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CHAPTER 8

OPTIMISING THE SHEETFED OFFSET PRINTING

PRESS TO ACHIEVE ECO FRIENDLY PRINTING

8.1 Introduction

Sheet-fed offset is the most widely used printing process as it is cost

effective and can deliver excellent output. Modern presses have many advanced
set-up and automation features that reduce make-ready times. They can be
integrated with prepress; there by high quality product can be delivered in short
time, this in turn will support Environment friendly printing concept.

8.2 Over View of Optimisation

Press Optimization is the means to achieve the concept of Eco friendly

printing / Green Printing. Through, optimising the press we achieve reduced
energy consumption, as well as VOC emissions, faster make-ready for job
change over, high quality print and less wastage. This will help in reducing
Carbon foot print in daily production. It also improves product quality. In
future, the demand for optimization in offset printing will increase with
corresponding effects on how modern print shops work. There are many factors
involved in the process of optimization of press and is given in the below Table
8.1. Optimisation create a common language between those involved;
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optimisation create production stability within a press due to clearly structured

workflows. Series of experiments were conducted at PMA on SM 74 – 4 – P – L.

Table 8.1 Factors involved in the process of standardization

Measurement Measuring Measuring Measuring

Machine Materials Method
& tolerance environment equipment parameters

Roller Warming Room

Plate ISO 12647-2 Densitometer Colour
setting up temperature

Packing
Blanket Pre inking FOGRA Humidity Spectrometer Density
thickness

Tightening Packing Ink pre

BRUNNER Cleanliness pH meter Lab value
torque sheet setting

Feeder Lateral Dot

Paper UGRA Dot meter
condition oscillation gain/loss

Delivery Pre Conductivity

Ink DIN Registration
condition dampening meter

Roller Fountain Post Print

Micro meter
condition solution dampening contrast
Feeder &
Gripper Washing
Delivery 3 dial gauge Trapping
system solution
setting
Ink duct
Cylinder Aerometer Ghosting
foil
Time of
Slur &
pull Hygrometer
Doubling
measure

Speed Eye glass pH

Screen ruling Conductivit

tester y

Thermometer Hardness

Torque
Thickness
wrench
Packing
Durometer
height
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Optimization first of all requires defined standards. Standards are

guidelines, processes and procedural instructions for production of multi-color
printed products with repeatable quality that are recognized in the graphic arts
industry and particularly in printing. The Standards Committee for Printing and
Prepress Technology Normenausschuss Druck- und Reproduktionstechnik,
(NDR) of the German Institute for Standardization, Deutsches Institut für
Normierung e.V., (DIN) works together with the International Organization for
Standardization (ISO) to develop worldwide standards. These standards are
published under the designations DIN, ISO, DIN ISO, or E DIN with the
appropriate numbers and must be purchased. The German Printing and Media
Industries Federation (Bundesverband Druck und Medien e.V., (bvdm) has
summarized all relevant standards in publication ("Medienstandard Druck
2003/4"). (Becker, M., (2002).

8.2.1 Purpose of process optimization

Essentiality of optimisation is better communication between agency

or print buyer, prepress and print shop, Exact reproductions, Problem-free
printing of mixed forms, Less waste copies, Shorter make-ready time on the
printing press, Tighter tolerances during print process and these will result in
increased production stability due to a smooth workflow, reduced costs for
material and time, improved quality of printed product (Bestmann, G., (2011).

There are international standards, which are drawn up by the ISO.

These include standards for process colors which ensure comparable printing ink
quality across manufacturers or different ink batches. They are also standards for
process monitoring in printing and proof printing, including film and plate
exposure, as well as standards for measurement technology and data
communication (Appendix 3). Alongside international standards there are also
so-called industry standards, which are developed by individual manufacturers or
joint ventures and assume the status of a standard through mutual agreement. An
example of a manufacturer agreement is the International Color Consortium
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(ICC), which drew up the profile format specifications. Adobe’s Portable

Document Format (PDF) is an example of a manufacturer standard that has
achieved the status of a generally accepted standard through market forces.
Alongside this, there are also national standards, such as DIN standards.

Offset printing in India is benefiting from improved technology in

prepress and process control. Offset machines now have PPF compatibility and
are moving towards Job Definition Format (JDF) compatibility. PPF was created
by the Heidelberg-inspired organisation CIP3 then developed into JDF. Printers
are interested in PPF because it has reduced start-up times to 10–15min and cut
wastage to the first 10–15 sheets (Arnel, P., (2006).

8.3 Process Integration: The Prerequisite for Sustainability

In order to achieve sustainability, printing companies must also

integrate their processes. The aim is to ensure their reliability and excellent
environmental performance in prepress. The use of image setters, excels low
power consumption of only 0.7 kilowatts per hour, Image setter gives off only
about a fifth as much waste heat, it can therefore be used without air-
conditioning. In combination with its low power consumption, this saves the user
a large amount of money spend for electricity bills, while reducing
environmental burdens. Some of the image setters available in the market work
not only with conventional and process less plate but also with chemical-free
plates (Bestmann, G., (2006).

8.3.1 Prepress Standardisation with Prinect Color Solutions

Optimisation in offset printing is done with the components of the

Prinect Color Solutions (PCS) for prepress. . The aim of PCS is to optimize
printing press presetting and monitor the printing process before, during and after
print. This is achieved essentially by improved integration of the printing press
into prepress workflows (Bestmann, G., (2011). The following data is exchanged
between prepress and press to this end:
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(i) Printing material parameters.

(ii) Parameters of printing inks and consumables.

(iii) Target values of the printing process for making presettings on the Prinect
CP2000 Center.

(iv) Zonal dot area values on the printing plate.

This allows printing presses to be set up fast following a job change.

For print control using Prinect Image Control and Prinect Axis Control,
information about the printing process and the contents of the print sheet is
through Prinect Prepress Interface. Prepress supplies the parameters for
presetting and monitoring the print. The parameters are generated by the Prinect
Signa Station, Prinect Print ready System and Prinect Meta Dimension
applications. The Calibration Manager is responsible for creating the correct
calibrations of the plate setter and the printing process, Print Open for profiling
printing and proofing processes and Quality Monitor for monitoring all the
components involved. Software used in standardizing the image carrier are
Prinect CP2000 Center Version 39, Option Color Assistant Version 43, Prinect
Image Control Version 4.0, Calibration Manager Version 2.3, Quality Monitor
Version 1.1 and Print Open Version 5.1

8.4 Optimising the Press System

Four-step sequence is followed when optimising a press system. They are:

(i) Diagnostic phase.

(ii) Capability Phase

(iii) Characterization Phase

(iv) Print evaluation phase

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8.4.1 Diagnostic Phase

There is a series of preliminary press settings and adjustments to

perform on the press. The proceeding list is highlighted because they help to
diagnose the status of a printing press. Failure of them can cause a decline in
print quality.

8.4.1.1 Selection of Paper for print

The type of substrate used has a great impact on the quality of the printed
sheet. It is to be remembered that the quality of the substrate has an impact on:

(i) The gamut (color space) that can be represented in the print.

(ii) The dot gain in the print.

(iii) The gloss.

(iv) The colour rendering (dirtiness due to paper additives)

(v) The show-through effect of the print on reverse side.

It is advisable to use the paper which meets ISO standard

requirements. Standardisation procedure for Uncoated and Coated paper is
explained in detail on Chapter 5. However the selection of the paper is
completely to the discretion of the customer. But, it is mandatory that the paper
should have straight edge and the corner should measure 900 on all four corners.
Deviation from this can have severe feeding problems resulting in more make-
ready time, more wastage as well as more production time requirement. It is
recommended to have the paper seasoned so that there can be elimination of
Static electricity during production. Seasoning process is a simple technique, the
external packing is removed and paper is kept in the shopfloor, few hours before
the actual commencement of printing. This helps the paper adjusted to the floor
temperature of 230 centigrade. The recommended humidity at the shop floor is
between 55 - 60.
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8.4.1.2 Paper feeder setting

The paper is loaded on to the machine at the feeder unit and the feeding
unit adjustments are carried out for the smooth flow of paper to the machine.
Double sheet, no sheet, late sheet and cross sheet detectors are set according to
the paper size and gsm. Side lay adjustments also should be checked for. Static
eliminating devices should be activated to reduce the possibility of double sheet
entry during the feeding. Blowers, suckers and pile height governor need to be
set accordingly as in Figure 8.1 (Spiridonov, I., (2011).

