WEB OFFSET TECHNOLOGY
By S.Ravichandran,B.E.,
SENIOR ENGINEER
THE HINDU
CHENNAI
PRESS CLASSIFICATION AND
INFEED UNITS DEVELOPMENT
• Alois Senefelder-the inventor of lithography 1796.
• In 19th century, lithography was outclassed by
letterpress for most printing and was confined largely
to the reproduction of illustrations ranging from works
of art to posters.
• But the invention of the offset press in the early 1900s,
coupled with the great strides in photography and
photomechanical platemaking, were soon to give
lithographers a big advantage.
• About 1904, Ira Rubel discovered that the rubber
blanket covering the impression cylinder on a rotary
press did a better job of printing than could be
obtained directly from the stone plate.
• Meanwhile, the increasing need for high-speed
printing created by the booming newspaper industry
had inspired the invention of the web perfecting press
in 1856.
• By 1875, a folding service was introduced, making
web printing even more efficient.
• By 1950, web offset was ready for serious competition
with letterpress, as well as with sheetfed lithography.
• The ability of the offset method to perfect – to print
simultaneously on both sides of the paper – was
unique and still is.
• 60s saw rapid acceleration of web offset’s growth in
the graphic arts industry.
• The continued growth of web offset has depended
upon improvements in both equipment and supplies.
• The quality of paper, inks, plates, blankets, and other
press supplies have constantly improved to meet the
ever-increasing requirements of greater speed and
quality placed on web offset printing.
• Improvements in both the basic press and its
equipment including dryers, infeeds, and folders have
kept pace with the growing need for increased speed
and quality production.
• In the past much of the swing of printing to web offset
was due to the economics involved.
• Savings alone motivated many printers to switch to
web offset, regardless of other factors.
• Today there are many products that depend upon the
ability of heatset web offset to produce printing that is
sharp and has high gloss and heavy coverage.
Web Offset Technology Class Notes
• Newspapers began the swing to web offset during
the 60s, when over half the weeklies and 20% of the
dailies made the switch from letterpress to web offset.
• The newspapers’ switch to web offset has been
influenced mainly by the size of each plant’s
operations.
• There has been a seeming lag in web offset
installation by the large dailies only because small
local plants found it easier to switch over to web offset
technology.
• As old equipment wears out and advertisers demand
higher-quality reproduction, web offset makes gradual
inroads into even the largest of daily newspaper
letterpress operations.
• The bulk of web offset printing still includes
promotional brochures, magazine inserts, catalogs,
annual reports, packaging, and all the miscellaneous
items that are best printed by the lithographic process.
• Lithography is the name of the printing process,
specifically the printing process using ink and water
to transfer an image from a level-surfaced plate onto
another surface.
• Offset means that the image carrier does not put the
ink directly onto the paper or other substrate, but
rather onto an intermediate surface first.
• Offset does not really mean lithography.
• It is common, however, to use the two words to
indicate the same thing.
• Web offset is so called because its presses print on
continuous webs of paper.
• This is the basic difference between web and sheetfed
presses.
• Two other significant differences between the two
are the much smaller gaps on the plate and blanket
cylinders of the web press, which means that a much
more continuous flow of ink and water is experienced,
and the lack of a hard impression cylinder on the
blanket-to-blanket web offset press.
• The elements of a web offset press are, in order,
infeed, printing units (press), dryer, chill rolls, and
delivery (either a folder, sheeter, or rewinder)
• A folder is used when the final product has one or
more folds in it.
• It delivers signatures ready for mailing or for binding
with other signatures to form a magazine or book.
• A sheeter cuts the web and delivers flat, printed
sheets.

• A rewinder, as the name implies, rewinds the printed
web back into a roll form.
• A folder produces signatures; a rewinder produces
rolls.
• The ends of the press are referred to as the infeed
and delivery.
• The sides also have special names.
• On one side of the press is the driveshaft and gears
that power the press. This side of the press is called
gear side.
• The crew always works on the other side because
this is where all the press controls are located. This is
called the operator side.
Printing couple
• The term printing couple refers to everything
necessary to put one color of ink on one side of the
paper.
• In offset lithography, the printing couple includes an
inking system, a dampening system, a plate cylinder, a
blanket cylinder, and an impression cylinder.
• If another color is to be put on the paper, the paper
has to go through another printing couple.
Printing unit
• The term printing unit is less easily defined.
• Generally, a printing unit is a single physical structure
in which a number of printing couples are mounted.
• The term perfecting means that the sheet or web is
printed on both sides during one run through the press
or unit.
• A blanket-to-blanket unit is therefore a perfecting unit
while a forms press may or may not be a perfecting
press.
Classification
• There are three types of web offset presses in use
today.
• IN-LINE
• BLANKET TO BLANKET
• COMMON IMPRESSION
» IN-LINE
• Each printing unit on an in-line press consists of a
single printing couple: an inking system, a dampening
system, a plate cylinder, a blanket cylinder, and an
impression cylinder.
• The printing units on an in-line press are
nonperfecting; that is, they can print only one side of
the web at a time.
Web Offset Technology Class Notes
» IN-LINE
• Most business forms are printed on presses of the in-
line type.
• These are nonperfecting presses in which each station
contains an inking system, a dampening system, a
plate cylinder, and an impression cylinder.
• Such presses are generally small and equipped with
auxiliary devices like imprinters, numbering devices,
perforators, and punches.
• Though these presses are generally smaller and less
flexible, flexibility is not an important criterion in this
unique and specialized application of web offset.
» BLANKET TO BLANKET
• The most common commercial web offset press is the
blanket-to-blanket press.
• Each printing unit on a blanket-to-blanket press has
two blanket cylinders simultaneously printing both
sides of the web, each blanket cylinder serving as the
other’s impression cylinder.
• Each blanket cylinder is part of a printing couple that
also has a dampening system, inking system, and
plate cylinder.
• The popularity of the blanket-to-blanket press is due to
several factors:
• It is capable of producing a high-quality product.
• Makereadies are very efficient.
• The press is flexible in terms of web configurations
and colors run in one pass.
• Paper passes through a dryer and cooling system only
once.
• Color is playing an ever-more-important role in the
web offset printing in the early 1980’s.
• On a blanket-to-blanket press, printing couples are
usually stacked in pairs, one on top of the other.
• The blanket of one couple is next to the blanket of the
other couple and the web runs squeezed in between
them.
• In other words, these presses have no impression
cylinders; the blanket cylinder of the top couple acts
as the impression cylinder for the bottom couple and
vice-versa.
• Since these units can print both sides of the web at
once, a blanket-to-blanket press is perfecting.
• On a blanket-to-blanket press, the printing units are
usually arranged one after the other, an arrangement
that offers a great deal of flexibility.
• With four units, one web can be run and four colors
printed on each side.
• Or the press can be set up so that four webs are run
and only one color printed per side.
• Blanket-to-blanket presses of the unit type come in

 two basic configurations.
• The most common is the horizontal one, in which the
web runs through the printing units in a horizontal
plane; the printing unit cylinders are therefore stacked
vertically, one on top of the other.
• The other, or vertical type of blanket-to-blanket press,
has the web running vertically between blankets, with
the cylinders laid out more or less horizontally.
• This kind of press allows for symmetrical design of
the printing units and provides easier access to the
printing couples.
» COMMON IMPRESSION
• Common impression cylinder press or the CIC press.
• Each printing unit on a CIC press has one very large
impression cylinder with four or five printing couples
arranged around it in radial fashion.
• Because of the arrangement of the couples and the
size of the impression cylinder, these presses are also
called satellite presses.
• Common-impression-cylinder (CIC) presses have
one large impression cylinder running in contact with
several blanket cylinders.
• The paper wraps around the surface of the impression
cylinder.
• Large size and longer makereadies are disadvantages
inherent in the design of the CIC.
• Their speed, however, is higher than that of the
blanket-to-blanket type.
• A CIC press can be made to perfect in two ways.
• The most common means is to run the web through
one unit, dry the ink, flip the web over, and run it
through a second unit to print the other side.
• The second method prints half-webs of paper; that is,
the width of the web is only half the width of the plate
cylinder.
• The web is threaded so that it runs along one side of
the printing unit, and the top of the web is printed.
• The web then travels through a dryer and chill rollers,
through a turning bay where it is flipped over, and
returned to the printing unit, where it runs on the other
side of the cylinder.
• On its second pass through the printing unit, the other
side of the web is printed.
• During operation, paper runs continuously on both
sides of the press. This is called double-ending.
Web Offset Technology Class Notes
ROLL STANDS OR REEL STANDS
• There are three main components in a reel stand:
• The reel support.
• The sidelay.
• The reel brake.
THE REEL SUPPORT
• This is usually either a shaft passing though the
reel centre and upheld at each end by the machine
framework, or a pair of chucks which enter the core
ends from each side of the reelstand structure.
THE SIDELAY
• A means of adjusting the lateral position of the reel in
the machine in relation to the printing units or other
items of equipment. This is often a simple screw-
thread adjustment, but may be pneumatically operated
or motorised for heavy reels or remote control
systems.
THE REEL BRAKE
• A means of controlling the rotation of the reel
in relation to the pull of the machine and the
requirements of web tension. This will vary in
complication according to the importance of web
tension control and the relationship of the brake to
other web control equipment.
DIFFERENT TYPES OF REELSTAND
• Single reelstand.
• Double reelstands.
• Revolving reelstands.
» SINGLE REELSTAND
• This is based on the shaft, sidelay and brake system.
• This type reelstand can hold only one reel at a time.
• It is suitable for short-to-medium run work where an
entire job or complete section can be completed in a
few reels.
• Reel changes are accomplished by stopping the
machine before the reel is completely expired,
breaking out the tail of the web, unloading the reel
stub and removing the shaft.
• The shaft is re-inserted into a fresh reel, which is then
loaded into the machine and the front edge of the new
web spliced to the tail of the previous one.

» DOUBLE REELSTANDS
• This type of reelstands hold two reels. One reel for
running and another reel for buffer.
• These may be used where longer runs are undertaken
and quicker changeovers required in order to cut down
the proportion of time taken in reelchanging.
• The second reelstand can be loaded and the reel
prepared while the machine is running, so that when
the machine is stopped at the completion of the first
reel the two web-ends can be quickly joined and
running re-commended within seconds.
» REVOLVING REELSTANDS
• These can provide even faster changeovers as a
fresh reel can be loaded and prepared for joining, then
rotated in close to the expiring web so that the join can
be made while the machine is running.
• Revolving reelstands are necessarily more
complicated than others, as motorised rotation is
usually necessary and reel braking systems need
more attention for efficient working.
• Manual, semi-automatic and fully automatic systems
are available according to the importance of rapid
changeovoer and machine speed.
• These reelstands also have advantage where very
large reels are in use, as the reels can be rolled in
between the arms of the reelstand, and the arms
located to the core for easy loading.
SITING THE REELSTAND
• In-line.
• Right-angle.
• Basement reelstands.
» IN-LINE
• The most common position for a reelstand is in-line
with the printing units, at floor level.
• For smaller presses reelstands may be integral within
the machine framework, while larger machines are
more likely to have freestanding reelstands, often
made by a specialist manufacturer.
• This situation has the advantages of a simple web
lead, compactness and good accessibility.
» RIGHT-ANGLE
• Where space is limited and machine length must be
kept to a minimum, the reelstand may be positioned
to one side of the machine and turned into the printing
unit over an angle bar.
• This system is particularly useful on multi-web
machines where a number of in-line reelstands would
Web Offset Technology Class Notes
considerably extend the length of the installation as
well as interfering with unit accessibility.
» BASEMENT REELSTANDS
• For large multi-web machines, such as newspaper
presses, the reelstands are often situated below the
printing units.
• This arrangement not only saves space at printing unit
level, but also gives complete accessibility around the
printing units and the reelstands.
• Reel handling, transport, loading and splicing are
conveniently carried out in the basement with a
minimum of interference to the rest of the machine.
SHAFTS
• The traditional method of holding a reel in a machine
is be means of a shaft with a pair of cones sliding
along it.
• The shaft usually has a boss at one end, which locates
the sidelay and sometimes locks in with the brake.
• The shaft is inserted into the reel with one cone in
position, then the opposing cone is located along the
shaft and forced tightly into the reel core.
• Both cones must be firmly locked into the core to
ensure that the reel does not turn on the shaft.
• Disadvantages of the shaft and cone system are that
the insertion and location of cones can take several
minutes, and over-tightening of the cones can damage
the cores, which cannot then be re-used.
• Cones are also unsuitable for use with plastic or metal
reel centres.
» EXPANDING SHAFTS
• These do not need cones as they can distend to lock
securely into the core without damaging it.
• These systems are generally quicker, simpler and
more economical than the sliding cone system.
• Mechanical devices are available in which the shaft
is segmented into a number of sections which can be
opened up or closed by a system of sliding wedges.
• Where a compressed air supply is available it is even
faster to employ pneumatic shafts, which can be
expanded or released at the touch of a button.
• This type of shaft can be based on the expanding
section principle or an alternative method in which a
number of studs are forced out from the shaft to press
firmly against the reel centre.
» TILT LOCK
• A unique approach is offered by the tilt-lock system, in
which a number of teeth in the shaft lock into the reel-

 core by the natural rotation of the reel.
• This method has many of the advantages of the
expanding shaft, without the need for an air supply.
• When the machine is stopped at the end of the reel
the teeth can be instantly released without the use of
tools or air lines.
CHUCKS (SHAFTLESS SYSTEMS)
• Where wide or heavy reels are in use shafts are liable
to distortion.
• Bent shafts will cause eccentric rotation of the reels
with consequent web tension problems and other
running difficulties.
• In these instances it may be better to use chucks,
which are inserted directly into the reel centre from
the machine frame or from massively constructed
reelstand arms.
• The principle is simple in operation, and lends itself
to quick changeovers, especially where revolving
reelstands are in use.
• Shaftless systems also have the advantage of allowing
large or heavy reels to be rolled into position between
the chucks, without the additional complications
of shaft insertion and lifting of the reel and shaft
assembly into position.
AUTOMATIC PASTERS
• Zero speed pasters.
• Flying paster or speed match paster.
» AUTOMATIC PASTERS
• Some of the components essential for auto pasting
system:
• Reel-stand to hold at least 2 reels.
• Braking system.
• Accumulator.
• Tension control.
• Diameter sensing.
• Web speed sensor.
• Timer.
• Accelerator or synchroniser.
• Pasting position identification.
• Signature mark.
» AUTOMATIC PASTERS ZERO PASTING
• Some basic steps involved in zero pasting
• The fresh reel with its glued edge must be positioned
close into the running web.
• Accumulator which will have festoon rollers (this
Web Offset Technology Class Notes
reservoir is generally in the form of a series of loops in
the web) supply the web to the machine at the time of
pasting.
• The web and reel must be brought into firm contact so
that the glued edge of the fresh reel travels with the
running web into the machine.
• A splicing system which is used to cut the old web
after pasting.
• Accelerator which accelerate the speed of the new
reel.
» ZERO SPEED PASTING
• The diameter of the running reel is set for auto
pasting.
• When the running reel reaches the particular diameter
the pasting operation starts.
• The running reel is stopped its rotation by means of its
braking system.
• During this pasting operation the web is supplied to
the machine from the accumulator (the festoon rollers
will come down). Same time the web tension is
maintained.
• The new reel which is made ready for pasting waits in
the close position to the running web.
• The running reel is made contact with the new reel by
means of mechanical or pneumatic system.
• After a few second the timer enables the splicing . So
the old web is broken.
• The Accelerator which accelerate the speed of the
new reel.
» BUTT SPLICING
• The web may be spliced by overlapping one web upon
the other and joining them together by tape or glue.
• For thicker substrates, such as boxboard or card, it is
desirable to avoid overlapping as the double thickness
may damage printing surfaces or catch up in other
parts of the machine.
• In this case a neater join is made by cutting the
respective ends of the webs squarely, butting them
up to each other and joining them with thin, adhesive
tape.
• The web ends can be cut square and tapes applied by
mechanical means.
• During this operation the accumulator will supply the
web to the press.
» AUTOMATIC PASTERS FLYING PASTER
• Some basic steps involved in flying auto pasting.
• The fresh reel with its glued edge must be positioned
close into the running web by rotating the reelstand to
the required location.

