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Some factors affecting ink transfer in gravure printing

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 Pigment & Resin Technology
Some factors affecting ink transfer in gravure printing
S. Elsayad F. Morsy S. El-Sherbiny E. Abdou
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S. Elsayad F. Morsy S. El-Sherbiny E. Abdou, (2002),"Some factors affecting ink transfer in gravure printing", Pigment &
Resin Technology, Vol. 31 Iss 4 pp. 234 - 240
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Contributed papers
Some factors affecting
ink transfer in gravure
printing
S. Elsayad
F. Morsy
S. El-Sherbiny and
E. Abdou
The authors
S. Elsayad, F. Morsy, S. El-Sherbiny and E. Abdou are at
the Chemistry Department, Printing and Packaging Lab.,
Faculty of Science, Helwan University, Cairo, Egypt.
Downloaded by CAIRO UNIVERSITY At 08:12 10 November 2015 (PT)
Keywords
Pigments, Printing
Abstract
Many factors affect the print quality and ink transfer. These
are either machine factors, paper factors, or Ink factors.
The aim of this work was to find out to what extent are the
amount of ink transferred influenced by the previously
mentioned factors. Atomic absorption was used for
quantitatively measuring the amount of ink transferred.
Copper phthalocyanine pigment was chosen. The amount
of copper detected is taken as an indication of the amount
of ink transferred. The results indicated that the amount of
ink transferred decreased as the printing speed increased.
It was expected to be increased with increasing printing
pressure. But It was found that the amount of ink
transferred to supercalendered paper decreased with
increasing printing pressure. The amount of ink transferred
increased as the ink viscosity increased. The type of ink
resin was found to have a considerable effect on the
amount of ink transferred.
Electronic access
The current issue and full text archive of this journal is
available at
http://www.emeraldinsight.com/0369-9420.htm
Pigment and Resin Technology
Volume 31 · Number 4 · 2002 · pp. 234– 240
q MCB UP Limited · ISSN 0369-9420
DOI 10.1108/03699420210432429
234
Introduction
Effect of printing speed, printing
pressure and ink viscosity on print
quality
The effects of printing speed and printing
pressure on the amount of ink transferred to
newsprint were originally described by Olsson
and Pihl (1952), for mineral oil and several
inks of known composition. Without exception,
increasing printing pressure increased the
total transfer, whereas increased printing
speed decreased the total transfer. More
extensive studies were reported by Fetsko and
Walker (1955), on both coated and uncoated
papers in evaluating the applicability of their
transfer equation. The effects of printing
speed and printing pressure on transfer were
similar to those reported by Olsson and Pihl.
More recent studies revealed similar trends
(Carlsson and Ginman, 1961; Fabbri and
Quattrucci, 1961; Fetsko, 1961, Froslev-
Nielsen, 1961; Hsu, 1961; Rupp, 1961).
The mechanism by which the transfer of
printing ink films occurs to paper surfaces was
investigated (Schaeffer et al., 1963). Two
coated and two uncoated papers were chosen
to provide representative samples for the
ranges of absorbency and smoothness
available in commercial grades, three inks
were prepared, of viscosities 275 to 400 poise.
Each combination of paper and ink was
printed over the entire range of speeds (80 to
240 f.p.m) and impression pressure (100 to
400 pli). The explanation of their data was
based on a partition of the ink during the
dwell time. If the liquid components of the
ink, i.e, solvent, oils, diffuse into the paper
more rapidly than the pigment-gel structures,
the residual ink film on the plate will become
richer in the latter components as the number
of prints increases. The results also concluded
that increasing the impression pressure and
decreasing the printing speed increased the
total transfer on both coated and uncoated
papers in the high ink film thickness region
where complete coverage was obtained. Also
the ink transfer was decreased as the ink
viscosity increased.
Joyce and Fuchs (1966), found that the ink
viscosity has a significant effect on transfer,
the less viscous inks cause a considerable
increase in transfer at lower ink volumes due
to easier penetration.
Hoyland and Field (1976), investigated the
capillary immobilisation concept which
 Some factors affecting ink transfer in gravure printing Pigment and Resin Technology
S. Elsayad, F. Morsy, S. El-Sherbiny and E. Abdou Volume 31 · Number 4 · 2002 · 234–240