Figure 8.1 Feeder setting with blowers, suckers and pile height governors

8.4.1.3 The printing blanket

The choice of the right blanket is a crucial factor to determine the

“print quality” because in offset printing technology blanket transfer the image to
paper, hence it decides the stability in the print of screen and full solids. The
requirements for blankets are specified in DIN 16621. There are no universally
valid means of predicting the quality of blankets. A good blanket is characterized
by a good combined effect of good springiness, ensures low sheet adhesion,
exact dot reproduction. Blankets are rubberised materials with a compressible
layer and a fiber backing. Cross section of the blanket is shown in Figure 8.2.
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Figure 8.2 Cross section of an offset printing blanket

Perfect Dot MXF, Day 3610 and Day 9500 are the most common
blankets used in commercial printing. The surface is rough enough to hold the
image transfered from the printing image carrier (plate). There are two types of
blanket available 1. Compressible and Non – Compressible. Modern commercial
printer preffer compressiable blanket as there will be a truthful image transfer
from plate to blanket and then blanket to substrate (paper). The durability is
approx. 1 to 3 million impressions. Good compressible blankets can withstand an
excess pressure of up to 0.4 mm.

DIN 53505 – with DIN EN ISO 868:1998-01 states that Shore

hardness is the resistance to penetration by a foreign body of a given shape,
allowing for a defined elasticity. The thickness of the test body shall be >6 mm.
Blankets have a running direction. In one direction, the blanket is very sturdy, in
the other direction, it is very flexible. Normally, printers do not pay much
attention to the running direction of a blanket, because blankets are cut in such a
way that they cannot be mounted incorrectly. Still, whenever large-format
blankets must be cut to a smaller format, the running direction must be taken into
account. The blanket must be mounted in the (sturdy) running direction. This
direction is usually indicated in two ways:

(i) A colored woven-in thread in running direction.

(ii) An inscription that marks the gripper edge.

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8.4.1.4 Mounting the blanket

In order to achieve the best possible printing result and run life of
blanket, it is imperative to ensure correct procedures for fitting the blanket -
(packing and tightening). Mounting the blanket is preferred by use metal-edged
blankets since they ensure uniform tension across the entire width of the blanket
and are easier, faster to mount. If using clamping bar the bars must be straight to
prevent an uneven tension of the blanket due to the clamp bolts. Tighten clamp
bolts from the middle to the edges or from one side to the other so that the
blanket can slacken and will not bulge in the middle. When inserting blankets,
make sure they are not on the bearers and lie in between the bearer. When
tensioning blankets, use the following rule of thumb. If the Print length is 50cm,
then the torque is 45 N/m (max.). ie print length in cm minus 10% (5N/m) equals
the torque in N/m (max.) (Figure 8.3). The tensioning process must be repeated 2
to 3 times, in between this repeated tensioning, the press must run a few
revolutions on impression.

Figure 8.3 Tightening the blanket with a torque wrench

If the blanket tension is too high, the fabric may be stretched too far
and become damaged. At the front and rear edge, at the place of this overstretch,
the blanket will print less well. If the blanket tension is too low, dot deformations
and doubling may be the result.
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8.4.1.5 Calculating packing height to the blanket

Providing adecute packing to support the blanket for a quality print is

mandatory. The calculation for finding the measure is given in Table 8.2. The
best way of working is characterized by an exact measurement and observation
of the packing heights. The packing sheets are special type of papers which have
high dimentional stability as they are pre-conditioned to avoid or reduce swelling
due to humididty. The thickness within a sheet varies less than 0.01 mm in order
to limit dot gain. (Figure 8.4)

Figure 8.4 Packing height requirement on blanket to achieve printing pressure

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Table 8.2 Calculation for packing thickness

Plate thickness + 0.28 mm

Plate cylinder undercut - 0.15 mm
Plate above bearer + 0.13 mm
Blanket thickness + 1.95 mm
Underlays + 0.35 mm
Blanket cylinder undercut - 2.30 mm
Blanket on bearer height 0.00 mm
Plate above bearer + 0.13 mm
Blanket on bearer height 0.00 mm
Pressure plate blanket + 0.13 mm
Blanket on bearer height 0.00 mm
Printing material + 0.10 mm
Pressure + 0.10 mm

8.4.1.6 Checking the bearer and blanket packing height

Figure 8.5 Checking the blanket pressure using 3 dial gauge

Packing heights are measured with the packing gauge recommended

by the manufacturer. Normally this is done with the help of a 3 dial guage as in
Figure 8.5. A thin sheet without creases is placed under the gauge to avoid
damaging printing plates and blankets. They have non-slip surface. This prevents
the sheets from moving under blanket or plate. The 3 dial gauge is placed in such
a way that one of the dial is resting on the bearer and the other two on the
blanket. Set the dial to zero and move the 3 dial gauge from DS to OS. If there is
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no height variation between the blanket and bearer then all the dials show same
readings. According to the variation there will be fluctuation on the 3 dial gauge
and the setting need to be rechecked again and increase or decrease the packing
sheet which ever is applicable. Usually the packing sheets are marked with the
thickness for calculation and identification.

8.4.1.7 Dry offset test

Figure 8.6 Squeeze pressure of 0.01 mm and with optimum pressure of

0.100mm

This test will help to know about the optimum squeeze pressure
required for a fine print as well as the quality of blanket. To proceed with, detach
the dampening unit of the press, thereby only inking will be applied on to the
plate. Keep the squeeze pressure to a minimum of 0.01 mm as shown in the
Figure 8.6, and keep increasing the pressure checking the quality of print. In this
case the required squeeze pressure is 0.100 mm. the test concludes that the print
should have even density and smooth image throughout the image area.

8.4.1.8 Dampening solution preparation

An ideal dampening solution should maintain these criteria. The plain

water should have water hardness of: 8 to 12°dH. Water hardness, is determined
mainly by the content of calcium and magnesium salts. By using water hardness
strips (Figure 8.7) it is possible to check the water hardness. If all the 4 green
colour patch turns red, it indicates that the water is very hard. If all four patches
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remain green, then water is very soft. Ideal for printing is 2 red and 2 green.
Conductivity of plain water can be between 300 to 500 micro Siemens.
Conductivity is the amount of impurities (unwanted salts). If the solution’s
conductivity gets increased by1000 micro Siemens from freshly mixed solution
conductivity value, then it is time to replace the dampening solution.

Figure 8.7 Test strip to check the water hardness

pH value of prepared solution should be 4.8 to 5.2. Hence the

dampening solution lie in the acid side of the pH scale. pH factor will decide on
the image life as well as the quality of print and it can be checked with a pH
meter. The temperature of the solution should be about 10°C below the ambient
temperature. IPA is added to reduce the surface tension of the solution. ie, this
will help to have an even dampening all over the plate which helps in scumming
of the plate. The IPA % is between 8-10. Purity of IPA should be >98%,
cosmetic quality. The cleanness and purity of IPA can be determined by filling a
clean glass with equal parts of water and alcohol. After 30 – 45 minutes, if the
alcohol is good, a clear liquid will remain in the glass. If the alcohol is unusable,
the liquid in the glass will be turbid or you will see turbid layers. Areometer is
the instrument used to check % of IPA in the dampening solution (Figure 8.8).
While taking the reading of IPA with Areometer it should be noted that the
areometer must be able to float freely in the glass cube or other container. There
must be no air bubbles in the liquid and at the areometer . Read the value at
vol%. Read off the temperature and offset it against the vol% value. Table 8.3 is
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used to determine the IPA content. For getting density of fountain solution
measure out exactly one liter of additive and weigh it on a precise scales.