• The fresh reel must be revolved to match the web FAN OUT
speed in order to avoid snatching when the splice is
• Fan out or Relative Print Width (RPW) refers to
made.
variation in size of the different colours as measured
• The web and reel must be brought into firm contact so
in across the web direction. Fan out is the result of
that the glued edge of the fresh reel travels with the
the web growing in the side to side direction as it goes
running web into the machine.
through the units.
• The web must be broken out from the expired reel,
• An image will change in width if the web changes in
leaving the new reel running in the machine.
width after it is printed.
• Accurate web control must be maintained during the
whole of the splicing cycle.
» CONTROLLING THE FAN OUT

FLYING PASTER • We can minimize its efforts by moving the plate

cylinders to split the difference and make the amount
• The new reel is made ready for pasting with glue or
of misregister equal on both sides of the image.
double side adhesive tape.
• Stepping out the images on the second, third and
• The pasting system calculates the speed of the
fourth plates.
machine ( web travels – meter per second) .
• Commonly used method for controlling fan out is
• According to the speed of the web travel the pasting
bustle wheels or air gun.
operation starts with a convenient diameter of running
web.
• The new reel is sensed for its diameter. » CONTROL OF FAN OUT USING BUSTLE WHEEL
• The new reel and the running web is made closer by • Bustle wheels are used to help reduce differences in
changing the position of the reel arms. relative print width (RPW) on a web undergoing fan
• The new reel is accelerated to the speed of the out.
running web (synchronizing). • The wheel is set to project into the underside of the
• At the same time the pasting arm come close to the web. The resulting tent-like deformation of the web
new web along with the running web. draws the web edges together. The wheel can be
• Waits to reach the diameter of the running reel is set finely adjusted by the handscrew on the bottom. The
for auto pasting. wheel should be mounted so that it always runs true in
• When the running reel reaches the particular diameter the direction of web travel.
the pasting starts.
• The pasting arm makes contacts the running web
to the new web by pushing the running web by » CONTROL OF FAN OUT USING AIR GUN
mechanical or pneumatic means.
• Instead of bustle wheels air guns are used in between
• This operation is made first in the non pasting
the units to control the fan out.
prepared area of the new reel. For this a sensing
• The air gun emits the air with pressure which is
device is incorporated in the system or a magnetic
adjustable on the web. So the web width is slightly
tape is pasted over the new reel at a particular
reduced and the RPW is controlled.
position.
• It is now widely used replacing the bustle wheels
• After a few seconds of pasting operation the splicing is
because of its advantages over the bustle wheels.
activated by means of a timer.
• The signature marks are added in the new reel during
the pasting preparation. So that the pasted copies are WEB TENSION
taken out in the mail room (which are waste copies).
• Paper does not flow but is drawn through a web offset
• Accumulator has a stroke of 5m and there are 4 rollers
press.
on the movable arm and 5 at the bottom. What would
• This creates a force in the web known as web tension.
be the splicing time within which the entire pasting
• When the pressman says he is controlling the tension,
cycle should be completed? Running Speed of the
he means he is controlling conditions under which the
press is 250m/min.
paper is drawn through the press.
• Accumulator has a stroke of 4m and there are 6 rollers
• The nature of paper, however, greatly complicates the
on the movable arm and 7 at the bottom. What would
pressman’s job.
be the splicing time within which the entire pasting
• Applying even relatively small force to paper causes
cycle should be completed? Running Speed of the
it to change dimensionally, and the change is not
press is 200m/min.

Web Offset Technology Class Notes 

 constant for a given paper or even, necessarily, within
a given roll.
• The erratic behavior of paper under stress often
results in inconsistencies in the finished product-
inconsistencies due to variation in unit-to-unit register,
side lay, cutoff, and folding accuracy.
• Thus, the fundamental problem in web control is
keeping paper behavior uniform through the press.
• The pressman, or press action such as drying and
chilling, can modify web tension at various points on
the press.
• The distances between these points are referred to
here as “tension spans”.
• Tension is uniform throughout each of these spans.
• Tension control devices embody one of two principles:
• Constant torque devices directly applying an
unchanging force to the web, like the weight of the
dancer roller, or variable speed devices, which control
the flow rate of the web.
» WEB CONTROL FACTORS
• Web control involves three major factors:
• Tension, length, and the modulus of elasticity of the
web.
• All three factors are fundamentally interrelated.
• A change in any one of the three must result in a
change in at least one of the remaining two.
» WEB TENSION VARIATION
• Periodic variation (reel out of round, mechanical
damage)
• Trend like variation. (winding characteristic, fluff
accumulation on blanket)
• Random variation. (elasticity of paper, variation in
temperature, variation in surface co-efficient of friction,
variation in tension in infeed)
INFEED UNITS
• There are two distinct tension spans before the first
printing unit.
• The first is from the roll to infeed tension control, and
the second is from infeed tension control to the first
printing unit.
• In theory, the dancer eliminates all tension variations
emanating from the unwinding roll, delivering a web
under uniform tension to the infeed metering rollers.
• Actually, the conventional dancer reduces, but does
not eliminate, tension variations.
• Constant tension is maintained as long as the effective
weight of the dancer remains unchanged.
• The dancer accommodates itself to the ever-present
Web Offset Technology Class Notes
changes in the paper feed rate off the roll by moving in
the web loop.
• But every time the dancer moves, it goes through
acceleration and deceleration phases that change the
effective weight of the roller.
• The effect is similar to the “drag” one feels while
an elevator (traveling up) picks up speed and the
“lightness” felt while it slows down.
• Thus, the dancer does not hold tension constant into
the first printing unit because it is itself a source of
tension variations.
• With the conventional infeed, tension into the press is
created by running the metering rollers slower than the
blanket cylinders of the press.
• With a given paper, the amount of tension established
in this span is directly related to the speed difference
between the printing unit and the metering rollers-
assuming no slip is occurring at either point, and
assuming that the reaction of the paper to stress has
not changed.
• But it is quite common for the web to slip over the
metering rollers.
• The amount of draw put on the web in this span is
determined by the effective speed of the metering
rollers.
» ADVANTAGES OF CONSTANT TENSION INFEEDS
• The second dancer corrects for a narrower range of
variation than the first dancer, greatly reducing dancer-
related variation.
• By its placement in the infeed, the second dancer
corrects for variations arising after the infeed metering
system.
• Because the masses involved are much smaller and
because the variable-speed drive offers inherently
finer control than the roll stand brake, control by the
second dancer is more precise.
• Because the second dancer can hold tension
variations to a minimum, tension levels in the infeed
can be higher without risking a web break.
• Higher tension levels in the infeed can lessen blanket
wrap and elastic recovery in the printing units, which
means better control over register.
» TYPES OF INFEEDS
• Single drum infeed.
• Rubber covered open drum infeed.
• Open S-wrap infeed unit.
• Nipped single roll infeed unit.
• Nipped S-wrap infeed unit.
• Surface driven infeed unit.

» INFEED DRIVES
• PIV- drive system.
• CLUTCH system.
• MAGNETIC POWDER CLUTCH system.
• Variable speed motor.
DANCER ROLLERS
• A properly designed dancer roller is a perfect tension
isolator, and will prevent shock waves from passing
through the unit to the machine’s processing section.
• Even a poorly designed dancer roller will absorb a
much larger portion of the unwinding tension shock
wave.
» TYPES OF DANCER ROLLERS
• Vertical dancer roller.
• Horizontal pivoting dancer roller.
• Vertical pivoting dancer.
• Horizontal dancer roller.
» VERTICAL DANCER ROLLER
• The vertical dancer roller is a floating type of idling
dead shaft roller which travels in a linear up and down
path.
• It can be supported by two flexible chains.
• It moves up and down on slide bushings.
• It is necessary to counterbalance the roller so that its
weight will not affect its movement in either direction.
» HORIZONTAL PIVOTING DANCER ROLLER
• The pivoting dancer design is the most popular type of
dancer configuration.
• A pivoting dancer roller swings through an arc
about its fulcrum shaft, and it can have a horizontal
movement.
• It is extremely important for horizontal pivoting dancers
to be mechanically counterbalanced so that they are
in a state of gravitational equilibrium when they are
unloaded.
» VERTICAL PIVOTING DANCER
• The vertical pivoting or pendulum dancer roller arm
extends down perpendicularly and swings in a side-to-
side arc.
• This type of dancer does not need counterweights
because gravity has an equal effect in both directions
of movement.
Web Offset Technology Class Notes
• The main advantages of pivoting dancer rollers are as
follows:
• Stroke magnification is easy to obtain through
leverage. A small stroke air cylinder can be used
to create large roller movements, and larger roller
movements are more desirable than smaller ones.
• It is quite simple to apply pneumatic counter loading
to pivoting arm dancers, and air loading is the most
versatile and accurate type of counter loading.
» HORIZONTAL DANCER ROLLER
• The horizontal dancer roller travels in a forward and
backward motion parallel to the floor.
• There is no need to counterbalance a horizontal
dancer, because the gravitational force is always at
right angles to the movement of the dancer roller.
• If you want a long stroke dance roller, using horizontal
type with a traveling air cylinder is suitable.
» INERTIA-COMPENSATED DANCER ROLLER
• An “inertia-compensated” dancer has been developed
that eliminates the change in effective weight when the
rate of dancer movement changes.
• The inertia-compensated dancer is an ordinary roller
with a flywheel mounted at each end.
• The flywheel changes the inertial properties of the
roller so that when the roller’s rate of movement
changes, there is no change in effective weight.
LOADCELL
• A loadcell is a device which is displaced (moves) from
its unloaded position to another position in proportion
to the force applied to it.
• The loadcell roller is usually an idling dead shaft roller.
• A dead shaft roller is one which rotates on internal
bearings around two stationary stub shafts.
• A live shaft roller, also called a rotating or integral
shaft roller, has its shaft permanently attached to the
roller, and both the shaft and roller rotate around two
external bearings.
• The loadcell supports the external bearing retainers in
this design.
• Rollers used on machines having a maximum speed
of 150 m/min (500 fpm) can be statically balanced, but
the loadcell rollers should be dynamically balanced.
• All rollers on machines operating at faster speeds
must be dynamically balanced.
» LOADCELL PRINCIPLE OF OPERATION
• All force transducers use the deflection principle to

 measure the difference between the preset load and
the applied tension load.
• Some loadcells compress a very small amount, while
others move further by means of a beam deflection
(magnification) mechanism.
• In effect, loadcells measure the amount of roller
movement under varying tension conditions, rather
than the actual pull of the web.
• Loadcells move in proportion to the resultant tension
effect on the roller, and the total load is an algebraic
sum of both loadcell movements.
• Any idling roller can be made into a tension roller
by the addition of a pair of pneumatic or electronic
• This condition allows tension variations to have some
upstream effect.
• Actual measurement on blanket-to-blanket web offset
presses shows that relatively small tension variations
in the infeed carry all the way through to the folder.
• On the other hand, on a four-unit press, fairly large
tension changes in the span between the fourth unit
and the chill rolls are rarely detectable between the
second and third unit and never between the first and
second unit.
» SETTING TENSIONS ON THE PRESS

loadcells. • The foregoing provides the necessary information for

• Never use a driven roller as the tension roller, as
power variations will affect the tension measurements.
• The angle of web wrap around a loadcell roller must
be constant, as the controller is programmed for a
specific resultant force.
arriving at the optimum tension-setting method on a
web press.
• The needs of the infeed and press sections should be
met first.
• Then the dryer-chill section should be balanced, and
finally the delivery section.

» RESULTANT FORCE FACTORS

» THE EFFECTS ON WEB TENSION (VARIOUS INK/
WATER CONDITIONS)
Wrap angle Resultant • Number of tests were conducted, they confirm the
observation that press water reduces tension.
0 .00
• Highest tension was recorded with no water and no
 . ink being run (1) and was followed by the sharpest
drop with water run and no ink.
0 . • A condition in which maximum water would reach the
0 .00 paper.
• Tension increased at points 3 and 4, probably due to
 0. water pickup by the ink, which reduced the amount of
water reaching the paper.
» Types of Loadcell • Running excess water when printing (5,6) also tended
to significantly decrease tension.
• Pneumatic loadcells.
• Electronic loadcells. High tension

• Hydraulic loadcells. 



TENSION CONTROL SYSTEMS Normal water,

Normal water,
ink


Normal water
with the help of brake No ink
ink

No water no ink
• Potentio meter Excess water, 
Normal ink
• Mechanical
Excess water,
• Hydraulic Low tension
ink

• Loadcell
• Sensor ¨ transducer ¨ signal conditioning ¨ modifying
signal ¨ actuator (display, brake, motor)
» ADVANTAGES OF TENSION CONTROL
• To reduce the flooding of web into the press on a quick
» TENSION FROM SPAN TO SPAN
stop.
• To control tension accurately during pasting, at change
• Most nips on web presses, including the printing nips over of brakes.
and the chill rolls, do have slip.