predicts that the amount of liquid that penetrate Table I Specifications of paper samples
into a porous material is proportional to the
Supercalendered
square root of the dwell time.
Test paper
A new ink transfer equation has been
developed (Zang, 1993), based on the Fetsco- 1. Basis weight (g/m2) 53.75
Walker equation by considering the 2. Smoothness (ml/min)* 19.7/25.1
asymmetric splitting of ink film in the printing 3. Porosity (ml/min) 10
nip. It has been found that the new model fits 4. Oil absorption (g/m2)* 3.17/3.33
the experimental data very well and the 5. Tear resistance (g/16 s) 32.73
decrease in immobilisation factor (b) with 6. Tensile strength (kg/15 mm) 3.83
increasing printing speed in the new model is 7. Brightness (per cent) 76.78
consistent with the capillary immobilisation 8. Opacity (per cent) 91.93
*
concept mentioned before. Top side and wire side respectively
The effect of printing pressure and ink
viscosity on optical density for coated paper Ink considerations
was studied, various ink viscosities (30 to Two types of inks were prepared based on
300 sec) were used (Gane and Hooper, 1993). maleic and ethyl cellulose resins.
Contrary to the expectations, the print density The inks were prepared by using a bead mill
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was reduced as the printing pressure increased of type (mini) MK II motor mill. The viscosity
related to the reduction in capillary driven of the inks were measured by a ford B4 flow
lateral spread within the printing nip (Swan, cup at 258C. Tables II and III show ink
1974). formulations for maleic and ethyl cellulose
based inks respectively.
Atomic absorption spectroscopy as an
ink transfer measuring technique Printing apparatus
For measuring ink transfer it was needed to The printed samples were prepared using the
dope the ink with a suitable metallic tracer, K printing proofer.
and then to use instrumental method to Table IV shows the cell depths of the
measure the amount of tracer in the printing plate.
transferred ink. Atomic absorption
spectroscopy was used, using copper as tracer Printing conditions
(Ginman and Riikola, 1977; George and On the light of optical density results (Abdou,
Welch, 1978). 1999), samples were chosen to study the effect
The greatest advantage of atomic
Table II Formulae of inks based on maleic resin
absorption spectroscopy is its selectivity for
individual elements. This is because of the Raw materials % content
very specific values of DE between the ground Sample no. 1 2 3 4 5
and excited states of atoms of various 1. Copper phthalocyanine 5 5 5 5 5
elements. This may be understood by 2. Maleic resin 40 42 43 44 45
considering the relationships (Day and 3. Toluene 55 53 52 51 50
Underwood, 1991): Total 100 100 100 100 100
DE ¼ y h ð1Þ Viscosity at 258C (sec) 17.5 19.5 22 23.5 27.3
and Table III Formulae of inks based on Ethyl cellulose resin
c
l¼ ð2Þ
y Raw materials % content
Sample no. 6 7 8 9 10
Where: h is Planck’s constant, n is the
frequency of light, l the wavelength of light 1. Copper phthalocyanine 5 5 5 5 5
and c is the velocity of light. 2. Ethyl cellulose resin 7 7.5 8 8.5 9
3. Toluene 88 87.5 87 86.5 86
Total 100 100 100 100 100
Viscosity at 258C (sec) 18.7 20.2 24 26 29
Experimental
Table IV Cell depths of the printing plate
Paper sample
Supercalendered paper was chosen, its optical Step 1 2 3 4
and physical properties are shown in Table I. Cell depth, microns 28 32 36 40

235
 Some factors affecting ink transfer in gravure printing Pigment and Resin Technology
S. Elsayad, F. Morsy, S. El-Sherbiny and E. Abdou Volume 31 · Number 4 · 2002 · 234–240

of printing speed, printing pressure, ink Figure 1 A schematic drawing of gravure cell
viscosity and ink resin on the ink transferred
to supercalendered paper as shown in Table V.
The samples showing optimum optical
density values with each of the variables were
selected.