Figure 8.8 Areometer for checking the IPA percentage

Table 8.3 Determining the IPA content

Density of % of
IPA IPA IPA IPA IPA IPA IPA IPA IPA IPA
additive Additive
1.05 2 3.1 5 6.8 8.7 10.5 12.4 14.2 16.1 17.9 19.7
3 2.8 4.6 6.4 8.2 10.1 11.9 13.7 15.5 17.3 19.1
4 2.5 4.3 6 7.8 9.6 11.4 13.1 14.9 16.7 18.5
1.1 2 2.5 4.3 6.1 7.9 9.7 11.4 13.2 15 16.8 18.6
3 1.9 3.6 5.3 7 8.8 10.5 12.2 13.9 15.6 17.4
4 1.2 2.9 4.5 6.2 7.9 9.5 11.2 12.8 14.5 16.1
1.15 2 1.9 3.6 5.3 7.1 8.8 10.5 12.2 14 15.7 17.4
3 0.9 2.6 4.2 5.8 7.5 9.1 10.7 12.3 14 15.6
4 0 1.5 3 4.6 6.1 7.6 9.2 10.7 12.3 13.8
1.2 2 1.3 2.9 4.6 6.3 7.9 9.6 11.2 12.9 14.6 16.2
3 0 1.5 3.1 4.6 6.1 7.7 9.2 10.8 12.3 13.8
4 -1.3 0.1 1.6 3 4.4 5.8 7.2 8.6 10 11.4
Actual
4 6 8 10 12 14 16 18 20 22
IPA in %

The % of the contents of Dampening solution should be as per the

Table 8.4 for preparing 100 liters of solution. Many times it is observed that
printers deviate from this mixing technique. Always make sure that water should
be the base solution and up on which IPA and Additives to be added. If the
chemicals are added first there are chances of a chemical reaction, which creates
a foggy effect to the solution as shown in the Figure 8.9 and solution will be
unusable.
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Table 8.4 Proportionate Percentage of contents in dampening solution

Desired Quantity 100 liters

- Additive 4 liters Additive 4%
- Alcohol 10 liters Alcohol 10%
= Water 86 liters Water 86%
Actual Quantity 100 liters Actual Quantity 100%

Figure 8.9 Unusable dampening solution due to foggy effect

Freshly prepared dampening solution will be transparent and odor

less. The temperature, pH and conductivity will be of standard. As the solution is
in use, there will be contamination of the solution. The causes for contamination
are from the paper, ink & washing solvents. Figure 8.10 shows fresh dampening
solution and contaminated dampening solution Figure 8.11. On a press which
works 24 x 7, the dampening solution need to be replaced once in 4 days.

Figure 8.10 Fresh dampening solution

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Figure 8.11 Questionable dampening solution & unusable dampening solution

Conductivity (μS/cm) describes how electricity is conducted through a

liquid; impurities in the dampening solution allow conductivity to increase.
Conductivity varies depending on the water and additives. The temperature and
the concentration of alcohol also influence conductivity. By increasing IPA,
conductivity declines. Modern conductivity gauges also measure for temperature.
It is important that the conductivity gauge in the central dampening solution be
regularly cleaned and recalibrated. Conductivity should be determined using a
“freshly prepared dampening solution”, so that this measure can then serve as a
“benchmark” when the dampening solution is later exchanged. When the
conductivity in the dampening solution has climbed by approx. 1000 μs/cm, this
should be taken as a signal that it is time to change the dampening solution. In
order to guard against printing problems, it is recommended that the dampening
solution be renewed every 14 days. By introducing optional dampening solution
filters, the useful life of the dampening solution can be substantially prolonged.
The pH-Balance, the temperature, as well as conductivity can be measured by
means of a universal test control device. All electronic measuring instruments
must be regularly re-calibrated. Always it is not advisable to go for Auto dozing
of Dampening solution. Because the machine setting may vary, this in turn will
affect the concentration of the chemistry in dampening solution, thus affecting
printing process. Comparative study on Auto dozing and manual preparation is
made and is given in Table 8.5 (Hattori, H., et al., (2008).
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Table 8.5 Comparative study on the difference in Auto dozing and manual
preparation of dampening solution

Hardness 1 lt of base Required in

0 pH μS/cm 0
C Liters
dH water tank
Separate Hard 300 18
Separate Soft 700 60.9 43
Mixed <8 7.4 446 29.4

Hardness 1 lt of damp Tank

0
dH
pH μS/cm 0
C
solution capacity
Liters
Normal
Additive 30 2.1
condition
In tank 70
<8 5.2 1008 10.5 Alcohol 100 7
condition
Water 870 60.9

% of
Alcohol in 10.5 3 10
Areometer
Color
legends
Type and Record manually After correction
Type values for auto calculation

8.4.1.9 Inking and dampening roller setting

A good inking unit should have a large storage capacity, while also
being able to react as fast as possible to corrections. An assessment measure for
the surface of an inking unit is the comparison between the largest print format
and the inking unit surface. It is calculated from the sum of the surfaces of all
rollers and distributor rollers, from the vibrator roller to the inking form rollers.

The number and circumference of the inking form rollers have a major
influence on the even inking of the printing plate. We know from experience that
it is simpler to apply a thin ink layer to the plate from several inking form rollers
in succession and then to smooth it, than to apply the same ink volume with
fewer rollers. Different diameters of the inking form rollers ensure even inking,
even for difficult forms. If all inking form rollers had the same diameter, the ink
consumption of the printed image would coincide exactly due to the same
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cylinder rolling, manifesting itself as an ink transfer error (ghosting). With 4

inking form rollers in correctly graded roller diameters, a sheet-fed offset presses
guarantee good inking (Breede, M.H., (2006).

Another important factor is the roller arrangement. It determines the

ink flow and directly effects the inking of the plate. Sheet-fed offset presses have
front-heavy inking units. The main ink stream is directed at the first form rollers.
Depending on the press model, they apply up to 90% of the required ink volume
to the printing form. The last two inking form rollers mainly have the task of
smoothing the ink layer on the plate.

8.4.1.10 Installation and adjustment:

In all adjustments, the contact is increased in the clockwise direction

and decreased in the counterclockwise direction. The cylinder gap is outside the
adjustment range. Diameter of White coloured form roller is 78 mm, of Blue is
60 mm, of Red is 72 mm and of Yellow is 66 mm (Figure 8.12).

Roller setting procedure is as follows. 1st step: Install rollers 1and 12,
then apply ink (yellow) and allow it to be distributed. 2nd step: Adjust 1 to C = 4
mm, 2 to D = 4 mm. Install rollers 13 and 14 and adjust 13 to D = 4 mm, 14 to C
= 4 mm. Note that Rollers 3 - 8 require no adjustment. Tighten the Allen screws
after installing roller 4. Remember that, Roller 12b  contact area is created
only by the roller weight. Roller 12 and 11  6 mm contact area. 3rd step:
Adjust 10 to 9 = 4-5 mm and 9 to B = 4 mm, then adjust 12 and 11= 6mm and
bring 12b into contact with 11. 4th step: Install the ink vibrator (15) and adjust
15 to the ink fountain roller = 4 mm, then 15 to A = 4 mm (adjust spring pressure
if necessary). Thus: 1st vibrator roller  ink fountain roller - 2nd vibrator roller
 distributor roller. 5th step: Set the inking form rollers down onto the plate.
Distance between dampening form rollers and plate = 4 mm.

Always avoid excess pressure for roller setting. Proper roller setting
can be best done by Strip method as shown in Figure 8.13. Ink grinding and
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transfer is not done by pressure it is done by shear force generated by the

different speed of roller with different diameter. Correct roller setting saves 27%
of ink, 15% of fountain solution, 9% of plates and also save power and also
improve the quality of print.

