrasion resistance and solvent resistance after the print is cured. After the printed sample is fed back to you, carefully analyze the printed sample to ensure that the printed result is satisfactory.
2. If you are satisfied with the results of the print test, you can begin to consider UV curing equipment, measuring tools and ink problems. Collect UV light curing system functionality and cost information from UV light curing equipment suppliers. Explain your production capacity to ink suppliers and they will give you some advice.
3. Carefully weigh the relationship between the performance characteristics of UV inks and the cost of equipment and materials, as well as the required process changes, to determine whether UV inks are a cost-effective printing method for your printing business and printing customers.
4. If you decide to go to UV ink gravure pad printing, you can start ordering inks and equipment at least 6 to 12 weeks in advance.
5. Installation and height equipment to meet your production needs and light curing requirements. When fine-tuning the photo-curing system, the ordered UV inks can be tested on common substrates.
6. Implement process quality control to ensure print quality. These process controls should include ink film thickness, UV intensity measurements, lamp life monitoring, routine maintenance schedules for the curing system, and color accuracy.
7. Once the production system is in normal working condition, after the production of UV ink printing starts, it is necessary to re-estimate the ink inventory and adjust it if necessary.
UV inks are the perfect solution?
When you turn to an unfamiliar technology, you need to research, test, and change the process. The same applies to UV inks applied to gravure pad printing. Adding UV technology to production requires knowledge of UV ink materials; investing in new equipment; new quality control procedures, etc.; and allowing workers to keep up with the new printing speeds brought about by new technologies. Investment for training. However, as long as the careful feasibility study is followed, the production efficiency is improved, and only a small amount of energy is needed to print high quality prints. (Guangdong Vocational and Technical College of Light Industry, Wang Shouhong) (Printing Magazine)
Printing ink film thickness: Gravure printing has excellent ink film thickness control method, which is favorable for UV ink printing. The gravure printing plate has a precise etching depth, and the printing ink film thickness provided by the gravure plate can be precisely controlled. Many printers can precisely control the thickness. Many printers use a technique with a depth of 15 to 25 μm on the steel plate. Photopolymer resins are also suitable for printing with UV inks, but they require more care during exposure and development. They need more care during exposure and development to control the depth of image corrosion.
As a general principle, the greater the specific gravity of the colorant contained in the UV ink layer, the greater the blocking effect of the ink layer on UV light, and it takes more time to fully cure the ink layer. The thicker the printed ink film, the stronger the abrasion resistance and solvent resistance of the print. Note that if the proportion of the pigment component in the UV ink is too large, and the printed ink layer is thick, only the surface of the ink layer is cured when the UV light is cured, and the entire layer of the ink is not completely cured. Therefore, the UV ink used for gravure pad printing must accurately control the specific gravity of the colorant during deployment.
Controlling the curing environment: In order to consistently deliver durable, high quality prints to the printing customer, it is necessary to maintain the appropriate curing conditions for each batch of printing jobs. This means that it is necessary to extend the quality control measures to the maintenance of regular measurement and control curing systems and curing systems.
We mentioned radiometers earlier in the article. Such instruments are necessary. It allows you to ensure that the energy emitted by the curing system remains consistent and that it meets the curing requirements of the ink used. There are now two types of radiation negotiation: one is to measure the real-time UV intensity; the other is to measure the intensity after UV light output. There are several types of radiometers that record the UV light energy output from a UV light curing system. Moreover, some UV light curing systems inherently have built-in radiometers that continuously monitor the UV energy of the curing system.
If the lamp power, conveyor belt, and other curing system settings remain the same, the attenuation of the UV energy output as the lamp head ages is also recorded. Over time, the output energy of the lamp head will gradually decrease, and slowly it will not be able to reach the energy required for proper curing. It is for this reason that daily or weekly measurements of UV energy output are part of the print production process using UV ink printing. The value should be recorded after each measurement. Set a lower limit (we recommend a 30% reduction in output energy), after which the lamp head should be replaced. The recorded data can also help predict how long the lamp can last. The lamp's general service life is 1,000 to 2,000 hours.
Multi-color printing UV inks can be used to print monochrome and multi-color printing jobs. In a multi-color printing job, if the print job involves three primary colors, the ink is often wet-overprinted, and the color is completely dried after printing. Under such working conditions, it is important that the printing color sequence be correct. In general, yellow and magenta inks have higher UV light transmittance than blue, violet, and green inks, and therefore print less transparent colors first.
However, some print jobs contain multi-color printing, each of which requires separate curing. For current gravure pad printing and curing systems, such curing requirements mean that after a color is printed, the printing job must be It is removed on a gravure pad printer, dried on a UV gravure system, and then printed on the gravure pad printing machine to print the next color. So this will create production time and the challenges of possible alignment issues. With the increasing use of UV inks, gravure pad printer manufacturers may develop multicolor intaglio pad printers that have a UV light curing unit for each pad, just like multicolor screen printing machines. Each printing unit has a UV curing unit.
The advantages of the UV ink gravure printing process include: fast drying, reduced solvent specific gravity, less VOC (organic volatiles) release (UV ink solvent volume accounts for 30% of the ink, and solvent inks reach 60% to 70 %); Reduced curing energy; Reduced number of sites required for printing production; Effective cross-linking reaction with very low energy (especially suitable for substrates with poor heat resistance); Single-component ink formulation makes ink useable Longer; excellent solvent resistance and abrasion resistance make the print very durable; in the closed ink hole, the ink's activation period (without cross-linking reaction) is unlimited; due to the ink cleaning easier and more automated, Labor is saved; the choice of ink color is very wide.
Where to start Do not rush to invest in UV ink gravure printing process. We recommend using a more cautious approach to consider whether UV inks are really suitable for your main printing job.
1. First, the used substrate is sent to the gravure pad printing UV ink supplier for ink compatibility printing test. The objectives of the test are stated in written form, including the expected abrasion resistance and solvent resistance after the print is cured. After the printed sample is fed back to you, carefully analyze the printed sample to ensure that the printed result is satisfactory.
2. If you are satisfied with the results of the print test, you can begin to consider UV curing equipment, measuring tools and ink problems. Collect UV light curing system functionality and cost information from UV light curing equipment suppliers. Explain your production capacity to ink suppliers and they will give you some advice.
3. Carefully weigh the relationship between the performance characteristics of UV inks and the cost of equipment and materials, as well as the required process changes, to determine whether UV inks are a cost-effective printing method for your printing business and printing customers.
4. If you decide to go to UV ink gravure pad printing, you can start ordering inks and equipment at least 6 to 12 weeks in advance.
5. Installation and height equipment to meet your production needs and light curing requirements. When fine-tuning the photo-curing system, the ordered UV inks can be tested on common substrates.
6. Implement process quality control to ensure print quality. These process controls should include ink film thickness, UV intensity measurements, lamp life monitoring, routine maintenance schedules for the curing system, and color accuracy.
7. Once the production system is in normal working condition, after the production of UV ink printing starts, it is necessary to re-estimate the ink inventory and adjust it if necessary.
UV inks are the perfect solution?
When you turn to an unfamiliar technology, you need to research, test, and change the process. The same applies to UV inks applied to gravure pad printing. Adding UV technology to production requires knowledge of UV ink materials; investing in new equipment; new quality control procedures, etc.; and allowing workers to keep up with the new printing speeds brought about by new technologies. Investment for training. However, as long as the careful feasibility study is followed, the production efficiency is improved, and only a small amount of energy is needed to print high quality prints. (Guangdong Vocational and Technical College of Light Industry, Wang Shouhong) (Printing Magazine)
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