Web Offset Technology Class Notes 

• While positioning the reels.
• While running roll is not round.
• During normal operations to control register.
• While feeding two or more webs into same folder.
• To avoid web breaks.
• Lessen the elastic recovery in the printing units.
» PIV
• A variable-speed drive that varies speed through two
pulleys and a metal link belt.
• The rims of each pulley can be moved closer together
or farther apart through a single control knob.
• The spread between rims determines how far up (or
down) the belt will ride in the pulley trough.
• As can be seen in the two side views, this changes the
effective pitch diameters of the two pulleys.
• In A, each revolution of the drive shaft gives several
revolutions of the metering shaft.
• In B, one revolution of the drive shaft gives only a
partial revolution of the metering shaft.
» WEB BREAK DETECTORS
• A number of systems currently in use to detect web
breaks.
• The oldest of these is a mechanical roller or finger with
a switch attached.
• Some devices couple a light source with a
photoelectric eye.
• Another type of web break detector uses a pneumatic
principle.
• More than one type of detector is used in presses for
safety.
• These detectors are used at different places of the
press. Infeed, unit, chiller, web path, folder.
• The choice of detectors depends upon the type of
substrate, and the place of incorporation.
• They are mounted in pairs.
• Many detector systems also incorporate web severing
devices, which immediately cut off the web on signal
of a web break.
• These prevent excessive paper wrapping up a printing
unit – a particularly useful feature on large, fast
presses.
• So web break detectors can be classified into three
types.
• Mechanical
• Electronic
• Pneumatic
» Mechanical web break detector
• Web break detectors of the mechanical type usually
Web Offset Technology Class Notes
consist of fingers that ride against the running web.
• They sense any decrease in tension.
• They give the mechanical web break detector an
advantage over the more modern methods in that it is
not necessary for the tail end of the break to run under
the web break detector before it senses the break.
• For this reason they are very effective when mounted
in long spans of web such as those that are generated
when more than one web is run through the press.
• In this case, the mechanical web break detector can
initiate a stop several impressions before it would be
initiated by an optical detector.
» Electronic web break detector
• Emitter receiver type. (photo electric eye). In this type
a light emitter is mounted on one side of the web and
a receiver is mounted on the other side. When the
receiver receives the light the detector is activated.
The disadvantage of this type of detector is when the
receiver is covered by the ink or by dust particles, the
detector will not activate.
• Reflector type. (infrared). Infrared web break
detectors are very easy to mount on the press since
they are quite insensitive to ink printed on the web
and can be mounted several inches from the web.
Because they use solid-state devices as the source
of the infrared beam, they have a very long life. This
type of detectors are widely used nowadays.
» Pneumatic web break detector
• A jet of air is blown at the web. On the other side of
the web is a pressure-sensitive switch that is activated
when the air jet strikes it.
• The energy requirement to produce continuous air
blow is a disadvantage of this type.
» ADVANTAGES OF WEB BREAK DETECTORS
• It avoids excess roll up at blankets, folders, infeed, ink
or dampening rollers. So the damage to this materials
is eliminated or minimized.
• It avoids the damage to machine parts.
• It saves time because of quicker restart of the press.
AUTOMATIC WEBBING UP DEVICE
• When a job is in production, it is the normal practice
to join the tail of the expiring web to the front flap of
the new reel in order to take the fresh web through the
machine.
• This is the easiest way of webbing-up the machine,
10
 but there are many occasions when it is necessary to
re-thread the web through the machine from reel stand
to delivery.
• This requires some care, forethought and a degree
of skill according to the nature of the work and the
complication of the machine.
• In the event of web breaks during the run there will
be an urgency about the work; on large, multi-web
machines there must be coordinated teamwork;
while many machines make provision for a variety
of web paths according to the job in hand, therefore
the correct lead must be carefully selected to avoid
unnecessary complication and web lead faults.
PREPARING THE REEL
• When starting with a fresh reel it is important to ensure
that the side lay adjustment is centralized and the reel
positioned laterally as accurately as possible to avoid
excessive side lay movement when the reel is running.
• The next step is to examine the circumference of the
reel for nicks, tears or other damage, particularly at
the edges, as these are the most common source of
web breaks.
• Any damaged areas should be removed either by
carefully removing the outer layers of paper or by
neatly trimming the edge with a sharp knife.
• The third operation is to prepare the leading edge for
feeding into the machine. The most common method
is to tear the leading edge into a neat, graduated
taper, starting from the working side of the machine
and running gradually to the offside.
• The reasons for this ‘tail’ are: (1) there is less paper to
handle when feeding the web, (2) lining up the edge of
the paper is easier, (3) handing over from one station
to the next is simpler, (4) threading the point through
complicated turns and places of difficult access will be
quicker and easier.
• The need for a tail and the length of its taper will vary
from one instance to another. On large news and
magazine installations a 3-4 metre tail is commonly
used, with a 15¢ª-20¢ª taper, for ease of handling
over the long distances involved, whereas smaller
machines may be quite easily laced up with a simpler
tail of 45¢ª or 60¢ª taper.
• Where leads are uncomplicated, such as on straight-
line, narrow-width machines, an alternative system is
to fold the lip of the paper over a number of times in
2-3 centimetre strips parallel to the core of the reel,
so that a ‘stick’ is formed at the leading edge, which
can then be quickly and simply handed through the
machine.
Web Offset Technology Class Notes
• This method is particularly successful on machines
which do not have impression throw-off, where a
tail consequently cannot be passed through the
impression nip but a ‘stick’ can easily be inserted into
a blanket gap and inched through.
THREADING THE WEB
• When leading the tail into the machine it must first be
remembered that it is important to keep the web in its
true line.
• If the web should wander from its true path even a
fraction of an inch it is liable to tear when tension is
applied.
• Even a lightweight newsprint can take a strain or 500g
per linear cm-if the load is applied evenly over the
entire width of the web.
• But, if the paper is moved slightly out of line, then the
strain will be concentrated at one extreme edge only
and a rupture is almost certain when stress is applied,
particularly if a small nick or tear should be present in
that edge of the web.
• Care should therefore be taken not to put too much
stress on the tail in order to avoid breakage.
• On the other hand the web must not be allowed to
become too slack as the loose paper will wander out
of true and possibly catch up in the machine, or snatch
and break when tension is eventually applied.
• For small machines and short leads the web may
be put through entirely by hand while the machine
is stationary, but on bigger machines it may be
necessary to turn the machine over slowly and take
the paper through while the machine is moving.
• This operation should only be undertaken be
experienced personnel as there is a degree of danger
involved.
• Particular care must be taken when feeding paper into
inward turning nips such as printing cylinders.
• Where this is essential it is advisable to stop the
machine first and tuck the paper into a blanket gap,
if one is available, or to tape the tail to a cylinder so
that the paper can be inched through the nip without
danger to the operator’s fingers.
• Where web paths are fairly standardized it is often
practicable to have a permanent tape lead built into
the machine, following the normal web path, so that
the tail of the web can be attached to the tape and
drawn through the machine as it is inched over.
AUTOMATIC WEBBING UP
• This sort of device is particularly useful on multi-level
machines where floor-to-floor jumps are required and
11
 difficult runs involved.
• More elaborate systems may be employed on the
larger news and magazine installations in the form of
endless chain drives with grippers attached.
• These are often provided with independent motor
drives so that the paper may be fed through without
using the full power of the machine.
• It should be noted that tape or chain leads usually
stop somewhere short of the folder where the lead
becomes too intricate for a tape to follow.
CHOOSING A LEAD
• There are few basic rules to be observed when
deciding the path to follow when putting a web through
a machine.
» 1) SHORTEST PATH:
• There is no advantage in taking a longer lead
than absolutely necessary, provided that all other
requirements are satisfactorily met.
• Unnecessarily extended leads take longer to put in,
increase traction problems, and are more liable to web
breaks, marking up and register fluctuations.
• There are a number of reasons why a straight-line
lead is not always taken, and each roller or cylinder
should be chosen specifically for a definite purpose.
» 2) WEB CONTROL:
• The most efficient control is obtained when the web is
wrapped around a roller or cylinder to obtain maximum
traction. Conversely, traction is least efficient when
the web merely passes over a roller at a tangent. For
this reason, where good web control is essential it is
advisable to provide a good wrapround of the member
concerned.
» 3) UNSUPPORTED STRETCHES:•
• Long sections of web without support are liable to
sag, flap, flutter or vibrate. Therefore it is advisable to
include supporting rollers in the web path, preferably
with an ‘S’ wrapround to ensure adequate web control
where there is some distance between one station and
the next.
» 4) REGISTER ROLLERS:
• On machines with movable rollers for adjusting the
length of web between one operation and the next, it
is essential to pass around at least one register roller
after each station in order to allow for adjustment of
Web Offset Technology Class Notes
one unit to another. For the most efficient use of a
register roller it may be necessary to incorporate it in a
‘U’ or ‘S’ system of rollers.
» 5) MARKING-UP:
• The chosen web route can influence the possibility
of marking-up after the web has been printed and
before drying or folding. The printed side of a web
should be kept away from subsequent rollers as long
as practicable so that marking-up will be minimized
and of course the web should avoid contact as far as
possible with non-rolling parts of the machine.
WEB ALIGNER CONCEPTS
» SIDELAY
• Sidelay is the side-to-side placement of the web
through the printing units and folder. Understandably,
sidelay affects the margins on the signature pages
through the side margins set up on the printed web
and the lay of the former fold line.
• For this reason, web sidelay should be controlled at
two points along the press: before the printing units
and before the folder.
• The web-steering device located in the infeed controls
the placement of the image from side to side on the
web, and the steering device between the press and
the folder registers the print to the former and chopper
folds.
• One common web-steering device is the box tilt, which
has four rollers arranged in a box shape.
• The first and fourth rollers in contact with the web are
in fixed position, while rollers two and three can be
moved in parallel and cocked relative to the other two.
• When the web crosses the cocked rollers, it moves to
one side of roller four, relative to its position when it
crossed the first roller.
• In this way, side-to-side position can be precisely
controlled before the web enters the printing units and
the folder.
• Other sidelay devices have three (sometimes only
two) rollers.
• Whichever kind is used, it is important that it is
designed to produce minimum stress in the web during
correction.
• One warning sign is the formation of wrinkles in the
web due to the action of the sidelay unit.
» SIDELAY SENSORS
• Web sidelay sensors have also been developed to a
12
 high degree of sophistication in recent years.
• One automatic sidelay device is a U-shaped apparatus
with the web moving through the space between the
two arms.
• One arm houses a light source and the other a
photoelectric sensor cell, or “eye”.
• As the web rides through the mouth of the U, the light
to the cell is partly blocked.
• The strength of the signal from the photocell unit
varies directly with the amount of light reaching the
cell, which is in turn determined by the position of the
web edge across the face of the cell.
• The strength of the signal determines the amount of
correction made be the web steering device (box tilt,
cocking roller, etc.).
• Systems of this type should have proportional control.
• The larger the detected error, the higher is the rate of
correction.
• This makes it possible to make very small changes
when needed.
• The use of air to clean the unit reduces maintenance
and helps eliminate problems.
• Normally webs are center-guided.
• Center-guiding holds the web center fixed with
reference to the press and folder.
• It is accomplished by mounting sidelay sensors in
pairs in each station on the press where guiding is
necessary.
• Center-guiding is best for work involving any folder.
• Edge-guiding, on the other hand, which holds only one
edge of the web fixed relative to the press and folder
is used for jobs involving sheeting.
• The guiding should be on the edge of the web that will
be used to register later operations.
• Occasionally, it is still possible to hear people debating
whether or not a web guide should be located in the
infeed section of the press or between the press and
the folder.
• The argument for placing the web guide in the infeed
section of the press says that this is necessary in
order to center the printing on the web.
• The argument for placing the web guide between the
press and folder says that this is necessary in order to
keep the fold in the center of the web.
• Actually, both positions are required to center the fold
on the printing.
• If web guiding is to be employed, web guides should
be used in both the infeed and between the press and
the folder.
Web Offset Technology Class Notes
UNIT - II
PRINTING UNIT,
INKING & DAMPNING SYSTEM
» THE PLATE CYLINDER
• The basic features found on all plate cylinders are the
same.
• Almost all have bearers: smooth, flat metal rings at the
extreme ends of the cylinder. Just inside each bearer
(between bearer and cylinder body), is a narrow
groove, called the gutter.
• Between the two gutters is the main portion – the body
– of the cylinder, on which the plate and packing are
mounted.
• The body of the cylinder is always lower than the
surface of the bearers; the exact difference in height
– called the cylinder undercut – varies with the
specifications agreed on by the manufacturer and
the printing plant. Often, the amount of undercut is
specified by the plant ordering the press.
• Knowing the exact amount of undercut on the plate
cylinder is essential to setting up proper pressures in
the printing unit.
• The surface of the plate cylinder body does not extend
all the way around the cylinder circumference.
• On nearly all presses, a deep gap runs from gutter to
gutter across the cylinder.
• This gap contains the clamping devices that hold the
plate tightly onto the cylinder. These are the basic
mechanisms of the plate lockup.
• The leading edge of the plate cylinder is the edge
along the gap that is followed by the cylinder body as
the cylinder rotates in the running direction.
• The trailing edge is followed by the cylinder gap.
• The leading edge of the gap is machined at an acute
angle to the surface of the cylinder body, and the
leading edge of the plate is bent to this angle before
mounting on the press.
• The plate is inserted in the slot. This plus lockup at
the trailing edge provides the gripping force necessary
to hold the plate tightly and smoothly against the
cylinder.
• The gap is, of course, a nonimage area. In fact, the
white space left on the web by the cylinder gap is
ultimately where the web is cut off.
• The cutoff length of a given press is fixed in that it
may be any one of a number of specific, more or less
standard, sizes.
• When a printer places an order for a web offset press,
there must be a clear idea of what kind of work will be
13
 run, as the fixed cutoff on these presses will always
make some job or other impractical.
• The gap on the plate cylinder usually about 1/8 in. (3
mm) narrower than that on the blanket cylinder.
• The leading edge of the plate should rotate ahead of
the leading edge of the blanket by about 1/16 in. (1.5
mm), and the plate trailing edge should follow that of
the blanket by the same amount.
• The reason for the wider blanket gap is that the
blanket and its mounting bars are much thicker than
the plate and require a wider lockup.
• The procedure for mounting a plate is simple but
requires care.
• First, the plate is bent on a bending fixture; the fixture
bends the leading and trailing edges of the plate so
the bends will conform exactly to the leading edge and
trailing edge lockup on the plate cylinder.
• This operation is as simple as it sounds, but it requires
great precision and care.
• Inaccurate bending will deform a plate so that it either • The blanket is clamped at both the leading and trailing
will not register with the other plates or will not fit
tightly around the cylinder. Improper fit is the cause of
plate cracking.
THE BLANKET CYLINDER
• The basic design of the blanket cylinder is the same
as that of the plate cylinder.
• Almost all plate and blanket cylinders have bearers,
smooth rings of hard metal at each end of the cylinder.
When running, the cylinders are set so that bearers
are in firm continuous contact.
• Just to the inside of the bearers are the cylinder
gutters.
• They help prevent chemicals from working in under
the blanket, and keep foreign matter picked up by the
bearers from moving onto the blanket surface.
• Between the gutters is the main part, the body, of the
cylinder. The blanket and its packing are mounted to
wrap around the cylinder body.
• Usually, the blanket cylinder body also has a gap
containing the lockup that holds the blanket at both
leading and trailing edges.
• The gap on the blanket cylinder is wider than that
on the plate cylinder, usually by 1/8 in. (3 mm) or
so, in order to accommodate the thicker blanket and
mounting bars.
• As on the plate cylinder, the blanket cylinder body is
lower than the surface of the bearers, and again, the
difference in height is called the undercut.
• The amount of undercut varies for different presses,
and on a blanket cylinder is greater than on a plate
cylinder, since blankets are thicker than plates.
• Blankets are usually three – or four – ply for
commercial work.
Web Offset Technology Class Notes
• A four – ply blanket is used on larger presses because
it has an extra layer of fabric backing for greater
strength. Three – ply blankets are generally used on
blanket cylinders with undercuts of 0.075 in. (1.9 mm)
or less.
• Four – ply blankets are used on presses with
undercuts of more than 0.075 in.
• Three – ply blankets generally are not run on cylinders
with undercuts designed to accommodate a four – ply
blanket. A three – ply blanket mounted on such a
cylinder would require an extra 0.010 in. (0.25 mm)
or so of packing. On the deeper undercut cylinders,
most pressmen prefer using a four – ply blanket and
less packing to avoid the problem of packing creep.
• Blankets are packed in the same way as plates. The
same packing materials are used. However, most
pressmen attach the packing to the cylinder body
and then mount the blanket instead of attaching the
packing to the back of the blanket.
edges, which are fitted with long metal strips called
blanket bars.
• The lockup grips these bars and not the blanket itself.
• In most web offset plants, blankets are ordered with
the bars already attached. The job of mounting the
bars on the blanket is very tedious and slow, and
most crews keep an extra set of blankets, with bars
attached, ready at all times in case of a press problem.
• Mounting a blanket is different from mounting a plate.
• Because of the elasticity of blankets, mounting tension
is critical. When tightening the lockup at the trailing
edge, the pressman should take care not to pull the
blanket thin at one spot or another.
• One factor is the strength of the pressman. Another is
the blanket itself; blanket A may stretch and decrease
in thickness only 0.001 in. (0.025 mm), whereas
blanket B will decrease 0.002 in. (0.05 mm).
• These factors make it more difficult to pack a blanket
properly than to pack a plate. Doing it right is
something that comes only with experience, although
mechanical aids are available.
• A torque wrench or air – operated wrench can be used
to apply a known amount of tension to the mounted
blanket. A torque wrench has an indicator giving an
exact reading of how much torque the pressman is
putting on the blanket reel as he tighten it.
14
 Adjustable torque wrench