Figure 8.12 Inking and dampening unit setting (mm)

Figure 8.13 Roller setting through strip method

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Figure 8.14 Flooding due to wrong setting & correct setting of dampening rollers

The roller setting must be as per the specification by the manufacturer.

Variation in roller setting will cause severe problems during printing. Figure 8.14
on the left side shows flooding of dampening solution which affect the colour
density and consistency.

The inking system consists of rubber and metal rollers. They are
arranged is such a way that there will be no interaction between 2 rubber rollers
or contact between two inking rollers. Interleaving fashion will make the ink to
grind properly and a smooth layer of ink can be supplied to the plate. If you look
new roller under microscope surface looks like peaks & valleys and soft (Figure
8.15). This peaks & valleys carry ink & water and constant agitation of them
keeps the ink and water in a stable emulsion. This roughness is created when
roller is made and the rubber stretches and breaks around the grinding wheel.
This roughness is called as Nap which can tested by moving the index finger
away from you down the axis of the roller if the roller obstruct the movement of
finger then it is good Nap required for good printing.

Filling up of peaks and valleys and sealed with particles of ink,

fountain solution, gum and paper is called as glazing. Improper washing, wrong
selection of wash up solvents, paper fluff, high conductivity of the fountain
solution were some of the important reasons for the rollers glazing. If you run
your index finger on the surface of rollers it will slide smoothly without any
obstruction. Then we can understand that roller is glazed.
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Figure 8.15 Comparison of Glazed roller surface and good roller surface

8.4.1.11 Checking the resilience of the inking and dampening rollers

Checking the roller hardness is very important. Due to the close

contact with various chemicals like wash up solvents, ink and dampening
solutions there is every possibility that the rubber roller tend to hard. Hardness of
above 40 shore hardness will lead to wrong roller setting resulting in excess dot
gain, mottling, streaks and colour inconsistency. Durometer is the instrument
used to measure the hardness of the rubber roller. The hardness value is
measured in Shores. 24 – 36 shore hardness is ideal. Hardness is determined at 5
points as in Figure 8.16 and average is taken. The five points are: 1. On the drive
side 2. On the operator side, 3, 4 and 5 are located 1800 apart along the
circumference in the middle of the roller. Points at the edges should be 1/10 of
the covering length away from the roller end.

Figure 8. 16 Checking the shore hardness of roller

There is one more way to check the quality of rubber roller. Apply
three or four drops of fountain solution on the surface of the roll and wait for five
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seconds. If the solution remains on roller surface like in the Figure 8.17, it is
roller surface is good and if the drop slips out fast leaving no trace of the solution
then it is bad surface. It is strongly recommended to frequently remove the
dampening form roller and clean the dull chrome roller thoroughly and apply a
thin film of gum and dry the rollers.

Figure 8. 17 Checking the surface of roller quality

8.4.1.12 Anti set off powder

Powder is not a drying agent. It only creates a space between freshly

printed sheets. Preventing offsetting and to promote drying through oxidation.
On addition can improve the sliding behavior of print sheets in the press.
Different kinds of powders are available which behave differently. There are
certain criteria to be considered while selecting the powder. The more colors are
printed on top of each other, the more powder is required. Recommend using a
grain size of at least 15 µm. The type of powder must be matched to the
subsequent operations (coating, laminating, hot foil stamping). Heavy powder
types (calcium carbonate) are can be applied to the sheet with more precision
than lighter (starch) powders, particularly at high printing speeds. The powder
sprayer mechanism must be set to release optimum spray. Detailed study of Anti
Set off Powder is explained in Chapter 7 of this thesis.

8.4.1.13 Delivery setting of the machine

Delivery side of the machine is the place where printed material is

collected as shown in Figure 8.18. The side and back joggers need to be adjusted
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according to the paper size. The landing speed to be controlled with the blowers,
fans, speed reducing vacuum belts. If these settings are not proper, printed sheet
do not land to the deliver pile board smoothly, can hit the front guards, this can
damage the edges of the paper. If the sheets are not jogged properly while
landing, the pile has to be jogged again for post press operations. This again is
time consuming and delaying the production.

Figure 8.18 Printed paper jogged and land in delivery pile.

With proper delivery setting the preliminary setting of the machine is

completed. Now the machine can be powered to begin printing. The speed of the
press should be maintained steady, Eg. If during the optimisation the speed was
at 10,000 imp/ hr, till the experiment is completed this speed to be maintained.

8.4.2 Capability Phase

The purpose of this phase is to make an analysis of the ink and water
balance, and further can be applied for the adjustment of the dampening and
inking units. It can also be used for the detection of mal-adjustments or incorrect
ink/water balance. This test helps to identify the best compatible dampening
chemistry. In case of complaints about streak marks, bad ink and tonal variation
usually happens when the ink and dampening chemistry is not compatible.

8.4.2.1 Registration setting

The dampening setting is kept to a minimum for Black, Cyan.

Magenta it was 27% and Yellow 30%. Magenta and Yellow colour at tail side is
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deviating towards OS. The registration is done with CP 2000 and the speed of the
press was 10,000 imp/hr.

Figure 8.19 Registration grid test chart.

If perfect register is achieved, there will be a uniform black grid

pattern with no color rain bowing (Figure 8.19). However, if any of the units is
out of register, a color outline will appear beside the grid lines (showing the color
which is missing registered). If a hand magnifier with a reticle is used, then a
measurement of the amount of misregister can be made. Typically, the register
will be best in the center of the form near the gripper edge and it will deteriorate
as it moves toward the corners at the trailing edge of the test form. The highlight
tint patches are particularly sensitive to misregister. Using a hand magnifier,
examine the inset tint patches to determine whether all the highlight dots have
imaged precisely one on top of the other. Again, the tint patches toward the
trailing corners will show the most misregister.

8.4.2.2 PAN4C analysis print test form

The PAN4C analysis print test form, developed by Dieter Kirchner,

(Figure 8.20) can be applied for the adjustment of the dampening and inking
units and for ink and dampening solutions compatibility. The print test form is
 215

mirrored in the mid of the sheet and should show the same measuring value on
each half of the sheet.

Figure 8.20 PAN4C analysis print test form

The single colour print test form has measuring patches at the front
edge with coverage values of 93, 90 and 80% area coverage as well as a
persistent full-tone bar to detect the area coverage values. These four values
serve the purpose of an even adjustment of the dampening over the sheet width.
The dampening potentiometer is adjusted in an optimal way if the area coverage
(including dot gain) shows values of 99%, 97% and 93%. If this doesn’t work,
check the running clean of the plate or test a different ink/fountain solution, if
available. (Figure 8.21)

Figure 8.21 99%, 97% and 93% patches

In the mean range of the print test form there are two tone value
gradations, 80-50% and 47-0% behind. The gradation 80%-50% to detect the
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scumming edge, 47%-0% shows faults of the ink/water balance (ink splitting).
Over the sheet width there are three rows with measuring areas of 6%-80% for
detecting the dot gain (Figure 8.22). The row with the pitch lines at intervals of
approx. 5mm (dependent on the scale) reflect the tolerance, based on the 50%
line a scumming area tolerance of 6 wide graduation marks has to be maintained.

50%
tone value

Figure 8.22 Line scumming area of 50%

In the middle of the printed sheet there are four measuring areas 43,
45, 47 and 49 each on DS and OS in order to detect the gradation curve for
further print test forms of (Figure 8.23) the PAN4C standardization and
furthermore for the determination of the CtP characteristic curve for other print
jobs. The area showing approximately the target value 55% (40% + dot gain
15%) when measuring the area coverage is used as characteristic curve. If the
print test forme is only used for setting or troubleshooting purposes this area has
only minor importance.

Figure 8.23 Measuring areas of 43, 45, 47 and 49 patch

Consider that the gradual fading over the whole sheet length does not
exceed the values of max. 10% prescribed by bvdm/FOGRA. For the detection
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and optimization of the gradual fading a full tone bar is installed in the right half
of the sheet in circumferential direction.