Print evaluation
Atomic absorption measurements
In order to obtain the ink transfer curves for
the printed samples, the amount of ink on the
plate (x, g/m2) and the amount of ink
transferred (y, g/m2) should be measured. Table VI Available ink on plate x, g/m2
Step 1 2 3 4
Calculation of the amount of ink on the plate Cell depth, microns 28 32 36 40
(x, g/m2) Ink available g/m2 10.68 12.2 13.73 15.3
In the current work, The amount of ink on the
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plate was measured by a mathematical spectrophotometer. Table VII shows the

method. The cell was viewed under a machine analysis conditions.
travelling microscope. The shape of the cell The blank paper (unprinted paper) was
was found as a frustum of a pyramid, Figure 1. measured, no copper metal was found. The
The cell edges were measured and the volume amount of ink transferred to paper surface
of cell can be calculated from the following y g/m2 was calculated.
equation (Fogiel, 1995):
1 pffiffiffiffiffiffiffiffiffiffiffi
Volume of frustum ¼ hðB1 þ B2 þ B1 B2 Þ
3 Results and discussions
ð3Þ
Effect of printing speed
where h ¼ distance between the bases, i.e cell
Figure 2 shows the ink transfer curves of
depth B1 and B2 ¼ areas of the bases of edge
supercalendered paper printed at various
lengthes b1 and b2 respectively
printing speeds and at printing pressure 1.
The calculated quantity of ink on plate at
Figure 3 shows the effect of printing speed on
various cell depths are represented in Table VI
the ink transfer parameters.
(the amount of ink in each cell equals the cell
The figures show that the amount of ink
volume multiplied by the density of the ink as
transferred decreased when printing speed is
measured by Sheen densitometer).
increased. the decrease in ink transfer with
increasing printing speed is consistent with
Determination of the amount of ink transferred to
paper (y, g/m2) Table VII Perkin-Elmer flame spectrophotometer conditions
The amount of ink transferred (y, g/m2) was
Flame Air/acetylene flame
calculated quantitatively by detecting the
Light source Hollow cathode lamp
amount of Cu metal using atomic absorption
Standard solution* Copper as Cu(NO3)2 100 Microgram/ml
measurements. The atomic absorption
Sensitivity 0.09 Microgram/ml Cu for 1% absorption
analysis was made on the clear solution on a
*
Perkin-Elmer model 2380-flame Supplied by Perkin-Elmer company

Table V Printing conditions

Variable Ink type Ink viscosity Printing speed Printing pressure
Effect of printing speed Ink 3 22 sec Varied 1
Effect of printing pressure Ink 3 22 sec 0.28 m/sec Varied*
Effect of ink viscosity All inks Varied 0.28 m/sec 1
*
The change of pressure was done by changing the distance between the impression roller and the printing plate by
means of a micrometer (at 3.95, 3.45, 2.95 and 2.45 mm) and expressed as pressures 1, 2, 3, and 4 (decreasing the
distance means increasing the pressure)

236
 Some factors affecting ink transfer in gravure printing Pigment and Resin Technology
S. Elsayad, F. Morsy, S. El-Sherbiny and E. Abdou Volume 31 · Number 4 · 2002 · 234–240

Figure 2 Ink transfer curve of supercalendered paper printed at various printing speeds and at printing pressure 1
(low pressure)
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the capillary immobilization concept
(Hoyland and Field, 1976).
The immobilisation constant (b) decreased
as the printing speed was increased, The ink
splitting factor (f) was slightly affected.
Effect of printing pressure
Figure 4 shows the ink transfer curves of
supercalendered paper printed at various
printing pressures and at constant speed
0.28 m/sec Figure 5(a and b) show the effect
of printing pressure on ink transfer
parameters.
The amount of ink transferred was
expected to increase with increasing the
printing pressure, but it was found in this
study that it decreased as the printing pressure
increased.
In accordance with the results of optical
density measurements (Abdou, 1999), the
amount of ink transferred to supercalendered
paper decreased as the printing pressure
increased. A possible exeplanation is that the
low absoptivity and low porosity of
supercalendered paper restricted further flow
of ink as the printing pressure is increased.
The immobilisation factor decreased as the
printing pressure increased (as the impression
distance decreased). A slight change occurred
with the ink splitting factor At higer pressure.