Paul meter

Web Offset Technology Class Notes 15

 XTRA NOTES
The Plate Cylinder
• Usually the uppermost cylinder in the printing unit
carries the printing plate. Since the plate is frequently
changed, the plate cylinder must be easily accessible.
• The plate cylinder has 4 primary functions
1. Hold the plate tightly in position.
2. Hold the plate while the dampening rollers are
contacting it and wetting the nonimage area.
3. Hold the plate while the inking rollers are contacting
it and applying ink to the image area.
4. Help transfer inked image to the blanket.
• The plate cylinder consists of a metal body ground to
close tolerances in diameter. On sheetfed presses it is
usually not a complete cylinder, but has a depressed
gap (about 20% of circumference) to accommodate
plate damping bars. The gap also permits the inking
system to recover before the next sheet is printed
and compensates for individual sheet feeding. Note,
Heidelberg has patented a “gapless” plate cylinder and
has been able to enforce unlicensed use in the U.S.
• On each end of the plate cylinder is a bearer which is
a hardened metal ring attached to the cylinder body
or journal. On many presses the plate cylinder bearer
is in contact with the blanket cylinder bearer during
printing. The diameter of the bearer is the effective
diameter of the cylinder and is the same as the pitch
diameter of the gear attached to the journal. The plate
cylinder is driven by this gear, which is in turn driven
by a similar gear on the blanket cylinder.
• The cylinder gears may be spur or helical. A spur
gear has teeth cut straight across, while helical gears
(generally on newer presses) have teeth cut at an
angle. A spur gear generally has a backlash gear,
a this second gear bolted to it to reduce “play” (free
or unimpeded movement). Presses which print with
bearers out of contact always have helical gears. The
plate cylinder can usually be rotated independently of
its gear.
• Adjusting the plate cylinder manipulates the printed
image position. However, moving the plate cylinder
to adjust the image position wastes time and paper.
Standard print and plate clamp margins should be
established, instead. The undercut of the plate cylinder
is the difference between the bearer and cylinder radii.
(Note the duplicators in our laboratory do not have
Web Offset Technology Class Notes
bearers, so the effective undercut is not defined in the
same way. For an example of bearer and undercut see
the Heidelberg KORDs.
• The undercut provides space for packing between
the plate and cylinder. This provides proper printing
height and adjusts cylinder circumference to control
print length. A plate clamp is a device designed to
grip the edge of the plate and pull it tight against
the cylinder body. There are a variety of designs but
all have provisions to move the plate laterally and
circumferentially.
Blanket Cylinder
• The blanket cylinder on a offset press carries the
blanket and has two primary functions.
1. To carry the blanket in contact with the inked image
on the printing plate.
2. To transfer (offset) the ink image to the substrate
carried by the impression cylinder. It is similar to the
plate cylinder in that it has a gap, gutters, bearers
(sometimes), gear and bearings. It does not have
clamps, but has reels for holding the blanket tight.
• The position of the blanket cylinder must be adjustable
for two reasons :
1. To bring it in and out of contact with plate and
impression cylinders.
2. To compensate for variations in substrate and
packing thickness. The blanket cylinder is undercut to
accommodate the blanket and packing.
The Blanket
• The blanket is a rubber-surfaced fabric that is clamped
around the blanket cylinder.
• The behavior of conventional blankets is controlled
primarily by that of the rubber itself.
• The properties of rubber are very special in that it can
be described as a nearly incompressible solid. For a
conventional blanket this causes it to bulge out on the
sides when squeezed at the nip in order to maintain its
total volume.
• This shortens plate life when excessive plate/blanket
impression pressure (squeeze) causes a rubbing
action against the plate as the blanket tries to recover
its original shape.
• The slipping of the blanket over the plate causes
slurring of the print.
• A compressible blanket employs a cellular or sponge
16
 rubber to improve the performance of the blanket. This
improves the packing tolerance of the blanket, reduces
slippage and improves plate life.

The Impression Cylinder

• The impression unit carries the substrate into the

printing unit. Contact with the blanket transfers the
image. The impression cylinder also has gears and a
gap.
• The impression cylinder may or may not be undercut.
It is approximately the diameter of the bearers of the
other two cylinders.
• The distance between blanket and impression
cylinders must be adjustable to control the transfer
squeeze.
• Squeeze is a measure of impression pressure.
However, it is not measured in pressure units, instead
it is measured in units of length.
• Plate to blanket squeeze is the combined height of
the plate and blanket over their respective bearers.
Blanket to impression squeeze is the blanket height
over its bearer.
• Squeeze pressure transfers ink from plate to blanket
and from blanket to substrate. Squeeze pressure is
controlled by plate and blanket packing.
• A packing gauge is used to measure the height
difference between cylinder and bearer. Therefore it
can be used to measure squeeze.
• Excessive squeeze causes friction that wears plate
images. Insufficient squeeze can cause rough edges,
snowflaking or low ink density.
• Offset compressible blankets are constructed from
two, three or four plies of a strong woven fabric
fastened together with thin layers of “rubber” adhesive
to form a laminate termed the carcass. The carcass
then receives many coats of a suitably compounded
polymer, applied to one side to produce the face layer
which is approximately 0.020” thick Total thickness,
i.e. face and carcass together, is between 0.030” and
0.075”, depending upon the number of fabric piles
employed. The number of fabric layers equals the
number of plys. Thus a 4 ply blanket would contain
4 fabric layers. To make the blanket “compressible”
a thin layer of air cells (for compression) is layered
between the fabric and rubber face. Conventional
blankets are made up of a rubber face and the fabric
carcass. A compressible blanket is made up of a
rubber face, fabric, compressible layer and a carcass.

• The conventional blanket will bulge at the printing nip

Lithography - Blankets (displace not compress), especially when over packed.
The conventional blanket is good when blanket
packing is critical, however, squeeze pressure must
• Offset press blankets are made of supporting fabric be precise. The conventional blanket is recommended
and a rubber composite. Various rubber materials where high print pressures are required. The
are used for the transfer of the image from the plate compressible blanket, on the other hand, will form only
to the blanket. Blankets come in compressible to a very slight bulge when overpacked.
hard finishes along with smooth to rough surfaces.
The majority of printers today use compressible type
blankets. These blankets give good compression
which eliminate many smashed blankets. Slightly
rough blankets are also preferred as they have less
contact with the paper surface thus reducing blanket
contamination.

Web Offset Technology Class Notes 17

• The diagram above shows the difference in
compression between the compressible and the
conventional blanket
» • Unlike the conventional blanket the compressible
blanket has many more features such as:
• Smash resistance which translates into longer blanket
life
• Compensates for variation in Blanket thickness and
substrate
• Wider latitude for packing
• Reduction in plate wear
• Reduction of slurring
• Minimizes mechanical press problems
» • Blankets are manufactured in three types of
surfaces:
• Cast - Surface finish produced by curing paper and
talc
• Ground (buffed) - Mechanical process of finishing the
surface of a blanket
• Texturized - Surface finish produced by chemical
means
• Below are magnifications (100X) of various blanket
surfaces (Cast, Buffed and Textured)
Web Offset Technology Class Notes
• Blankets will generally last 3 to 6 months depending
on the type of press (web/sheetfed) and types of
jobs run. Conventional blankets are hard and give
a high amount of resistance when the blanket and
plate cylinder are squeezed together, as shown in the
drawing on the next page. Compressible blankets, as
their name implies, are compressible and give under
the squeeze.
» Properties required in an offset blanket:
• The fabric piles must be strong and stretch very little.
There should be, however, some degree of stretch to
allow the blanket to fit tightly on to the cylinder, since a
slack blanket can cause doubling and slurring. On the
other hand, excessive tensioning through high stretch
will cause uneven thickness and result in low areas
in the print. The thickness must be uniform between
closely defined limits.
• With an compressible blanket, slight bulges do form,
but to a much lesser degree than the conventional
blanket. Compressible blankets are used to print
uncoated and lighter coated papers. When a blankets
wrap occurs, due to a web break or paper sticking to
the blanket, the compressible blanket has the best
chance for surface recovery. The conventional blanket,
due to its very hard surface, will not retract like the
compressible surface.
• The conventional blanket bulges at impact point.
Rubber displaces rather than compresses and will
bulge when subjected to pressure. Because of this
displacement, the surface speed of the conventional
balnket is slightly different than the surface speed of
the plate. One possible result is slurring. Conventional
blankents can be used when highly coated papers.
» The face of the blanket should be
• free from pinholes, and blemishes which could affect
print quality non-abrasive to reduce plate wear
• resilient
• of uniform surface hardness and hard enough to be
capable of reproducing a facimile of the printing image
• very smooth, having a matt surface with no low spots
or raised areas
• resistant to ink vehicle, cleaning solvent and varnish
• ink-receptive
• resistant to peeling, blistering, embossing, debossing,
glazing or tackiness, also abrasion from paper or
board
• capable of giving good release (ink and paper)
18
» Packing
• Packing is very important to the life of a press, blanket,
plate, etc. When a new blanket is put on a press, it will
first stretch. Usually the pressmen will, after installing,
run the press under impression for several hundred
or thousand impressions then retorque the blanket.
Blankets should always be torqued to assure proper
tension. To attain the proper squeeze between the
plate and blanket (to assure proper transfer of the
image) special paper, known as packing material, is
placed under the blanket and plate. A special “packing
micometer” is used to determine the amount of
packing material needed. See page 3-35 for a diagram
of blanket packing. It is important that you always
recheck packing, after installing a new blanket, several
thousand impressions after.
1. Common blanket problems include:
2. Incorrectly installed (over/under packed)
3. Overtightened - hand vs. torquing
4. Poor blanket maintenance - using harsh cleaning
materials that contain acetone, toluene, etc.
5. Out of square blanket
6. Wrong blanket for application
7. Poor release blanket
• As there are many types and styles of blankets, the
printer must evaluate the type of blanket he wishes
to use and work with a blanket supplier such as Day
International. Most printers are printing a wide range
of papers and can not change a blanket for every
paper printed. A printer must work with a supplier and
choose the right blanket that gives him the best overall
performance for a wide range of papers printed.
Using a packing gauge
Web Offset Technology Class Notes
» How to pack a blanket...
• Plate cylinder is .020” undercut. The offset plate is
.012”thick. To bring the plate to a pressure squeeze of
.004” (over bearers) we need to add 0.012” packing
material.
• The blanket cylinder is .090” undercut and the blanket
is 0.065” thick, then 0.025” packing is required to bring
the blanket to the surface.
• This then will allow the squeeze to be 0.004” between
the plate and the blanket.
Offset Plate Technology
• We have come a long way from the stone plate.
As you can well imagine, it would be very difficult
to mount a piece of stone on modern high-speed
presses. Senefelder’s first press was flat, so the
use of stone was easy. Today’s presses use curved
cylinders to hold the offset plates. The basis of
modern lithography is a combination of photography
and Senefelder’s original observation that “oil and
water do not mix”. All offset plates made today
employ this offset principle, they use as an image
carrier such as thin paper, plastic, or a metal sheet
which once exposed and processed can be wrapped
around a cylinder of a press for printing. This modern
offset plate contains two areas; image areas, which
repel water (remain dry and accept ink) and non-
image areas, which accept water. This is the basic
requirement of all modern lithography - the ability to
produce a plate which will have image areas that are
“hydrophobic” (meaning water hating) and non-image
areas that are “hydrophilic” (meaning water loving).
While the basic principle is common, there are many
differences between offset plates and the method they
use to separate the image from the non-image areas.
19