Printing procedure is to mount the plate first and run up the ink. Then
disengage dampening unit, this will cause solid ink on the plate. Solids should
have a density of approx. 1.10 in Cyan or Magenta, approx. 1.30 in Black.
Engage dampening and run the plate clean. Set to reference densities over whole
sheet width as in Printing unit (PU) PU1: B=Dv 1.80-1.90, PU2: C=Dv 1.50-
1.60, PU3: M=Dv 1.50-1.60 and in PU4: C or M= Dv 1.50-1.60. (Dv = Density
variation) Yellow is not used as the contrast ink/paper is too slight. Print sheets
with reference density and run up the scumming edge at the front edge, +
increase max. 4% . Print 100 sheets with checking the inking stability. Try to
achieve the scumming edge at the 50 % scumming, which will basically appear
while decreasing the potentiometer to the half amount of the current setting.
Work very accurate. Print sample is scumming equal over the whole width at the
50% scumming line at front and tail edge. If ink water balance is good, no streak
marks will appear in the 47-2% range. Take out print samples and run the plate
clean by changing back to the former setting of the potentiometer. The value for
the clean plate might be 2-4% higher than before to achieve a clean plate.
Analysis made on the print sample by measuring all relevant values. Reference
values for dampening: 99% (in 92% patch); 97% (in 90% patch); 93% (in 80%
patch) (Figure 8.24)
99%

97%

93%

Figure 8.24 Reference values for dampening

8.4.2.3 Detection of faults

(i) Bad ink splitting: Bad ink splitting is caused by a chemical problem in
the combination of ink and dampening water. This appears in form of
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striation when printing the test form (left photo) or as stripes in the range
of 47-2% area coverage (right photo) in Figure 8.25. If such problems
occur you have to change chemistry (e.g. dampening solution) at first
and then rinse the dampening solution circulation several times (cleaning
of system).

Figure 8.25 Bad ink splitting in Cyan and Black

(ii) Unbalanced roller adjustment : Due to an unbalanced adjustment of the

contact strips of the rollers the transfer of ink and water on the printing
plate varies. The fault shows an unbalanced dampening of the plate,
therefore a check of the dampening unit would be the correct procedure.
However, the dampening potentiometer is often raised in a way that on
both OS & DS sides a non-scumming image occurs (Figure 8.26). That
way a significant dampening surplus on the drive side arises which may
partially result in over dampening and thus lead to one-sided drying
problems which may consequently lead to offsetting.

Figure 8.26 Scum start variation at OS and DS

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(iii) Damaged rollers in inking/dampening unit: Damaged or worn rollers

often don’t show faults until they are below the scumming edge as high
dampening adjustments cover many faults. In this case the fault arises
because of a damaged inking roller when reaching the 50% scumming
edge. In the cases shown below an inking roller in the Magenta is
damaged and in the Black the dampening roller is worn.
(iv) Dampening guidance is too low/too high : Measuring in the dampening
measuring area: Set the adjustment of the hand-held densitometer to
measuring mode. Measuring 100% solid, then 90% area (1) and 80%
area (2) in all zones and all colours. Area coverage values should show
99/98/93%. If the values in the 90% (less than 97%) and 80% (less than
92%), the dampening potentiometer setting is too high  reduce
potentiometer. If the values in the 90% (more than 98%) and 80% (more
than 94%), the dampening potentiometer setting is too low  increase
potentiometer.
(v) Unbalanced dot gain by comparing of the 20/80% and 40/60% values: If
an optimum gradation of the exposure characteristic curve is plotted, the
areas 20/80% and the areas 40/60% show the same dot gains. The dot
gain in the lower value patch should be similar, but anyhow never higher
to the higher value patch.

8.4.2.4 Conclusion & Inference

In Cyan the FOGRA Density (FD) 40% area shows 14% dot gain, the
FD 60% area shows 11% dot gain. Consequently there is a difference of more
than 2% and the low value shows a higher dot gain in comparison to the high
value as shown in Table 8.6. Such is the case, the gradation of the CtP
characteristic curve has to be checked. The risk is very high that the tone range
will not be transferred completely and then e.g. the 2% dot is lacking.

The aim points and tolerances determined through this test represent
the best sustainable quality that the press system can produce. The aim points are
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as close as practical to the points of maximum contrast without allowing the

natural variability of the system to be in a condition of over inking.

Table 8.6 FOGRA dot gain values

Dot gain according to ISO/bvdm/FOGRA Dot gain reference value and tolerances (%)
Chromatic Colors C,M,Y
in 40%area 9 – 13 - 17
in 80% area 8 – 11 - 14
Black
in 40%area 12 – 16 - 20
in 80% area 9 – 13 - 16

This concludes the second step of the optimization process, but it is

important to realize that optimum ink and dampening density settings will not, in
themselves, lead to higher quality printing. If the color separations and proofing
system are not properly calibrated to these press conditions, then no quality
improvement can be expected. Considering the above explained ink water
balance test and the results obtained is rectified and can be used as reference.

8.4.3 Characterization Phase

The goal of the characterization phase is to measure the print

characteristics of the press system when it is running at the optimum ink
densities. A series of tests were conducted with different test forms for finding
out various print characteristics, thus to check if the press is Optimised. This
fingerprint of the press is meaningful because it relates to best printing that the
press system can deliver. The press characterization will only be valid for the
specific press system being tested. Changes in inks or paper will alter the results
to some extent. The characterization information is only valid if the screen
frequency and dot shape of the targets is the same as the half toning that will be
used in live work.

If color management is being applied to the press system, the press

profile should be made at this point. The color management output target is run
on the press system to the ink densities determined from the capability study. The
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resulting ICC profile will represent the best printing that the press system can
deliver.

In a traditional calibration procedure, the reproduction characteristics

that are measured in this phase are used to optimize color files to lit the
requirements of the press system. The essential information that should be
collected includes: dot gain curves, minimum and maximum reproducible dots,
gray balance values, total ink coverage requirements, and secondary color
information.

8.4.3.1 Print Contrast Test

Figure 8.27 Print Contrast Test chart

This Contrast Test Image Chart helps to know the contrast of the
printed image. Maintain same ink zone value for all the 23 zones and take a print.
The test chart is so designed that, the image diminishes from OS to DS (Figure
8.27) and vice versa. Eg. take Black printer, the ink consumed on the OS is more
when compared at the DS. On measuring the Lab value of print at the patches,
we can see that there will be variation from the reference Lab value. The point
where the reference value gets closer to the measured value will be the density
value for that particular print. The first press test uses print contrast as the quality
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attribute to find optimum densities. The print contrast attribute can also be
calculated mathematically, it is calculated as follows:

(Solid density - Density of 75% tint) (8.1)

Print Contrast =
Solid density x 100

After the plates are mounted on the press, the press is brought into
register and balanced to achieve a deliberately low density in each process color.
First run 100 sheets of scrape stock through the press to confirm that it has
stabilized, then run five sheets of the test paper and collect these sheets. Measure
print contrast from a single point on the press form, using the same point for all
measurements in one color. It is not necessary to use the same ink key zone for
each of the process colors, but it is important to stay consistent within one color.
Also, pick the ink key zone with some care, avoiding ink keys that are over
gutters where there is little ink draw and also avoiding ink keys at the extreme
edges of the form (Arnel, P (2006). After calculating print contrast for a given
color from the same spot on all five sheets of good paper, find the average of
these values by summing them up and dividing by five.

When the print contrast value decreases, a point of over inking has
been reached where, in order to increase the solid density any further, the ink
film thickness is increased to such an extent that the 75% tint density is growing
faster than the solid density. This reduces the number of gray levels that can be
imaged with the press system and leads to serious press maladies like setoff and
back trapping. The point of maximum contrast is the density value at which the
press can image the most gray levels, and, theoretically, the best printed
reproductions. If there were no variability in the ink density of a lithographic
press, then the best density aim point would be the point of maximum contrast.
However, lithography exhibits relatively high variability in ink density. If the
density aim point is set for the point of maximum contrast, the system will be
operating in the zone of over inking about half the time.
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8.4.3.2 Test to find out dot gain and ghosting

With this ink splitting test chart, we can identify the dot gain, ghosting,
Lab value of YMCK and RGB, Density across the sheet and Tonal Ink Value
(TIV).