Figure 3 (a, b) Effect of printing speed on ink transfer parameters

237
 Some factors affecting ink transfer in gravure printing Pigment and Resin Technology
S. Elsayad, F. Morsy, S. El-Sherbiny and E. Abdou Volume 31 · Number 4 · 2002 · 234–240

Figure 4 Ink transfer curves of supercalendered paper printed at various printing pressures and at printing speed 0.28 m/
sec
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Effect of ink viscosity Fuchs, 1966; Smith, 1956). Arnamo, 1962,

Figure 6 shows the ink transfer curves of inks
1 to 5 with various ink viscosities. Figure 7
shows the ink transfer curves of inks 6 to 10
with various ink viscosities. Figure 8 (a and b)
show the effect of ink viscosities on the ink
transfer parameters for both maleic and ethyl
cellulose based inks.
For both types of inks, maleic and ethyl
cellulose based, The amount of ink
transferred increased as the ink viscosity
increased in view of the low viscosity range
chosen (17 –29 sec). A wide range of ink
viscosities was used in previous studies (ink
viscosties 30 to 400 sec) (Gane and Hooper,
1993; Elsayad, 1975; Banks, 1967; Joyce and
found that at low ink viscosity optical densities
decreased rather rapidly at decreasing
viscosity [this is consistent with the case in this
study and with other extention work (under
publication)].
It was noticed that the amount of ink
transferred in case of maleic based inks are
less than that in case of ethyl cellulose based
inks at the same amount of ink available
(Figures 6 and 7). [Although the optical
density of maleic inks was found to be higher
(work under publication)]. It may be
concluded that the two phases of ethyl
cellulose inks penetrated into paper pores
more than that of maleic based inks, Thus the

Figure 5 (a, b) Effect of printing pressure on ink transfer parameters. The pressure increases as the impression distance
decreases

238
 Some factors affecting ink transfer in gravure printing Pigment and Resin Technology
S. Elsayad, F. Morsy, S. El-Sherbiny and E. Abdou Volume 31 · Number 4 · 2002 · 234–240

Figure 6 Ink transfer curves of supercalendered paper printed with inks of various viscosities (maleic resin)

Figure 7 Ink transfer curves of supercalendered paper printed with inks of various viscosities (ethyl cellulose resin)
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pigment concentration on paper surface

Figure 8 (a, b) Effect of ink viscosity on ink transfer
became smaller. This may explain why the
parameters
optical density was found to have lower
values.
The immobilisation constant (b) increased
as the ink viscosity increased for both types of
inks. The film splitting factor (f) behaved
reversibly with the two types of Inks
(Figure 8a, b).

Conclusion

The amount of ink transferred to paper in the

nip area is influenced by printing speed,
Printing pressure, ink viscosity and type of ink
resin.

References
Abdou, E. (1999), M.Sc. Thesis, Univ. of Helwan.
Arnamo, A. (1999), ERA Printability Commision Report
No. 5, May.
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S. Elsayad, F. Morsy, S. El-Sherbiny and E. Abdou
Banks, W.H. (1967), Adv. Print. Sci. Tech., 4, p. 103.
Carlsson, G.E. and Ginman, R. (1961), The Sixth Int. Conf.
of Printing Research Inst., Elsinor Denmark.
Day, R.A., and Underwood, A.L. (1991), Quantitative
Analysis, Sixth Edition, p. 592.
Elsayad, S. (1975), Professional Printer, 19 No. 2.
Elsayad, S., Morsy, F., El-sherbiny, S., Abdou, E., Under
publication.
Fetsko, J. (1961), The Sixth Int. Conf. of Printing Research
Inst., Elsinor Denmark.
Fogiel, M. (1995), The Geometry Problem Solver, Staff of
Research and Education Association, p. 896.
Froslev-Nielsen, A. (1961), The Sixth Int. Conf. of Printing
Research Inst., Elsinor Denmark.
Fabbri, I. and Quattrucci, A. (1961), The Sixth Int. Conf. of
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Pigment and Resin Technology
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Rupp, E. (1961), The Sixth Int. Conf. of Printing Research
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