• Today, the majority of lithographic plates are made
of aluminum sheets of varying thickness (usually
between .008” and .0015”) with a surface grain or
granular finish. This grain serves to give water-
carrying properties to the plate and to give anchorage
to the image forming material. Practically all plates are
presensitized, that is they are supplied ready coated
with a light sensitive diazo compound or photopolymer
resin material ready for light exposure.
• This photopolymer coating, as the term implies, is a
chemical resin or polymer that will react with ultraviolet
light - much like photographic film. When UV light
strikes the photopolymer on the plate, it is “hardened”.
Photopolymer that is not exposed to the light is not
“hardened” and can be easily removed. This is the
principle of the modern offset plate.
• The light is reflected away from the dark portions
of the negative and will not cause a cross linking or
hardening of the polymer. Light, however, will pass
Web Offset Technology Class Notes
through the clear areas of the negative and cause a
cross linking (hardening) of the polymer resulting in
the image areas of the plate after processing.
• Exposing an Offset plate to produce a usable plate for
the offset press
• There are seven major types of lithographic plates
used in the printing industry today:
1. Diazo
2. Photopolymer
3. Silver Halide
4. Electrophotographic
5. Bimetal
6. Waterless
7. Spark Discharge (digital waterless)
8. Laser (digital waterless)
9. Computer-to-plate - Various types of Plate Material
• Film positives and negatives along with digital
information (computer) are used for making or
exposing most types of offset plates today. While there
are several types of offset plates, they are all generally
classified as either positive or negative working plates.
» Negative-working
Negative-working plates are comparatively
inexpensive and commonly used in the United States.
As the name implies, film negatives are used to
image the negative working plate. These plates are
generally coated with a photopolymer and are known
as negative working presensitised plates. Exposure
and processing of this type of plate is usually within
ten minutes. To expose the plate, a film negative is
placed over the light sensitive coating and exposed to
UV light. Light that passes through the clear areas of
the negative causes a reaction with the “monomers”
of the photopolymer which chemically cross-link with
each other to form polymers. These polymers can be
thought of as complex chains of monomers, which are
linked so strongly, that they behave as a single, hard,
wear-resistant molecule. The actinic light cannot pass
through the black areas of the negative so no reaction
takes place with the polymer under the non-clear
areas of the negative. Processing removes unexposed
non-hardened polymer. An application of a gum
solution to the non-image areas of the plate to make
it water-attracting/ink rejecting. The processing does
not wash off the hardened polymer image areas of the
plate.
20
» Positive working
Positive working plates are more expensive than
their negative-working counterparts. These types of
plates are used more by European printers. As the
name implies, film positives are used to image this
type of plate. The photopolymer used to produce a
positive working plate is different from the polymer
used in the negative working plate as it is hardened
before exposure. The photopolymer used here
becomes unstable when exposed to ultraviolet light
and remains hard where no light strikes the polymer.
Plate processing is similar to the negative plate except
that the processor removes the exposed photopolymer
from the plate and applies a thin layer of gum to
protect the non-image areas from ink.
Plates are generally made from aluminum. Other
base materials can be used such as paper, polyester
and multi-metal. Multi-metal plates are used for long
extensive press runs due to their durability. Paper
type plates are used in small offset presses known
as duplicators for very short runs (1,000 - 10,000
impressions). Polyester plates may be used in small
press or in larger sheetfed presses. Like paper plates,
these are intended for short runs. In general, the
polyester and paper plates are much less expensive
than the aluminum or multi-metal plates. Cost, run
length, type of press and the type of job dictate the
type of plate used by a printer.
» Offset Plate Technology
The aluminum-based plate contains the light-sensitive
coating applied or coated over the aluminum. Paper
and polyester plates are treated very similarly.
The multi-metal plate, however, is similar but the
structure of the base plate is slightly different from
that of the aluminum, paper, etc. Multi-Metal Plates
were developed to extend press run life. In general,
multi-metal plates are presensitized polymer plates
consisting of a metal base with one or more metals
plated to it. Today, there are two basic types of “bi” or
multi-metal plates:
• Copper plated onto stainless steel or aluminum
• Chromium plated on copper
They are the most durable and the most expensive.
These plates can be coated with either diazo or
photopolymer and can be either negative or positive
working.
Web Offset Technology Class Notes
They are designed with a purpose in mind. In most
cases, a major determining factor is press run length.
A long run length, for example, on a small offset
duplicator might be 10,000 impressions (copies) with
a short run length being in the neighborhood of 2,000
impressions. When you talk about larger commercial
4 to 6 color sheetfed presses, short run lengths would
be around 20,000 with long run lenghts being up to
100,000. High speed webs differ even more. Long run
lengths generally will be in the 1,000,000 impression
range. So it is difficult to give a generalization of run
length for a particular plate.
» Diazo
Diazo - is a compound used to coat the offset plate.
Diazo coatings are organic compounds that are used
to make presensitized plates with a shelf life of about
a year and for wipe-on type plates that can be in-plant
coated with a shelf-life about one to two weeks. These
plates can be both negative or positive working. Once
exposed, they are treated with an emulsion developer
which consists of a lacquer and gum in an acid
solution. As the unexposed diazo is dissolved by the
solution, the gum deposits on the non-printing areas
ensuring water receptivity. The lacquer deposits on
the exposed areas making them ink receptive. Once
developed, the plate is rinsed with water and coated
with a protective gum arabic solution. Run lengths are
short with these type of plates. Run lengths of 100,000
to 250,000 impressions with web and sheetfed
presses can be achieved.
» Photopolymer
Photopolymer - coatings used to make photopolymer
plates are organic compounds which are very inert
and abrasion resistant, allowing longer press runs
than diazo coatings (up to 1,000,000 sheetfed or
web impressions). This type of coating is the most
widely used material in platemaking. Plates made
with photopolymer can be both negative or positive-
working. The photopolymer coating is different from
other sensitizers as they change in molecular weight
during exposure. This accounts for many of their
unusual properties such as long runs, resistance to
abrasive wear and increase in wear resistance after
baking (processing technique to extend run length).
Today, new high-speed photopolymer plates have
been developed with a dye sensitized photopolymer
that can be exposed by laser and used in digital
imaging systems (computer based desktop systems).
The photopolymer plates are by far the most widely
21
 used plates in the printing industry today.
» Silver Halide
Silver Halide - are high speed plates that use a
photosensitive coating similar to photographic film
except that the silver halide emulsions are slower. The
emulsions are color-blind and very light sensitive in the
blue region of the visible spectrum so they have to be
handled in yellow filtered light. This type of coating can
be exposed optically using negatives or by lasers from
digital data. The processing solutions contain heavy
metal (silver) by-products which must be either carried
away to special treating plants or treated in-plant with
silver recovery chemicals before being allowed to
drain into municipal sewers. Film-based plates are
used to print single color business forms, reports,
etc. from digital information. These plates may also
be exposed like photographic film in a large camera
then following exposure, developed and placed on
the press for printing. Silver-halide plates are used for
spot and process color reproduction using digital data.
These types of plates are popular with short run, quick
turnaround printers.
» Electrophotographic
Electrophotographic - plates are based on the
principles of the electrostatic copier. There are two
types of plates:
• Inorganic photoconductor on a drum
• Organic photoconductor on a substrate
The photoconductor is sensitized to light by charging
with a corona discharge. The charge is dissipated in
the areas exposed to light. The charge remaining on
the unexposed areas attracts a dry or liquid toner with
an opposite charge. The base photoconductor material
used is normally selenium or cadium sulfide coated
onto paper, plastic, etc.
Plates for laser imaging are coated on electrograined
anodized aluminum. During processing, the coating
must be removed in the non-printing areas, and
the plates are treated with etch and gum to make
them water receptive. In the chemical removal
process the image elements (dots) become slightly
ragged which can affect their use for fine screen,
high quality process color printing. Another type of
electrophotographic plate is the Zinc Oxide paper
plate used by quick printers. These plates are very
similar except the Zinc Oxide is the photoconductor.
Web Offset Technology Class Notes
These types of plates are normally used for short run
duplicators by quick printers.
» Waterless plates
Waterless plates - are similar to the conventional
offset plate except that a layer of silicone is applied
on the surface of the light sensitive photopolymer. The
thin layer of silicone is bonded to the photopolymer.
Exposure is similar to that of the conventional offset
plate. Exposure light passes through the clear areas
of the film negative and silicone layer striking the
photopolymer material beneath. The light activates the
photopolymer, causing a break in the bond between
the photopolymer and the silicone layers. Areas where
light does not pass through negative, no break in the
silicone bond occurs. Processing removes the un-
bonded silicone leaving only the photopolymer which
is ink receptive. Silicone rubber has a very low surface
energy and is not wet by the ink.
Systems have been developed for waterless printing
using special ink temperature control systems on
press to assist in stabilizing the ink and its viscosity.
Waterless plates can be either negative or positive-
working. This type of printing has advantages as it
eliminates the gum-water based fountain solution.
Fountain solution, as it emulsifies with the ink, can
dull printed colors, increase dot gain and make
controlling the press more diffi cult. Printing with the
waterless process allows the printer to print with finer
line screens (300 lines per inch and higher) due to the
absence of the fountain solution resulting in higher
resolution pictures. The plates, due to the silicone,
have shorter run lengths (under 100,000) and scratch
easily requiring press shutdown for plate repair.
This type of system is also more expensive than the
conventional offset plate.
» Direct Imaging
Heidelberg GTO-DI (Direct Imaging) - plates are
used on the Heidelberg GTO-DI press system. These
plates are very similar to the above waterless plates
except they are imaged on press by computer. In a
way, the press is the printer for the computer much
like a dot matrix printer is. The plates are imaged in
this case, however, by lasers. The plates are made in
a three layer composition. The base material is either
polyester or aluminum. The middle layer is an infrared-
absorbent material. This layer matches the laser’s
22
 output wavelength and its role is simply to vaporize
when struck by the laser light. Over this layer is a thin
layer of silicone. As the laser strikes the plate, the
infrared vaporizes and loosens the silicone layer which
is wiped away following imaging. The wiped area is
now the image area as no silicone remains. The non-
image area is the area containing silicone which was
not removed during the imaging process.
The same plate and technology is used in the
Heidleberg Quickmaster DI-46-4 press with the
exception that instead of a single plate a plate roll is
used. See the first section under Printing Processes
for a more detailed description. These plates are very
short run plates (under 25,000 impressions). Once the
plate has been imaged, the waterless process is near
similar to the above waterless plate. These plates are
near similar to the Toray Waterless plates mentioned
in the Waterless Section in the previous page.
» Computer to Plate (CTP)
Heidelberg Quickmaster D146-4 (Direct Imaging)
- Like it’s predecessor the GTO-DI, the Quickmaster
uses a waterless plate. Unlike the earlier versions of
the OTO-DI (which used the “spark” imaging system)
the Quickmaster waterless plate is imaged via an laser
array. Data (Postscript level 2) is converted in the RIP
(Raster Image Processor) into screen data, which is
in turn converted into control signals for 64 infrared
laser diodes (16 diodes per printing unit) in the printing
press. An Ethernet interface is sufficient to transmit
digital documents from the prepress directly without
film exposure, plate exposure and stripping tot he
Quickmaster DI. The laser beams created by the laser
diodes are led to optics via fiber-optic cables, and are
bundled into a precise ray of light. On a special, multi-
layer plate very small sharp-edged depressions are
created through high levels of energy. Analogous to
other dry offset processes these depressions accept
ink, which is repelled by a silicon layer on all other
places on the plate. The system can image up to
1,270 dpi or 2,540 dpi. This is sufficient for printing
a 150 Ipi screen in very good offset quality. Imaging
time ranges from 6 minutes (1,270 dpi) to 12 minutes
(2,640 dpi). Since all four printing units are imaged at
the same time, all are in registration. The plate itself is
very similar to the waterless plate used in the GTO-DI
with the exception the plate comes in roll form (see
Printing Methods, Section 2). Like with the OTO-DI
Waterless plate, the Quickmaster plate is on a mylar
or polyester base and is flexible.
MAN Dicoweb or the CTPress (Direct
Imaging) - Meaning “Digital Change Over Web”
is the latest digital technology to hit the printing
scene, however, it is not yet commercially available.
Web Offset Technology Class Notes
The Dicoweb works by printing digitally to a “plate”
cylinder, printing the job and then cleaning the “plate”
cylinder for re-imaging. The process works by using
a laser head to directly image the printing cylinder via
a thermal ribbon. The thermal material transferred
from the ribbon to the plate cylinder (which is actually
a sleeve). The thermal image laser deposited is ink
receptive. The areas of the cylinder that received
no thermal material are the non-image areas which
accept no ink but fountain solution instead. After
the completion of a print run, the cylinder surface is
automatically cleaned by a device similar to a blanket
washer. Once washed, the cylinder is reading for more
imaging. See the Printing Methods Section for more
details.
Computer to Plate (CTP) - Computer to plate systems
today can use a variety of plate material - depending
upon the manufacturer, system design, etc. CTP
systems can use several systems which include:
• Silver Halide
• Thermal
• Direct Thermal - Requires the use of a special
substrate that changes color when exposed to heat.
• Thermal Transfer - This approach uses a thermal
array to transfer colorant from a ribbon to a substrate.
• Photopolymer
• Ink Jet
• Hybrid
No matter how what technique is used, the end result
is the same; an offset lithographic plate with the image
areas that will accept ink and a non-image area which
will accept no ink. Computer to Plate is a technology
whose time has come. It was only a few short years
ago when only 2 or 3 major vendors were available,
now today there are over 46!
XTRA NOTES
23
 UNIT CONFIGURATION • The contact pattern of two teeth brought into mesh
takes the form of a straight line as the gears rotate,
• Unit type – blanket to blanket type
and from this contact line the involute can be derived.
• Inline type
• “Y” – type
• The angle between this straight contact line and the
• Common impression type
tangent at the pitch circle is the angle of action.
• Semi drum type
• “H” Tower or “I” - type
• Most manufacturers cut their gears on an involute
• Double cylinder system (Ten cylinder type)
curve for an action of 20¢ª but others prefer a 15¢ª
action angle to keep gear play within closer limits
WEBBING UP OPTIONS where the distance between axes must be altered,
such as when making pressure adjustments to one
• Draw the webbing up of four color on each side with
cylinder only.
the following available units. Two unit of semi drum
type with one vertical blanket to blanket unit. One reel
• The second method, chosen by most manufacturers,
stand, total couples 8.
is to dispense with the need for bearer contact and to
• Draw the webbing up for the following inputs. 4 H type
obtain a smooth, accurate performance from the gear
blanket to blanket, 4 inverted Y in which 2 tower type,
drive itself.
one blanket to blanket vertical type. Page 1,2,3,4
should be in 4 color. Page 6 in 2 color. Center spread
• The gear teeth will be of involute design and cut at
in 4 color. The total page level is 16.
an angle to provide helical meshing so that the teeth
receive gradual loading and share the drive with other
WEBBING UP OPTIONS teeth at all times.
• Draw the webbing up for the following inputs. 2 inline
• The greater this angle, the more the loading is shared,
presses , 2 blanket to blanket press, one 9 cylinder
but to the detriment of forward drive efficiency, and it
configuration, 2 reel stand. In 8 pages 1 & 8, 4 & 5 in
follows that the helix needs to be less acute on large
four color.
presses where power requirements are higher.

CYLINDER DRIVES • More elaborate gear designs can include curved

• Modern lithographic machines need absolute control
of cylinder drive and circumference ratios to obtain
high quality work. This means that the driving wheels
must roll against each other on the pitch circle and the
interaction of every tooth must be consistent and free
of vibration.
shapes and V patterns but the increased efficiency
must be measured against cost and replacement.
• Another problem affecting mechanical efficiency on
large machines arises from the flexing of cylinder
shafts under load.

• Two methods are used to attain this ideal.
• The first method requires hardened steel bearers at
both ends of each cylinder, machined to the pitch
circle and running in contact with adjacent cylinder
bearers to provide smooth running.
• This can occur with rollers and cylinders where a load
is applied at the ends, causing the centre to bow.
• Most modern machines have inker and damper roller
bearings inside the framework of the machine to
minimise shaft length and reduce distortion.

• It is claimed that this system is less wearing to the • Driving gears are placed outside the framework for
drive gears, which can be of a straight cut type for stability and this also keeps the gears free from dust,
simplicity, but places strict discipline on impression lint and ink as they can be safely contained within
control. sideguards.

• Straight cut gear teeth are in complete contact for only

part of their mesh cycle and interruptions to the drive
can cause streaks and gear-marking.

• A better gear design is to cut the teeth so that the

tooth flanks follow an involute curve.
Web Offset Technology Class Notes 24
 CIRCUMFERENTIAL REGISTER
CONTROLS
• The actual length of material flowing through a
machine will change during printing because of
variations in the materials and processing conditions,
and also the backlash in the mechanical parts.
• The tension levels, dryer temperatures, cooling
conditions, and the design of the machine as well,
influence the accuracy of its circumferential color
register.
• Circumferential color register is concerned with
the imposition of the various colored images in the
direction of web flow, or around the circumference of a
rotary printing cylinder .
• The shrinkage and elongation web length changes,
as well as the printing cylinder position (timing) errors,
can cause the relative position (registration) of the
series of ink layers which make up a multicolored
image to vary enough to become unacceptable.
• All printing presses are built with a manual or auto
color register control device, which will allow the
operator to reposition any one of the colored images
which have become misaligned during the printing run.
• An automatic color register control performs the
inspection, analysis, and corrective functions without
the intervention of the machine operator.
• The operator must establish the desired registration
manually during the makeready procedure, and
then the automatic color register controls use
this positioning as a reference for any variation in
circumferential positioning during the run.
PRINT CYLINDER REGISTER
CONTROL
• There are two methods of changing the circumferential
positioning of a printed image during the run, the web
and cylinder correction methods.
• Cylinder register control or cylinder correction is
accomplished by changing the angular relationship
of one of the printing cylinders in relation to the first
cylinder.
• Cylinder correction is accomplished by maintaining
a fixed web length between the printing units, and
altering the phase relationship of the cylinders.
Web Offset Technology Class Notes
• There are many types of cylinder correction devices
such as the sliding worm, epicyclic gear helical gear,
and differential gear mechanisms.
• The most press uses mainly the helical and differential
gears to obtain unit-to-unit color registration.
• Only the 360¢ª differential gear system offers unlimited
cylinder correction potential, as all of the other
mechanisms have limited phase shifting capability.
» A typical helical gear cylinder correction system
• The teeth of helical gears are set at an angle to their
face, and the slope can be as much as 45 .
O
• If one helical gear is moved sideways across the face
of another helical gear, its phase relationship will
change in relation to the other gear.
• A helical gear set translates lateral linear motion into
angular rotational movement, and the amount of
phase shifting (register correction) is a function of the
slope of the teeth, the amount of side movement,
and the diameter of the printing cylinder.
• Plate cylinder which is held stationary in one position
in the press to maintain the side register of the various
colored images.
• The movable bottom helical gear is located at its
maximum right-hand position.
• The bottom helical gear lateral movement has caused
a rotational action on the plate cylinder in conjunction
with the drive rotation provided by another set of
gears.
• If the phase shifting occurs in the direction of cylinder
rotation, the combined rotary movement increases the
cylinder’s speed momentarily during the movement of
the helical gear.
• If the helical gear travels in the reciprocal direction, the
phase shifting will occur in the opposite direction, and
the plate cylinder will be slowed momentarily.
• Once the sliding helical gear is stopped, the plate
cylinder reverts to its normal rotational speed in an
exact 1:1 relationship with the other plate cylinders.
• The momentary speed increase or decrease of the
plate cylinder is the basis of all cylinder correction
color register control mechanisms.
25