Figure 8.28 Test form for cecking the dot gain and ghosting

Dot gain is a geometrical & visual expansion of printed dot in relation

to dots on film or plate. Dot gain cannot be avoided and must be taken into
account in the printing process. What matters is not the level of dot gain, but its
constancy during printing and that it is taken into account in prepress. This chart
helps to find out the dot gain as there are strips of Y,M,C,K in it. (Figure 8.28).
Changes in prepress and / or at the press that are not taken into account can cause
deviations in the print results. Densitometer or Spectrophotometer is used for
measuring the dot gain. Select the dot area or dot gain mode. Ensure it is
calibrated. Always calibrate with paper white. First measure solid patch, then
measure the screen patch. In dot area mode it is shown as % of dot of the
particular field. In dot gain mode it is shown as % of gain on particular field.
 224

Factor contributing to dot gain on print is mechanical, physical and optical.. This
optical effect is measured and factored into press dot gain by using formula of
Murray Davis.

1-10-DD
DP = x 100 (%) (8.2)
-SD
1-10
Where, DP = Density percentage, DD = Dot density, SD = Solid density.

Table 8.7 Density, dot area and corresponding dot gain

Densities Dot area Dot Gain

Field C M Y K C% M% Y% K% C% M% Y% K%
100% 1.36 1.30 1.07 1.54 100% 100% 100% 100% 0% 0% 0% 0%
95% 1.33 1.29 1.06 1.54 100% 100% 100% 100% 5% 5% 5% 5%
75% 0.95 0.86 0.83 1.11 93% 91% 93% 95% 18% 16% 18% 20%
50% 0.55 0.46 0.48 0.62 75% 69% 73% 78% 25% 19% 23% 28%
25% 0.25 0.21 0.21 0.28 46% 40% 42% 49% 21% 15% 17% 24%
5% 0.06 0.05 0.05 0.06 13% 11% 12% 13% 8% 6% 7% 8%
0% 0.00 0.00 0.00 0.00 0% 0% 0% 0% 0% 0% 0% 0%

Ghosting factor is found out using the below formula

Density S1 – Density S2
S= x 100 (8.3)
Density S1
Density S1 = 1.39

Density S2 = 1.32

S (%) = 1.39 – 1.32 x 100 = 0.07 x 100 = 5.035%

1.39 1.39

8.4.3.3 Ink trapping

This “PAN 4C Mixed test form 45” is a multifunctional test form

Figure 8.29, where we can measure number of print characteristics like, Dot gain
 225

and copy, grey scale, test fields black and entire ink application. Control of
screen program regarding Moire and texturing. Comparison pictures in grey
field. Reproduction of a slide for comparison. Bright grey picture for copy
control. Reproduction of a original picture. Print control wedge. Pictures for
multiple-ups control. Exposition of simultaneous contrast to white, grey, black.
Check of ghosting. Trapping of ink is over printing of colours. The following
applies to overprinting with two colours.

Figure 8. 29 PAN 4C Mixed test form 45 for print characteristics

D1+2 – D1
FA2[%] = x 100% (8.4)
1
D2

Where, D1+2: the ink density of overprinting both colours. D1: the ink
density of the colour printed first. D2: the ink density of the colour printed last.
All ink densities have to be measured with the filter for the second colour. The
following applies to overprinting with three colours:

D1+2+3 – D1+2
FA3[%] = x 100% (8.5)
2
1 D3
 226

Where, D1+2+3: the ink density of overprinting all three colours, D1+2:
the ink density of the 2 first printed colours, D3: the ink density of the colour
printed last. All ink densities have to be measured with the filter for the third,
last-printed colour.

Relative printing contrast (K) = DV - DR / DV x 100

DV = 1.75

DR = 0.65

K(%) = 1.75 – 0.65 x 100

1.75

= 1.10 x 100
1.75

= 62.85%

8.5 Material Matrix Test

Offset printing technology is a unique printing process. “Oil (Ink) and

Water (Dampening solution)” do not mix each other is the concept of this
printing, which no other printing processes has (Keppler, G., (2009). This
uniqueness has made Offset Printing distinct from other technologies. In process
of printing, the ink and water (dampening solution) is forced for a mix and the
result obtained is “Emulsified ink”, which has properties of solvent and water.
Unlike other print technologies to achieve a consistent colour in offset print is a
big task, because there are number of variables that decide the print. However
there are techniques to maintain colour consistency, wastage reduction, reduce
VOC emission and reduce startup time which is otherwise called as “Optimising
the Offset Printing Press” (Werner, K., et al., (2011).

Offset printing is an oscillation process. There are five sequences

involved in achieving one print cycle. They are as shown in Figure 8.30.
Emulsification process begin with Titration, here the two liquids (ink and
 227

dampening solution) is brought together to combine. As both liquids belong to

opposite families they resist, but due to the pressure applied by the inking and
dampening rollers they emulsify. That is the ink molecules start accepting water
molecules. This process continues till saturation of the liquids. After saturation is
releasing, the emulsified ink is released on paper as print (Adams et. al., (2005).

Figure 8.30 Emulsification process

The emulsified ink is released to the paper which is called as ink

splitting (Figure 8.31) the solvent and water in the ink gets evaporated leaving
pigment as color. By optimizing the press what we achieve is the reduced
reaction time, ie quick ok sheet without wasting time and materials.

Figure 8.31 Ink splitting technique

Ink splitting is the process by which emulsified ink is released to the

paper. At the nip of printing the ink gets in contact with paper. As the paper is
 228

moving forward and the blanket cylinder is rotating, it creates a cavity in the ink
film, and it is extended to filamentation which makes the ink to break to settle in
paper. If the ink and water balance is good the ink filament will break at the
center (50:50) releasing sufficient ink to the paper, which we call as good ink
density. When there is more water the proportionate will be (65: 35 or 75:25)
resulting in low ink density. Test chart (Figure 8.32) shows sufficient ink density
on the DS and low ink density at the OS of the magenta strip. The cause for this
density variation is more dampening solution at the OS. This will result in
inconsistency in the print causing wastage. Easy check for optimum ink water
balance is to check the gripper side of the mounted plate, if there is an 1mm ink
strip extending from DS to OS, ink water balance is good as in (Figure 8.33). If
the dampening solution is less, the strip thickness increases and if dampening
solution is more there will be no trace of this strip (Peter, N., et al., (2012).

Figure 8.32 Magenta showing density variation due to excess of dampening solution

Figure 8.33 One mm yellow ink strip is an indicates optimum ink water balance
 229

The blue colored sine wave in Figure 8.34 shows inconsistency of the ink
density, (ie. ink density varies from 0.9 to 2.5) whereas the red sine wave
indicates quick reaction time and consistency in color. This is achieved by
selecting the best ink and dampening solution which have extremely good
compatibility.

Figure 8.34 Minimum oscillations to keep the color density stable

Chapter 6 of this thesis explains about standardisation of ink. A series

of experiments were conducted to find the best available ink in the Indian
market. The experiments concluded by selecting HEI PREMIUM INK. Material
matrix tests were conducted to find out the best dampening chemistry which is
best compatible with Hei Premium. Seven different types of Fount were selected
and experiments were conducted on three different types of ink. Hei Premium,
Hei Utility and Hei Edition. The tabulated result concludes that Hei Premium Ink
has best ink split with the Fount Varn Protector. The experiment was extended to
3 different type of blanket and the conclusion is that Perfect dot which has 13%
of dot gain in 80% patch with nominal dampening feed has smoother effect on
half tone areas of the screen, hence can be considered as best with HEI Premium,
HEI Utility and HEI Edition ink series.
 230

Beside the Analysis test form the Gradation test form (Figure 8.35) is the
second one to get to running in standardized conditions. As the Analysis Test
form is made to check the settings of the rollers, ink splitting and ink-water-
balance,

8.5.1 PAN4C Gradation print test form (43-49)

Figure 8.35 YMCK Gradation test form

The Gradation Test form is developed to find the right characteristic

curves for the press parameters and the inks used. This test form will be produced
after finding out the correct characteristic curve while printing the Analysis test
form. This test form will be printed with a characteristic curve either 43, 45 47 or
49. Basically you have to strive for the same characteristic curves in all 4 colors.
If it is not possible to achieve values according to ISO standard, a change of the
characteristic curve will be necessary, for example from 45 to 43 or 47. The test
form contains:

(i) Measuring patches from 2 % – 100 %

(ii) Reference values of Dot gain according to ISO Standard from 2% - 95%
(iii) Element to check ink-/water balance and ink fading
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(iv) Color bar to measure dampening, grey scale, trapping and dot gain
comparison 20/80%, and 40/60%
(v) This test form has to be printed with the Standard densities as before at the
Analysis test form

PU1: B=Dv 1.80-1.90

PU2: C=Dv 1.50-1.60
PU3: M=Dv 1.50-1.60
PU4: Y= Dv 1.30-1.40
All dot gains values have to be within the pre-instructed range. For
example: Measurement at 40% halftone patch shows a measuring value of 54%.
That means, dot gain is 14%, according to ISO Standard a range of 9-17%, is to
be accepted. But nevertheless, a perfectly set press in combination with a good
ink will be able to reach a deviation of +/-1% from 2% to 95% coverage and over
all three chromatic colors C, M and Y. It is essential to keep the deviation
between the colors and measuring patches on a very low level, since a grey solid,
consisting of three colors will only then be neutral when dot gains of those three
colors are similar (Figure 8.36).

Neutral Bluish Reddish

Figure 8.36 Effect of Dot gain on Grey balance solid patch

8.5.1.1 Use of Colour control bar

Screen patch for checking amount of dampening solution. Patches for
measuring spectral data CMYK, RGB. Grey patches for visual check of Delta
(∆) E deviation for Proof and Print. Measuring of ∆ E deviation in CMY and
three color overprint for circumferential ∆ E deviation. Field for copy control
(2%), 4 fields for measuring the dot gain curve. Two fields for measurement of
the smearing limit.
 232

Table 8.8 Additive compatibility with (Varn Protector) Inference & conclusion
 233

Table 8.9 Additive compatibility with (Akron Gold) Inference & conclusion
 234

Table 8.10 Additive compatibility with (Huber Hydro) Inference & conclusion
 235

Table 8.11 Additive compatibility with (Total Care) Inference & conclusion
 236

Table 8.12 Additive compatibility with (DSC Stabilat) Inference & conclusion
 237

Table 8.13 Additive compatibility with (Saphira FS 13) Inference & conclusion
 238

Table 8.14 Blanket compatibility with (Perfect Dot) Test Inference & conclusion

Excess water feeding is required created new speed compensation

dampening curve HDM-material matrix by 200 rpm all speed.
 239

Table 8.15 Blanket compatibility test (Day 3000) Test Inference & conclusion

Excess water feeding is required created new speed compensation

dampening curve HDM-material matrix by 200 rpm all speed.
 240

Table 8.16 Blanket compatibility test (Conti Air) Test Inference & conclusion

Excess water feeding is required created new speed compensation

dampening curve HDM-material matrix by 200 rpm all speed.
 241

Table 8.17 Summary of Compatibility Test

Ink splitting in
Ink Additive type Smearing effect
screen area
Hei Premium Varn protector FAIR GOOD
Akron gold BAD BETTER
Huber Hydrolith BS FAIR BETTER
F 605 BAD BETTER
Total Care SFD BAD FAIR
DSC Stabilat- D 2010 BETTER BETTER
Saphira FS13-200 BAD FAIR

Hei Utility Varn protector GOOD FAIR

Akron gold BETTER BAD
Huber Hydrolith BS BETTER BAD
F 605 BETTER FAIR
Total Care SFD BAD GOOD
DSC Stabilat- D 2010 BAD BAD
Saphira FS13-200 BAD BAD

Hei Edition Varn protector GOOD BAD

Akron gold FAIR BAD
Huber Hydrolith BS BAD BETTER
F 605 BAD BETTER
Total Care SFD BAD BAD
DSC Stabilat- D 2010 BETTER BAD
Saphira FS13-200 FAIR BAD

Blanket Dot gain in 80% Dampening feed Screen smoothness

Perfect dot 13% Normal Good

Day
14% More Better
International

Conti Air 15% High Fair

 242

8.6 Eco Friendly Printing and Calculating the Co2 Emission

Sheet-fed offset is the most widely used printing process as it is cost

effective and can deliver excellent output. Though, modern presses have many
advanced set-up and automation features that reduce pollutants that harm the
environment, many times we see that these are not met with. During production
of a printed product, various types pollutants are generated. The printer input
paper, ink and energy to the machine to take out a printed sheet. Unfortunately
without knowledge there is generation of Ammonia, VOC, noise, dust, heat are
generated. This will have a negative impact on the atmosphere increasing the
CFP.

In the earlier Chapters we have discussed and concluded about

standardizing the paper, ink, dampening chemistry and optimizing the printing
machine. Taking those into consideration printing was conducted to find out the
carbon released during production. For a comparative study the experiment was
conducted in two phases.

(i) Print before optimizing the machine and calculating the CFD.

(ii) Print after optimizing the machine and calculating the CFD.

8.6.1 Presetting the ink opening

Figure 8.37 Test form to adjust the Ink Presetting

 243

When the print data comes from the prepress each colour element in
the test form will have different ink coverage, this will make the ink opening
different for different areas. In the Ink presetting test form ( Figure 8.37) larger
the colour patch, more should be the ink opening. Achieve the house standard at
all sampling points of the test form. Check and possibly change the curves of pre-
inking. The speedcompensation of ink influences the default setting (duct
change). Determine the house standard. Load the ink data via Prepress Interface.
Put the duct sweep down to 30%. Evaluate the density values per ink zone
coverage. Correct the density settings percentage wise accordingly. Rinse the
inking unit and the plate. Wait approx. 3 min. after wash-up. Load the ink data
via Prepress Interface. Ink balance 30%. Evaluate the density values per ink zone
coverage and correct the diode settings percentage wise accordingly. Repeat the
steps as long as the standard is achieved.

8.6.2 Calculating the CO2 emissions of the printing process

For the input/output data Heidelberg’s CO2 emission data was used
Table 8.17. A more often used figure would be 1.19 kg CO2/kg paper (Nature
Office) or 1.27 kg CO2/kg paper (BVDM). For the energy consumption average
factor for electricity of 0.514 kg CO2/kWh. was used. Calculating a print product,
the calculator of BVDM was used, which is recognized by print research
institutions like FOGRA and UGRA (Appendix 9). In the BVDM calculation
transportation of material and waste is included, as well as the conveyance of
employees from home to print shop.