• A helical gear system usually has a circumferential
register movement of ± 3 mm.
• The sliding worm gear set which creates an angular
movement in the worm wheel whenever the worm
gear is moved laterally, in an action similar to that of
the helical gear system.
• The epicyclic cylinder correction system is one type of
360 gearbox.
O OFFSET PRINTING BLANKETS
• The most common type of unlimited rotation phase
shifting device is the differential cylinder correction
system .
• A differential gearbox consists of 3 or 4 bevel gears.
• All differentials must have an input and output bevel
gear, but they can have one or two spider or planetary
gears.
• If a manual or motorized rotation of the control shaft
is performed, the input-to-output speed relationship is
changed.
• Correctional rotation in the direction of the output shaft
rotation adds to the drive relationship, and corrections
in the opposite direction subtract from the rotational
speed of the output shaft.
• When the correction shaft is stationary, the speed
relationship between the input and output shafts is
constant, and it is equal to the speed of the other
differential gears in the printing section.
» WEB COMPENSATOR REGISTER CONTROL
• The old type of circumferential register correction
device used on inline and blanket to blanket presses is
the web compensator roller.
• The web compensator, commonly called the
compensator, is a movable roller which is locked in
one position as long as its hand wheel or correction
motor is not turned.
• One compensator is needed to control the register
between two operations, either color-to-color or color-
to-cutting.
• This means that the number of web compensators
on a web-fed machine is one less than the number of
registered units.
• A web compensator roller mounted between two units.
Web Offset Technology Class Notes
• The compensator roller corrective action is based on
the principle that the length of the web between units
determines the placement of the two images.
• The helical gear has 35 degree helix angle. The
amount of circumferential movement have to impact
5mm,the lead pitch is 0.5mm. How many turns have to
make, to get the desired movement.
BLANKET BASICS
• An offset blanket is the lynch pin of the printing
process. Its function is to transfer ink from a printing
plate to a print surface without loss or impairment of
the image.
• All offset blankets comprise two basic elements, a
carcase and a surface layer. Each element endows
a blanket with certain properties and the subsequent
behavior and, sometimes, misbehavior of the blanket
on a press can often be attributed to the complex
interaction between these properties.
» BLANKET CONSTRUCTION
• The primary function of the carcase is to provide a
base upon which the surface layer can be securely
mounted. Two types of carcase are most commonly
used, the conventional and the compressible.
• The conventional blanket (carcase) is so called
because its construction has remained basically
unaltered since the early part of this century.
• It comprises two or three plies of fabric bonded
together with rubber adhesive to form a laminate of
the required thickness.
• A laminated carcase provides the flexible strength and
stability necessary to securely mount a blanket onto a
press cylinder under tension.
• Additionally, air trapped within and around individual
filament yarns of the carcase fabric provides a degree
of compressibility.
• To avoid confusion, it must be appreciated that rubber
is virtually incompressible, but it is deformable. Thus,
when it is subjected to pressure, rubber will change its
shape without being reduced in volume. Air, however,
will reduce in volume, or compress, when put under
pressure. This significant difference becomes
important when the dynamic characteristics of a
blanket are considered.
26
» COMPRESSIBLE BLANKET
• The compressible carcase, introduced in the 1950’s
and now representing 80% of the total market, is
formed by introducing a layer of microcellular sponge
between two of the fabric plies.
• The sponge, normally between 0.25 mm and
0.5 mm thick, entraps air which increases the
compressibility of the carcase beyond that obtained
from a conventional type. The fact that the air-laden
sponge layer is itself surrounded by resilient rubber
allows this type of carcase to recover more rapidly
from indentations of smashes experienced on a
press. Additionally, over pressure caused by creased
or doubled sheets passing through the printing nip,
causes less damage to the blanket.
» BLANKET SURFACE LAYER
• The surface layer of a blanket is the medium by
which ink is transferred from the plate to the material
being printed. To do this effectively and consistently,
throughout the life of the blanket, the face layer should
have the following properties:
• It must be receptive to the ink being used.
• It must not swell when treated with ink vehicles and
wash solvents.
• It must be free from blemishes.
• It must be of uniform and precise thickness.
• It must be of uniform smoothness on the surface.
• It must have good ink and sheet release properties so
that the paper does not stick to the blanket.
• It must be resilient.
• It must be of uniform hardness.
• It must not be abraded by the plate or the material
being printed.
• It must resist glazing, tackiness and blistering.
• The stringent demands of modern inks, papers,
printing stocks and processes dictate that blanket
manufacturers select the appropriate rubber
and compounding ingredients to give optimum
performance for a particular application.
» BLANKET THICKNESS
• The normal thickness of offset blankets is either 1.68
mm or 1.95 mm, often referred as three ply or four ply,
respectively.
» HOW BLANKETS ARE MADE
• The offset blanket is made from a laminate of fabric
and rubber, therefore the manufacturing process
basically consists of applying rubber to fabric.
However, the need for accurate thickness and
freedom from blemishes demands a very specialised
Web Offset Technology Class Notes
manufacturing process.
• The rubber must first be mixed or compounded
with numerous other ingredients to give the desired
hardness, solvent resistance, resilience and colour
on the final blanket. This is normally carried out in
an internal mixer, the purpose of which is to form a
homogeneous dry compound. Addition of suitable
solvents to this dry compound with the aid of a ‘Z’
blade type mixer produces a dough-like solution.
• The coating is carried out on a spreading machine
using a knife over roller technique. A drum at the
back of the machine pulls the fabric with controlled
speed and tension under the knife where a thin layer
of solution is applied. The fabric passes over a heated
chest where the solvent is evaporated and removed
with suction equipment. The process is repeated,
adding layer upon layer until the required thickness is
achieved. Each coat may be as little as 0.01mm thick
so that as many as 50 or 60 layer passes are required
to achieve the final blanket gauge.
• The carcase of 2,3 or 4 fabric plies is prepared first.
Single ply cloth is coated with specially formulated
rubber adhesive compound to the required thickness.
The plies of this are laminated together by passing
between pressurised rollers. Additional plies can be
similarly added to give the desired thickness.
• It is essential that the printing face is well bonded
to the carcase. This is ensured by applying coats
of primer to the carcase prior to building up the face
layer. During face spreading there are frequent
checks on evenness of gauge and quality of surface.
The direction of spreading is reversed between coats
and increasing care has to be taken as the blanket
nears its final thickness. In this way it is possible to
achieve a thickness tolerance + 0.03mm over 150
square metres of material produced. After the last
coat the blanket is dusted with a protective layer of
chalk.
• At this stage the rubber is soft and doughy in nature.
The blanket is then tightly wound onto a large drum
and interleaved with a special paper before its
insertion into an autoclave.
• The compounds contain various chemicals that
transform the rubber to a true elastic state with the
application of heat. This vulcanisation or curing
process takes several hours during which the blanket
face moulds itself to the paper. This results in the
smooth ink receptive texture that is an important
feature of litho blankets.
27
• After vulcanistion, the paper is stripped off the roll
of blanket which is then ready for inspection, quality
control testing, trimming and cutting into individual
blankets.
» GETTING THE BEST FROM YOUR OFFSET BLANKET
• Offset blankets are the final point of contact between
ink and print surface and as such are considered the
heart of the printing process.
• We have to choose the correct type of blanket.
» BLANKET TYPE
• Getting the best results from an offset blanket,
however, requires thought and action long before
mounting it onto a press.
• Firstly, the correct type of blanket must be selected for
its particular application. Also, paper type, ink grade
and cost are all factors which contribute to selection of
the correct blanket.
• When in doubt about these factors contact the
supplier.
» BLANKET SIZE
• Secondly, the size and thickness of blanket required
must be accurately assessed and specified.
• For many reasons, printers often decide to take
blankets of slightly different size than that designed for
the press, and suppliers are not always aware of the
size required for a printers particular press.
• Therefore, accurate specification is advisable when
ordering. Normal convention demands the size across
the gripper followed by the cylinder circumferential
dimension.
• If blanket gauge or thickness is critical, then it is
advisable and realistic to specify a tolerance.
» GAUGING
• The type of gauge used to measure blanket thickness
can influence the reading. Therefore, if gauge is
critical, give the supplier a sample with the gauge
reading on it, or invite his agent to measure the
thickness with his own micrometer.
• In this way, the supplier can guarantee delivery of
consistent, precisely gauged blankets.
» STORAGE
• Blankets are normally delivered rolled in tubes but are
best stored flat, face to face.
• Storing face to back is not advisable as there is a
danger of interaction between the weave pattern on a
blanket back being embedded into the surface layer.
Web Offset Technology Class Notes
• Blankets should be stored in cool, dark conditions
away from sunlight.
» CHECKING
• Where possible, and before mounting them onto a
press, check that the dimensions of the blanket are
within ± 3mm of those specified. If the blanket has
warp stripes, check that the blanket has been cut with
the stripes and not against.
• Normal permitted tolerance on blankets cut out of line
is 1 .
O
» HANDLING
• Special care is needed when handling blankets,
particularly if large press formats are used.
• Blankets which are rolled up or doubled over so that
the face is turned in are more susceptible to damage.
• Accidental pressure on the roll of the blanket will
kink or wrinkle the surface and will be impossible to
remove.
• It is better to handle blankets face out, making sure
the face is not scuffed.
» MOUNTING
• Prior to mounting, gauge the thickness of a blanket
with a micrometer. If packing sheets or underblankets
are to be used, check and double check that the total
blanket height is correct.
• The blanket edges should be sealed to prevent
ingress of solvent.
• When the blanket has been mounted onto the press
cylinder, wash off residual chalk or talc from the
surface to ensure good ink transfer from the start.
» LONGEVITY
• Blankets do not normally wear out; rather their
longevity is decreased by smashes caused by
incorrect paper type or press settings.
• Checking and maintaining these at optimum will
certainly reduce the number of blankets used.
• A record log should also be kept showing date of
mounting as well as date and reason for its removal
from the press.
• Good recording enables the user to determine which
type of blanket lasts longer, and can prove useful if
claims against paper or board suppliers ensue.
» PRESS SETTINGS
• Press setting are best taken from the press
manufacturers handbook. In general, compressible
blankets should be overpacked by 0.05mm to 0.1mm,
28
 though most press manufacturers will specify the • Frequency of the wash will depend upon type of stock
packing required for conventional and compressible and ink used; obviously, a blanket should always be
blankets. Initially, follow the recommendations but washed when it fails to transfer ink properly.
if problems do occur, adopt procedures to check
settings.
• Blanket life can be extended by using the correct
» EFFECTIVE CLEANING

wash, washing method and mounting procedure.

Every step should be taken to prevent solvent coming • Effective cleaning of an offset blanket provides the
into contact with the back of the blanket. The blanket best insurance for its long life and high performance.
is designed to be undercut and thus wrap over the A correctly cleaned blanket assists the printer to
packing sheet to jam against the bearer, preventing produce consistently high quality work with the
solvent getting in underneath the blanket. minimum amount of press downtime and paper
spoilage.
• Cleaning or wash up procedures recommended
» FACTORS INFLUENCING BLANKET SELECTION
by different blanket manufacturers may vary. For
• Press types. this reason, litho technicians recommend close
• Inks & washes. consultation with the blanket manufacturers
• Printing substrate. representative concerning type and frequency of
wash.
» FAULT RECOGNITION & DIAGNOSIS • Consultation is particularly recommended in plants
where two or more brand name products are in use.
• Glazed blanket.
• Interference patterning.
• Fabric patterning. • Most manufacturers agree on two important points:
• Face removal. • 1) Do not allow ink and/or gum to dry on a blanket
• Blanket gapping. surface.
• Smashed blanket. • 2) Avoid the use of slow evaporation cleaning
• White specks in print (Hickies) substances such as kerosene; avoid chlorinated or
• Mottled print. coaltar solvents such as carbon tetrachloride, carbon
• Overall light print. disulphide, ketones, ethers or mineral spirits.
• Linting/fluffing.
• Slur.
• Embossed blanket surface, ghosting, KB ¨KAURI-BUTANOL
• Mis-register • The pressman must also take care that the blanket
washes he uses are matched to his ink and blankets.
• Pressure on the blanket. • Repeated use of a solvent easily absorbed by the
• Blanket hardness: rubber blanket will cause deterioration.
• A) shore hardness. B) micro hardness. • Washes with high Kauri-butanol (KB) solvents should
• Tensioning & torque wrenches. be avoided.
• A low KB number indicates low solvency power.
» MOUNTING & BLANKET CARE • A high KB solvent will be absorbed by the rubber more
easily and evaporate more slowly.
• Blanket problems can be eliminated by using precise
• Rate of evaporation is important.
mounting and tightening techniques as well as taking
• A low evaporation rate forces delays in reinking
careful thickness checks.
after a blanket wash.
• Problems are not confined to those blankets which
• Retained solvent increases the tackiness and
have produced thousands of impressions, they can
frictional co-efficient of the blanket.
equally occur after just a few hundred.
• Washes for heat set blankets should have a KB
• Unless the problem stems from irreparable damage, a
number of 30 (or) less.
pressman can usually correct the deficiency in a short
time.

» WASHING FREQUENCY
• Opinions vary on the method and frequency of
washing blankets. There are no hard and fast rules.