Table 8.18 CO2 Factor for typical consumables in printing presses

Material CO2 Factor ( CO2 in kg/kg material
Paper 1.27
Ink 2.5
IPA 3.8
Additive in Fountain solution
Cleaning agent 2.3
Varnish 1.5
Aluminium plate 15 (7.875 kg/m2, 0.3mm)
Rubber blanket 6.5 kg/m2, 2mm
Energy 36 W
 244

8.6.3 Printing before optimizing

The print tests were performed in line with a comprehensive test

program. Before optimizing the press the practical tests were started; the press
was test-printed with the inputs stated as in Table 8.19.
8.6.3.1 Input to the printing machine before optimizing
Table 8.19 Input Material Attributes before optimising
Input Material Attributes
Paper BILT Royal C2S Gloss 130 gsm
Packing below blanket 0.40 mm (Mark 3Z Calibrated)
Water After hardening >8 DH/pH 6.7/300
Blanket torque 45Nm
Plate Technova Thermostat TN
Lpi 200 Lpi
Imaging details Linearised
Dot shape AM/Round
Test Form Greeting Cards
Press SM 74-4P+L
Press speed 10,000 imp/hr
Colour Sequence 1-K, 2-C, 3-M, 4-Y
% of Additive 2.5% 1.5 Liters
Alcohol Type Prisol EL
% of IPA 8% 4.8 Liters
% of Water 53.61 Liters
% of Hardner 0.15% 100 ml
Tank Capacity 60 Liters
Temperature/pH/Conductivity 10 deg cent./ 5.1/ 1280
Measuring equip. used Gretag Spectro Eye
Measuring condition D50, 2 deg, Pol, white, DIN

8.6.3.2 Print Evaluation

Printing was conducted as per Standard Operating Procedure (SOP) at

80% of maximum speed. The result obtained is Figure 8.38. On evaluating the
image it was observed (Figure 8.39 and Figure 8.40) that the Dot gain is high
making the print darker. Color variation is there from gripper to tail and the
trapping and color contrast is poor.
 245

Figure 8.38 Print taken before optimizing the press

Figure 8.39 Ink trapping percentage (M+Y 72%, C+Y 80%, C+M 63%)

Figure 8.40 Graphical representation of print

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8.6.3.3 Observations & Inference of Experiment 1

Table 8. 20 Calculating the CO2 release

Energy consumption for 51 x 74 format = 36kw

Average CO2 factor for electricity per kWh = 0.514 kg CO2
CO2 for 36 kW for 4 hours = 74.01 kg CO2
CO2 factor for Blanket = 6.5 kg/m2
For blanket size 0.772 x0 .627 m = 0.484 m2 x 6.5 kg CO2 /m2 = 3.146 kg CO2
For 4 printing blankets = 12.58 kg CO2
CO2 factor for Plate = 7.88kg/m2
For plate size 0.745 m x 0.605 m= 0.450 m2 x 7.88 kg CO2 /m2 = 3.551 kg CO2
For 4 printing plates = 14.2 kg CO2

CO2 in kg/kg material for IPA = 3.8

IPA used = 6.4 kg
CO2 for 6.4 kg = 24.32 kg
CO2 in kg/kg material for Wash-up solvents = 2.3
Material used = 2.5 kg
CO2 for 2.5 kg = 5.75 kg
CO2 in kg/kg material for Fount = 2.0
Fount used = 1.28 kg
CO2 for 1.28 kg = 2.56 kg
CO2 in kg/kg material for Ink = 2.5
Ink used = 2.0 kg
CO2 for 2.0 kg = 5.0 kg
CO2 in kg/kg material for Paper = 1.27
Paper used (8 reams x 21.3/kg) = 639 kg
CO2 for 639 kg = 216.40 kg

Total CO2 release during this exercise is 354.82 kg.

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8.6.4 Input to the printing machine after optimizing

8.6.4.1 Input Material Attributes after optimising

Table 8. 21 Input Material Attributes after optimising

Input Material Attributes

Paper BILT Royal C2S Gloss 130 gsm
Packing below blanket 0.40 mm (Mark 3Z Calibrated)
Water After hardening >8 DH/pH 6.7/300
Blanket torque 45Nm
Plate Technova Thermostat TN
Lpi 200 Lpi
Imaging details Process calibrated
Dot shape AM/Round
Test Form Greeting Cards
Press SM 74-4P+L
Press speed 10,000 imp/hr
Colour Sequence 1-K, 2-C, 3-M, 4-Y
% of Additive 2.5% 1.5 Liters
Alcohol Type Prisol EL
% of IPA 8% 4.8 Liters
% of Water 53.61 Liters
% of Hardner 0.15% 100 ml
Tank Capacity 60 Liters
Temparature/pH/Conductivity 10 deg cent./ 5.1/ 1280
Measuring equip. used Gretag Spectro Eye
Measuring condition D50, 2 deg, Pol, white, DIN

8.6.4.2 Print Evaluation

Printing was conducted as per Standard Operating Procedure (SOP) at

80% of maximum speed. The result obtained is Figure 8.41. On the CP 2000 the
ink zone values were sowing excellent (Figure 8.42). Graphical representation is
plotted (Figure 8.43). On evaluating the image it was observed that the Dot gain
is normal making the print in acceptable quality. Gripper to tail color variation is
nil, trapping is good as well as color contrast as well as trapping (Figure 8.44).
 248

Figure 8.41 Print taken after optimizing the press

Figure 8.42 CP 2000 reading on SM 74

Where Z70 is the dot gain at 70%, S/D is the Slur and Doubling
values, dE is the delta error, in Lab value L stands for the lightness, a for value
between red and green and b for value between blue and yellow. Delta E0 is the
delta E possible, dF is the delta Fabbe ie delta of ink, this rule is suitable to get
reference or not.

Figure 8.43 Graphical representation of print

 249

8.6.4.3 Observations & Inference in Experiment 2

Table 8. 22 Calculating the CO2 release

Energy consumption for 51 x 74 format = 36kw
Average CO2 factor for electricity per kWh = 0.514 kg CO2
CO2 for 36 kW for 2 hours = 37.00 kg CO2
CO2 factor for Blanket = 6.5 kg/m2
For blanket size 0.772 x0.627 m = 0.484 m2 x 6.5 kg CO2 /m2 = 3.146 kg CO2
For 4 printing blankets = 12.58 kg CO2
CO2 factor for Plate = 7.88kg/m2
For plate size 0.745 m x 0.605 m =0.450 m2 x 7.88 kg CO2 /m2 = 3.551 kg CO2
For 4 printing plates = 14.20 kg CO2

CO2 in kg/kg material for IPA = 3.8

IPA used = 6.4 kg
CO2 for 6.4 kg = 24.32 kg
CO2 in kg/kg material for Wash up Solvents = 2.3
Material used = 0.75 kg
CO2 for 0.75 kg = 1.72 kg
CO2 in kg/kg material for Fount = 2.0
Fount used = 1.28 kg
CO2 for 1.28 kg = 2.56 kg
CO2 in kg/kg material for Ink = 2.5
Ink used = 1.0 kg
CO2 for 1.0 kg = 2.5 kg
CO2 in kg/kg material for Paper = 1.27
Paper used (4 reams x 21.3/kg) = 106.5 kg
CO2 for 106.5 kg = 108.20 kg

Total CO2 release during this exercise is 203.08 kg.

 250

Comparison of Carbon Foot Print Savings

Potential savings of CO2 release
Total CO2 release during this Exercise (1) - Total CO2 release during this Exercise(2)
Potential savings of CO2 release = 354.82 kg – 203.08 kg = 151.74 kg

Figure 8.44 Ink trapping percentage (M+Y 73%, C+Y 87%, C+M 64%)

8.7 Chapter Conclusion

This chapter focus on the practical application of optimizing the

printing press in order to reduce CFP. (Table 8.19) Exp.1. 354.82 kg - (Table 8.
21) Exp.2. 203.08 kg = 151.74 kg) Optimization is achieved essentially by
improved integration of the printing press into prepress, presetting of the press
and monitor the printing process before, during and after print. The data is
exchanged between prepress and press for ideal optimization are: Printing
material parameters, Parameters of printing inks and consumables, Target values
of the printing process for making presetting, Zonal dot area values on the
printing plate (Ross, G., (2008) and (Zobel, T., et al., (2004).

In future the demand for standardization in printing materials and

optimization of offset press will increase with corresponding effects on how
modern presses work. The reasons for this is: Improved productivity throughout
the entire added value chain there by helps in reducing wastages favoring eco
friendliness, detailed coordination throughout the entire process i.e. from
prepress to printing and increased process reliability and repeatability due to
systematic quality control.