Web Offset Technology Class Notes 29

 THE INKING SYSTEM
• The inking system of the lithographic press consists of
a series of rollers that carries the ink from the fountain
to the plate.
• On blanket-to-blanket web offset presses, there are, of
course, two inking systems per unit: one supplying ink
to the top plate, and another to the bottom.
• The inking system has several important functions. Its
primary purpose is to deliver an even, controlled ink
film to the plate.
• The thick film entering the system on each ductor
stroke is split among many rollers, so that the
intermittent ink feed from the ductor is changed into
the continuous feed required by the plate.
• Second, the inking system deposits the ink film as
needed onto the plate. To do this, the system must
not only control the amount of ink flowing to the plate
around the cylinder, but must do so in the across-the-
cylinder direction as well.
• Third, the inking system acts as a reservoir to keep
color consistent between ductor cycles and from
impression to impression.
• Fourth, the inking system helps to control dampening
on the plate by picking up some water as the press
runs.
• Some of the water mixes with the ink, forming an
emulsion. Too much emulsification will cause the
pressman problems, but in controlled amounts,
emulsification is essential to the lithographic process.
• Some water is also picked up by the blanket and is
transferred to the sheet.
• The rest of the water evaporates and is of no further
concern to the pressman.
• Fifth, the inking system also helps keep the plate clean
during running by picking up foreign matter that may
collect on the plate.
• A roller specially designed for this purpose is often
used in one of the form roller positions.
• In general design, the inking system consists of (a)
a fountain holding a supply of ink, (b) a ductor or
transfer roller that carries the ink from the fountain
to the roller train, (c) a roller train that works
and distributes the ink, and (d) forme rollers that
deposit the ink onto the plate.
» Ink Fountain
• The ink fountain is a trough, shaped like a V tipped
on its side, holding the ink supply. The bottom of
the trough is a one strip of flexible steel (or several
number of) blade, called a fountain blade.
• The fountain roller, which forms the other side of the
ink trough, is fixed into the fountain assembly and
rotates in place.
• With most fountain rollers, the amount of roller rotation
Web Offset Technology Class Notes
per cycle of the ductor can be varied.
• On most presses, the fountain roller is driven by its
own variable-speed motor.
• Some fountain rollers cannot be adjusted at all but
rotate at a constant speed.
» Ink adjustment
• To avoid roller wear, the fountain blade should not
touch the fountain roller; instead, there should be a
narrow gap between the two. This setting is called as
zero setting the ink duct.
• Underneath the fountain blade on most presses is a
row of screws called fountain keys, evenly spaced
along the entire width of the blade.
• By adjusting the keys, the blade can be moved closer
to or farther away from the fountain roller, controlling
the thickness of the ink film across the roller.
» Ink adjustment
• In an alternative to the conventional screw-type ink
fountain key adjustment, the position of the fountain
blade relative to the fountain roller is controlled by an
eccentric roller or cam that in turn is controlled by a
lever.
• This type of ink fountain adjustment has been used
on some newspaper-type web offset presses. One of
the advantages of this type of control is the ease and
rapidity of adjustments. Another advantage is that the
position of the various control handles across the ink
fountain automatically give an indication of the setting
of the fountain blade across the press.
• The major disadvantage is that the precision of
adjustment available from either the conventional
screw-type or the newer remote control ink fountain is
not attainable.
Ductor roller
• A ductor roller that oscillates every few revolutions of
the blanket cylinder takes ink from the fountain roller
and deposits it on the first roller in the inking train.
The amount of ink put on the ductor and fed into the
inking train depends on two things:
• (a) the thickness of the ink film on the fountain roller
which, as explained above, is determined by the gap
between the fountain blade and the fountain roller, and
• (b) the amount of fountain roller rotation while in
contact with the ductor.
• The ductor roller “dwells” against the fountain roller
for a time, picking up ink, then swings over to the first
driven roller in the inking train and dwells against it,
depositing ink.
• This cycle is repeated periodically and fresh ink is fed
into the inking train as the press runs.
30
• The ductor is the only roller in the inking system that
swings or oscillates in this way.
• Because of the action of the ductor, fresh ink enters
the inking train intermittently, not continuously.
• The different diameters and rotation periods of the
rollers help smooth out the feed, making the ink flow to
the plate more nearly uniform.
» Ductorless” inking systems
• A number of “ductorless” inking systems have been
designed. the systems utilize metal rollers rotating in
place.
• Generally, the surface of these rollers has a raised
pattern, such as a spiral or diamond-shape, so that
only a fraction of the full roller surface carries ink.
• This is necessary because with a continuously rotating
fountain roller there is a tendency to supply too much
ink.
» Distributors
• Distributors, which transfer and help condition the ink,
have special mountings in the press frame, by means
of which they can be adjusted against adjacent rollers.
• Distributors are composed of an elastomeric material
containing mixtures of plastics, pigments, and several
other ingredients.
» Riders
• Riders are a special type of roller used in some inking
systems. Running against only one roller, the rider
further enlarges the inking system and works the ink
before it reaches the plate.
• Riders are also effective in collecting unwanted foreign
particles from the ink. By holding these particles on
their surfaces, the riders keep them out of the main
path of the ink flow.
• Soft riders are generally set against hard rollers, while
steel riders are set against soft rollers.
» Forme rollers
• The inking system rollers that contact the plate are
called ink forme rollers or, more simply, forme rollers.
Some presses have four forme rollers while others
have only two or three.
• The shore hardness of these rollers are 26 to 30.
» Roller glazing
• Rollers are subject to surface buildup of dried ink,
gum, and sometimes, paper coating material. This
Web Offset Technology Class Notes
condition is known as glazing; when it occurs, the
roller loses its ability to properly carry and transfer
ink. Periodic washup with multistep solvents is usually
enough to prevent glazing on the press.
» Stripping
• Steel vibrator rollers are subject to different problems.
Probably the most common one is stripping, in which
the roller becomes water-receptive because gum is
adhering to its surface.
• The usual cause of roller stripping is too much gum in
the fountain solution. But if the fountain pH is too low,
the tendency to strip is increased greatly because acid
improves gum’s ability to stick to the roller surface.
• The cure for a stripped roller is to vigorously rub the
roller down with pumice and water, and then go over it
with an etch.
• The etch is usually a diluted acid, such as acetic,
hydrochloric, or nitric acid mixed with water.
DAMPENING SYSTEMS
• The dampening system on a lithographic press wets
the plate down before the ink form rollers meet it.
• Dampening systems vary more widely in basic design
than inking systems.
» CONVENTIONAL DAMPENING SYSTEM
• The conventional dampening system is still
used, despite its comparatively slow response to
adjustments.
• In general design, conventional dampening systems
resemble those for inking.
• A supply of fountain solution is held in a water pan. A
brass or chrome-plated pan roller rotates in the pan.
• As the roller turns, it draws a film of water onto its
surface. It is usually driven by its own motor, separate
from the main press drive, or by a variable-speed drive
off the press.
• A ductor roller, which oscillates periodically, takes the
fountain solution from the pan roller and transfers it to
the surface of a metal vibrator.
• As in the inking system, the dampening ductor swings
back and forth between the pan roller and the vibrator.
Some slippage has to be built into the dampening
system.
• The pan roller cannot run at press speed without
throwing solution all over the press area, but other
dampening rollers run at press speed. The ductor
speeds up and slows down during its cycle to bridge
this speed difference.
31
• The ductor is made of a plasticized-rubber compound
and is always covered to increase its water storage
capacity.
• A vibrator is the next roller in the dampening system.
It is driven from the press drive and, like the vibrators
in the inking system, oscillates from side to side.
There is no setting adjustment on this roller, which is
permanently fixed in the dampener unit frame. The
dampening vibrator is usually chrome-plated steel.
• The dampener form rollers wet down the plate directly.
Most presses have one dampening form roller,
although some have two in use. Dampeners are
nondriven, rubber rollers, or covered with a cloth.
• Newspaper presses employ rubber rollers as
dampening forme.
• The conventional dampening system is an intermittent
feed system. Water does not move in a continuous
film from the fountain pan to the plate.
• The amount of water in the dampening system is
lowest just before the ductor contacts the vibrator.
Then water surges through the system when the
ductor makes contact.
• These surges of water make control of the
conventional dampening system difficult, and the
problem is more serious here than in the inking system
because the dampening system is so short.
• Because the problem is inherent in the design, the
pressman must learn how to control it.
• Absorbent cloth and paper dampener covers help to
provide more uniform dampening by increasing the
storage capacity of the rollers.
• Increased storage capacity in the dampening system
acts like a sponge, absorbing excess water and giving
it up when the supply becomes low.
• This produces a dampening flow to the plate that has
less variation and therefore delivers less total water.
The advantages of increased storage are better
control and minimum water delivered to the plate.
• The problems with large capacity dampening systems
are their slow response to changes. In such a system,
if the pressman wishes to increase the amount of
water, the dampening system is turned up and a spray
bottle is used to increase the amount of dampening
solution in the system.
» Dampening forme (molleton)
• The most widely used material for covering dampening
form rollers is cloth, usually a fabric called molleton,
woven as a sleeve, slipped over the roller and tied at
the roller ends.
• Molleton has a relatively long nap and is good for
Web Offset Technology Class Notes
storing water. However, it easily becomes greasy and
will release lint when new. In addition, depending
on how dirty or greasy it gets, its thickness can vary,
changing the effective radius of the roller.
• In effect, this change in radius changes the roller
setting, which in turn makes it difficult to maintain a
uniform film of water unless the pressman resets the
dampener rollers.
• Setting the pressure between the various dampening
rollers is critical. With too little pressure the rollers
won’t drive efficiently. Too much pressure will wring
water from the rollers and not enough will reach the
plate.
• The basic setting procedure is the same as that for the
inking rollers. Three film strips are used, or for more
accurate results, the metal tongue of a roller-setting
gauge may be inserted in place of strip.
• As in the inking system, the reference point used
in setting the rollers is the vibrator, which must be
parallel to the fountain roller and to the plate cylinder.
This should be checked periodically as part of long-
term maintenance. If the vibrator is not parallel, the
pressman should not attempt to reset it himself. Such
settings are extremely critical and should be made by
a press mechanic.
• In most cases, dampening form-to-plate pressure
should be less than that between the dampener and
the vibrator. Too tight a setting can “squeegee” water
from the plate and also increase plate wear. The ideal
is to set just enough pressure so that adequate water
transfers smoothly to the plate.
• To set the ductor, the printing unit is inched until the
ductor is at maximum pressure against the vibrator.
The film strips are inserted between the two rollers
and tested for drag. The strips should be inserted at
three or two points along the length of the ductor.
• The printing unit is then inched until the ductor touches
the fountain pan roller. Again, the strips are used
in three positions along the ductor to ensure correct
setting and alignment.
» Controlling flow of water
• All dampening systems meter, or measure, the water
into the press. On a conventional system, this is done
in two ways.
• The fountain pan roller is driven, though not by the
press drive. It has its own motor, which can be
adjusted for faster or slower rotation..
• The second adjustment in the dampening system
controls the length of time the ductor dwells against
the fountain roller.
• When the pan roller rotates at high speed and the
32
 ductor dwells against it for a comparatively long time,
water is put on the entire surface of the ductor. On
the other hand, when the pan roller turns slowly, and
the ductor dwells for a short time, only a narrow band
of water is deposited on the ductor. These are, of
course, extreme settings. The important thing is that
the flow of water to the plate be as continuous and
uniform as possible.
• Adjusting water feed by column is possible. This
involves the setting of special tabs, squeegees or
rollers called water stops against the surface of the
pan roller. This modulates the flow of water across the
press and is equivalent to closing the setting on the
blade in the ink fountain.
• Water stops are especially useful when running
narrow webs. Moisture will build up on the roller ends
unless water stops are used to hold it back.
• The smooth metal surface of the vibrator can become
greasy. The pressman can sometimes see it because
the film of water on the vibrator surface will be broken.
• Such a roller should be thoroughly rinsed with a
solvent that will cut grease. The solvent should then
be washed away with water, and the roller etched. (A
plate etch is fine for this)
• The roller should then be wet down to see if the water
beads. If it beads, the cleaning operation should be
repeated. If it doesn’t, the roller is ready for operation.
» CONVENTIONAL SYSTEM (flap)
• Another type of intermittent-feed system is the flap
ductor. Its pan roller has a removable covering of
canvas flaps, and the vibrator is mounted close
enough to the flap roller to touch the ends of the flaps.
Usually a single, molleton-covered dampener wets
down the plate.
• The principle of the system is simple. The flapper
“paints” the vibrator with solution. The faster the
flap roller rotates, the more solution is transferred to
the vibrator. A major advantage is that the system
eliminates ductor shock, which can be important on
larger, high-speed presses. The major disadvantage
is that the system makes it difficult to modulate water
feed across the press.
» Brush dampening system
• Continuous-feed systems starts with the elimination,
in one way or another, of an intermittent water supply,
thereby getting rid of some of the problems associated
with conventional systems.
• One major type of continuous feed is the brush
system. One brush system has the usual pan roller
with a brush roller mounted over it.
Web Offset Technology Class Notes
• The bristles of the brush roller ride in contact with the
variable-speed pan roller.
• The brush roller rotates at a constant speed and is set
at a constant pressure against the pan roller.
• This pressure is great enough to flex the bristles. The
bristles “flick” solution at the vibrator, which is not in
contact with the brush.
• The amount of solution fed is varied by changing
the speed of the pan roller, and water flow can be
modulated across the press by the use of water stops.
This system uses a single form roller which is usually
covered, but can be run bareback (without a cover).
• A second type of brush system is equipped with a
row of flicker fingers pressing against a brush roller
mounted in the pan itself. The fingers flex the bristles
and perform a metering function, the amount of flex
determining the amount of water flicked. The amount
of feed can be varied across the plate because each
finger is independently adjustable. The rotation of the
brush roller can also be varied to throw more or less
water on the plate.
• The settings between vibrator and dampener and
between dampener and plate on all brush systems are
determined by the film strip method. The uniformity
of the setting on the brush roller can be checked by
inserting a gauge .
• In operation, the brush roller should be set light
initially, then advanced to its proper settings. Heavy
setting can cause undue wear, which can break down
the brush roller. When this happens, the pressman
begins to find bristles on the plate, and those still on
the roller lose their flexibility.
• Some pressmen change the conventional dampening
system by running the dampeners bareback. This is
often done with brush systems because it makes the
entire system more sensitive (more rapidly responsive)
to changes in fountain settings.
• Alcohol is usually added to the fountain solution to
help bareback dampeners run efficiently. Alcohol acts
as a wetting agent and reduces the surface tension of
water, in effect making it “wetter”.
• This helps the uncovered rubber roller in picking up
solution and wetting down the plate.
• Isopropyl alcohol is being used in fountain solutions
on a large number of web offset presses. These
presses are usually equipped with one type of non-
conventional dampening system or another, although
alcohol is reportedly being used on many conventional
systems as well.
• Today there are a number of alcohol substitutes being
run very successfully on web offset presses.
• Although a lot of printers are having trouble running
33
 alcohol substitutes successfully, the problem appears
to be with the settings and maintenance on the press
rather than any problem with alcohol substitutes.
• In those pressrooms where press settings are
carefully controlled and press maintenance is good,
there seems to be no problem with running alcohol
substitutes.
» THE DAHLGREN DAMPENING SYSTEM
• The Dahlgren dampening system is quite different
from the conventional system.
• One of the Dahlgren’s main features is the use of the
first inking form as a combination inking/dampening
form roller.
• Another difference is that it does not have a ductor.
• The Dahlgren is a continuous-feed system, which is
one of its advantages.
• A very important advantage is the system’s rapid
response to changes in fountain settings, largely
attributable to the absence of storage capacity in the
system.
• The Dahlgren dampener consists of two rollers that
deliver water to an ink form roller.
• One of these two rollers is a chrome-plated steel roller,
the other is a soft roller.
• Which of the two is the pan roller depends on the
particular press requirements.
• Another feature, particular to the system, is that the
rollers are driven completely independently of the
press and their surface speed is not the same as that
of the plate. The hard roller in the system rubs against
a special first ink form roller. The rubber roller meters
the water film on the hard roller.
• The rotation of the form roller carries the water
deposited on it directly to the plate.
• Control of water supply is attained through speed
control of the two rollers as well as the adjustable
squeeze between them.
• Isopropyl alcohol, or a satisfactory substitute, is
required in fountain solutions run with the Dahlgren
dampening system. One of the differences this makes
is the replacement of some of the water, usually 20-
25%, with alcohol. A more important consideration is
the need to have the water film lay smoothly on top
of the ink-covered form roller. This is accomplished
by the wetting properties of either the alcohol or the
alcohol substitute.
• Setting the rollers on a Dahlgren system is different
from setting rollers on a conventional system.
The form roller is set heavier to the plate than
on conventional systems because the roller is
considerably softer. The form roller should leave a
stripe of about ½ in. (12 mm) or more on the plate
when “taking a picture” of roller settings.
Web Offset Technology Class Notes
• One variation on the Dahlgren restores a separate
dampening form roller to the dampening system, and
uses an oscillating roller riding in contact with only the
dampening form roller. According to the manufacturer,
this oscillator performs a “clean-up” job, preventing
foreign matter from working back from the plate
through the dampening system and contaminating the
fountain.
» Spray dampening system
• The design of the spray dampening system is unique.
Fine mists of solution are sprayed directly onto the
rollers system.
• The sprays come from a row of nozzles mounted on a
bar across the press.
• Each nozzle can be independently metered.
• There is no recirculation of fountain solution. This is
a distinct advantage in that fresh fountain solution is
constantly being used to dampen the plate.
• Because of the reduced exposure to atmospheric and
press conditions, there is little or no chance of any
changes in the fountain solution taking place. This
eliminates one of the big drawbacks encountered
with dampening systems that re-circulate the fountain
solution.
• The biggest problem with running this system is the
possibility of contamination of the individual pumps
and spray nozzles by minerals that are present in
most water supplies. Treating water so that it will not
clog either the pumps or the spray nozzles can be a
problem.
• The spray bar is located at an angle so that it sprays
down into an in-running nip. Depending upon the
physical location of the rollers and the dampening
system, this may or may not require the addition of
extra rollers.
XTRA NOTES
The Inking System
The inking system has 4 basic functions
1. Move the ink from the ink fountain to the plate.
2. Break down the thick charge of ink into a thin
uniform film around the rollers.
3. Work the ink into printing condition.
4. Remove image repeats on the form from previous
printing cycles. The inking system on sheetfed presses
usually has 10 rollers.
34
 intermittently or continuously, a fountain blade, which
It includes the following parts: may be a spring steel plate, steel segments or plastic
approaching the fountain roller at an angle and two
» 1. Ink fountain - fountain cheeks, which are vertical metal pieces that
contact the fountain roller edges. As the fountain roller
• A pan that contains the ink supply. turns, the majority of the ink is held back by the blade,
which is very close to the fountain roller. The distance
» 2. Ductor or ductor roller - between the blade and fountain roller is controlled by
the fountain keys.
• A transfer roller that alternately contacts the ink
• These can be used to control the amount of ink
fountain roller and the first roller of the inking system.
delivered to different areas of the plate. Ductor roller-
Often an oscillator.
The first roller in the train, feeds a metered amount
of ink from the fountain to the inking system by
alternately contacting the fountain roller and the first
» 3. Oscillators or vibrators - oscillator. A properly timed ductor roller contacts the
oscillator when the form rollers are in the plate gap.
• Gear or chain driven rollers that not only rotate but
This negates the effect of ductor shock, the vibration
oscillate from side to side.
sent through the system when the ductor first contacts
Distribute and smooth out the ink film and erase image
the oscillator.
patterns from the form roller.

» Oscillators -
» 4. Intermediate Rollers - • Accepts ink from the ductor, passing it onto the
remaining rollers in the train where the ink is worked
• Friction- or gravity-driven rollers between the ductor
down to a smooth film. An inking system has several
and form roller that transfer and condition the ink.
oscillators (also called drums or vibrators) which are
Often called the distributors if they contact two rollers
usually made of steel tubing covered with copper,
or riders if they contact a single roller (such as an
ebonite, nylon or some other oil receptive material.
oscillator).
They move laterally (side to side) at least once every
revolution of the plate cylinder. This smoothes out the
ink film and reduces banding.
» 5. Form rollers -
• A series of 3 or 4 rollers (usually differing diameters) » Distributors -
that contact the plate and transfer ink to it. The series
of rollers is often called the roller train. The roller train • Resilient rollers that carry the ink from one oscillator
is composed of a series of hard and soft rollers. This to another. Driven by surface friction contact with
long roller train is necessary because of the unique oscillators.
character of the paste ink. The ink is both thixotropic
and pseudoplastic (shear thinning). » Riders -
• This property causes the initially large apparent
• Hard rollers that make contact with only a single
viscosity to be greatly reduced under the shear
roller and do not transfer ink. Help condition the ink
provided by the rollers. The apparent viscosity
by increasing the ink path and collect debris such as
decreases with time under a constant shear rate
paper fiber and dried ink.
and also decreases with increasing shear rate. The
hard rollers are usually steel covered with copper,
ebonite or nylon. The soft rollers (ductor, intermediate » Form rollers -
and form) are made of synthetic rubber or other
• Several (2-4) resilient rollers that contact the plate.
polymer. They may be PVC (polyvinl chloride),
Usually have different diameters to reduce mechanical
Buna-N (copolymer of butadiene and acrylonitrile) or
ghosting (ghost image appearing in the printed image
polyurethane. due to uneven ink take-off from the form rollers). They
lift off from the plate when the press is idling.
» Ink fountain -
• Trough that holds the ink supply. The ink is formed
by the fountain roller, a metal roller that turns
Web Offset Technology Class Notes 35
 Dampening Systems
» The conventional or Direct dampening system
The conventional or Direct dampening system employs
a fountain roller which picks up the fountain solution
in the fountain pan. A ductor roller takes the fountain
solution from the fountain roller and passes it to a
distributor roller. From here the fountain solution is
transferred to the offset plate via one or two fountain
form rollers. The ductor and form rollers (rollers that
contact the plate) of the system usually have a cloth or
paper cover which some printers call a “sock”. In years
past they were known as “molleton” covers. Today the
rollers are covered with 3M paper sleeves or a fabric
type such as Veratec Red Runners.
A drawback of this system is the slow reaction time in
making adjustments due to the “back and forth” action
of the ductor. Also the cloth covers become soiled with
ink and need cleaning, otherwise they can transfer the
ink to the non-image areas of the plate.
» The Indirect conventional dampening system
The Indirect conventional dampening system feeds the
fountain solution directly into one of the ink form (roller
that touches the plate) rollers. This system is known as
“indirect” since the fountain travels to the plate via an
ink form roller and not directly to the plate as the above
system does. Some indirect systems, such as the one
Web Offset Technology Class Notes
shown on the right, will have the ability to feed the
fountain solution into the ink system as well as to the
offset plate. A ductor roller still picks up the fountain
solution and transfers it to the transfer rolls and then to
the form rollers. Most newer presses today, however,
do not employ the ductor roller but use a continuous
feed system (see inset).
A fine emulsion of ink and water is then developed on
this ink roller. This is one reason printers need to know
about “water Pickup” or what percentage of water can
be taken up by the ink. This system is also known as
an “integrated” dampening system as it is integrated
into the ink system. One of the benefits of this system,
is that is does not use covers thus it reacts quicker
when dampening changes are made.
You generally find this type of dampening on newer
and faster press equipment today.
» The continuous dampener
The continuous dampener is actually a roll type coater.
There area two types of continuous dampeners - one
type feeds fountain solution directly to the plate and
the other feeds it directly into the ink system. The
continuous dampener uses a four roller system:
• Fountain Pickup roller
• Slip roller
• Transfer roller
• Water form roller
36

The slip roller controls the amount of fountain solution
supplied to the plate. Speed the roller up and you feed
more fountain solution. Slow it down and you supply
less. The use of alcohol on these type of dampeners
was standard for years. Alcohol (Isopropyl Alcohol)
was used as it increased the fountain solution viscosity
and made it “more wettable” so that transfer was
easier from one roller to the other. The Government,
however, has pushed to eliminate the use of alcohol
as it is contains VOC’s (Volatile Organic Compounds).
Alcohol substitutes such as Glycol ethers, Butyl
Cellusolve, etc., are being used today to accomplish
the same task. Roller hardness is also being changed
to help accomplish the same job - easy transfer of the
fountain solution.
Continuous dampeners can either feed directly to the
plate (above) or directly into the ink system (right).
Advantage can vary but usually is determined by the
press manufacturer.
Recall that most lithographic plates function on the
principle of water and ink receptive areas. In order for
ink to adhere only to the image areas on the plate, a
layer of moisture must be placed over the nonimage
areas. The dampening system accomplishes this by
moistening the plate consistently throughout the press
run.
Web Offset Technology Class Notes
» The Dampening System
• The dampening system applies a aqueous
dampening solution to the plate before it is inked. This
keeps the nonimage area moistened to that it will not
accept ink.
• Gum in the fountain solution adsorbs on the
nonimage area to keep it water-wet. The gum does not
adsorb on the image area which is not water-wet. This
area is generally oil-wet.
• A concentrated form used to mix a fountain solution is
called fountain concentrate, fountain etch or just etch.
These usually contain Gum Arabic or synthetic gums
for desensitizing.
• Most dampening solutions are acidic (pH 4-5)
because the gum performs best under acid conditions.
Recall that the gum reacts with and attaches to the
Aluminum oxide surface of the plate.
Other material contained in dampening solution are
1) corrosion inhibitors to prevent reactions with the plate,
2) a pH buffer, wetting agents such as isopropanol or its
substitutes,
3) a fungicide to prevent mildew and the growth of fungus
and bacteria in the dampening system, and
4) an antifoaming agent facilitate even distribution of
dampening solution. Some concentrates may require
37
 added alcohol in addition to water.
• Water - The effectiveness of dampening solution
depends on local water supply. Hard water requires
stronger acid than soft.
• To assure the most consistent performance, use
distilled or deionized water. The plate wetting
characteristics depend on surface tension of
dampening solution.
• This is reduced by both the gum (surfactant) and the
alcohol (cosurfactant). The alcohol also increases the
viscosity of the dampening solution which allows a
thicker layer of dampening solution to be applied to
the nonimage area of the plate.
• The alcohol evaporates faster than water so that less
dampening solution reaches the paper. The alcohol
reduces the tendency of ink to emulsify into the
dampening solution.
systems.
The AB Dick and Ryoobi duplicators are examples of
presses which employ integrated dampening systems.
3. Continuous flow dampening systems do not employ
ductor rollers to deliver dampening solution. There
are two types, inker-feed and plate-feed. Both use
metering rollers instead of ductors. The inker-feed
systems operate similar to integrated dampening
systems in that only one set of form rollers are
employed. The plate-feed have separate ink and water
trains like conventional dampening systems and may
employ cloth wrapped form rollers.

» Types of Dampening Systems

Dampening systems are classified by whether the

water flow is intermittent or continuous and whether
cloth form rollers are employed to transfer fountain
solution to the plate. Of the possible combinations, 3
are in use.

1. Separate (from inking system) dampening system

rollers with cloth covered form rollers and ductor
rollers in both ink and water fountains. Usually called
Conventional dampening
systems.

The Heidelberg Kord as

shown next is an example of
a conventional dampening
system.

The Hamada 600 CD

duplicators also have
conventional dampening
systems.

2. Combined (ink and

dampening) - consists of
rollers which carry fountain
solution to the plate on
ink covered rollers. Ductor
rollers are included in both
fountains. Since there is no
distinction between ink and
dampening form rollers, no
cloth can be used on the
form rollers. These are called
integrated dampening systems or indirect dampening

Web Offset Technology Class Notes 38

 Web Offset Machines
The machine on which a web of paper or any other
material is continuous feeding is printed, is called web
offset printing machine. In this process, the unwinding
of paper reel is a continuous feeding system from start
to the delivery part of the machine. Web-fed offset
printing machines were invented to overcome the
problems of sheet-fed single and multi-colour printing
machines. The registration and carrying of sheets from
pile board to the delivery board has also complicated
mechanisms.
Printing machines of such principles are designed
into different units. Number of units of a machine are
designed according to the different requirements of
the nature of jobs to be printed. The size of the web to
be fed and printed in the machine differs according to
the size of the machine and jobs. Web offset machines
are being used for printing books, newspapers,
magazines, stationery materials etc. there is very
slight difference in all the above job suited machines.
Generally, web printing machines are made in one
to four units. The whole machine may cover a floor
length of 8 to 13 meter and may be 2.5 to 3.5 meters
high. Therefore it is necessary to divide the important
parts of the huge machine into some groups for
detailed study.
» Design of web machines
Web-fed offset printing machines are designed to print
both sides of the paper at a time. For this purpose,
these machines are made into one to four units. Each
unit of the machine prints both side of a web in one
colour.
In this way, each unit of a web-fed machine requires
one reel stand to hold its reel and print it on both
sides but generally, it is not so. Most of the multi unit
machines have one or two extra units, Which do not
need separate reel stand. The extra units are used to
print another colour on any side of the web. Therefore
it is obvious that one unit of web-fed machine must
have two plates, two blankets and two impression
cylinders. In the same way, each unit should have two
inking and two dampening systems.
Besides the above main features in one unit, there
is web controlling device which look like another
unit. The machine is so designed that all the webs
of each reel fetch first in this unit and get proper
tension. Thereafter all the webs are forwarded into
their printing units. After printing all the webs through
Web Offset Technology Class Notes
different units, they reach overlapping on the kite
former.
The end par of the machine is called delivery unit.
Here all the webs are folded once, twice or thrice as
required.
Some of the machines also have slitting, cutting,
stiching and other attachments. In this way, these
machines produce complete printed books or
magazines at the delivery part. Some of the machines
produce 8 to 16 page sections only folded and slitted.
The covering and stitching operations are performed
by hand or seprate machines are used.
» Driving Mechanism
From the above description, it is obvious that web-fed
offset machines are so designed that they cover a
large area on the floor. Hence the driving mechanism
of such machines also has large field to study in detail.
The main driving features are described as under in
different groups.
» Eelectrical Arrangements
Web offset machines containing three or four units
require nearly 40 horse power motor to drive all the
parts of the machine. The electrical arrangements to
control and maintain the operations of various parts
are provided in one or two large almirahs. These
almirahs are fitted about two meteres away from the
machine.
The almirah contains main electric switch controls the
current coming from out side. Beside, this, separate
electrical arrangements in the almirah are provided for
driving the main motor of the machine, compressor,
pumping dampening water and other functions.
Various electric wires go out of almirah and are
assembled into the consol (control) box. All the wires
have different switches and are connected with the
operating parts of the machine.
» Controlling box
Most of the web offset printing machines have a
controlling box fitted nearly 1.5 to 2 meter away from
the machine. To controlling box is installed near the
delivery part of the machine to easily check and
control the quality of printing. All the operating and
controlling connections come in it from the electrical
almirah. The same are then joined with the functioning
parts of the machine.
39

The controlling box has various switches to control the
functions of the machine which are as follows:
• Lock of the machine: It has a locking point to lock
and open all the functions of this box. The locking
and opening of the box is done through a key like the
ordinary locks.
• Operating switches: One top of the box, these are
more than 20 to 40 switches to inch, show, run the
machine etc. It has also a switch to stop the running
machine. Besides these, the box has two switches
on for reducing and another for increasing the speed
of the machine. Some of the machines have only two
switches for this purpose. The pressing of the switches
increases of reduces the speed of the machine.
Generally, web-fed machines are made for more than
10 to 30 thousand impressions per hour and run at
nearly half or three fourth of the maximum speed.
Separate switches are provided for compressor motor,
impression and off, reel tear prevention and water
dampening. One switch is also there for reverse
running of the machine. In this way, various switches
are for different functions, adjustments and controls.
• Counting machine: Some of the web offset printing
machines have only one counting machine in the
controlling box or at delivery part. Generally, some
of the controlling boxes have two counting machines
along with their switches.
Only one counting machine is used at a time and
another is stopped. The counting machine of the
controlling box receives signals from the counter
fitted at delivery part of the machine. These counting
machines count the number of copies being printed.
The counted numbers of the machine generally
multiplied by 2 or 10. It becomes very easy to see the
counter and stop the machine.
Different designs or marks are also made near all the
switches do denote the function of the switch. Small
web offset machines equipped with one or two units
or one side printing units have small controlling boxes
fitted in the body of the machine near the delivery part.
» Machine driving
To drive the large size web offset printing machine a
heavy horse power main driving motor is provided.
Nearly 30 to 40 H.P. motors are used in these
machines. Four to six belts are fitted on the motor
pulley, which join with the main driving wheel of the
Web Offset Technology Class Notes
machine. There is a thick shaft in the center of the
driving wheel. Its other end has a gear whose teeth
mesh with the gears of each unit driving shaft. Each
cylinder of the printing unit revolves through the gears
fitted in the driving shafts of the unit.
At each unit, the driving shaft has a helical gear
to revolve the cylinders and inking rollers. All the
functions of the machine are performed through these
gears attached with the main driving shaft.
» Oiling systems
Such type of huge and large machines have many
number of frictional parts. Obviously they need proper
lubrication. Web offset printing machines are equipped
with pump mechanism. On top of each unit gear box
has continuous lubricating systems through pump
mechanism. On top of each unit there is a small glass
cap to see whether he oil flow is continuous or not.
Beside, all unit gear boxes and other frictional parts
are also joined with the oil pipes. The mobil oil flows
through the tubes and reaches upto the frictional parts
of the machine have spartat small oil tanks. These oil
tanks are filled with mobil oil when needed.
Web-fed machines have a number of small and
large bearing. Each tension roller, forwarding rollers,
oscillating rollers, some of the steel drums and
cylinders have bearings, which require lubricating daily
or after a week or two. Good quality grease should be
applied in the bearing by a grease gun or by hand and
oil by oil gun or by oil can. Large sized 4 units web
offset printing machines requires nearly 5 liter mobil oil
in each unit gear box after a week or two. Generally,
the gears of the cylinders have continuous showering
of mobil oil through pump circulating system.
» Reel stand unit
The first and very important part of a web-fed offset
printing machine is reel stand. The side walls of the
stand are fitted on the floor. Different types of reel
stands are named as single, double and revolving
systems. Single reel stand has only one reel, double
stand has two reels and revolving type of stand may
have two or three at one place. Revolving reel stand
has automatic reel changing device. A reel of paper
is suspended in a shaft and fitted on the stand. It has
a knife, gumming brush and paster arm for changing
new reel automatically in slow running.
40
 Following are the main working parts related with the the shaft between two wedge shaped couplings.
unwinding and pre-infeed system of a reel.

The round plate has two or three holes to insert the

pin of the lever, which is used to tighten or loosen the
reel in the reel shaft. The round plate acts as a puller
to pull the reel in the required position. The reel is
very firmly tightened or easily loosened by turning the
» Reel shaft round plate.

A thick steel rod is inserted in the central hole (core) of » Brake wheel
the reel. There is one wedge shaped coupling at one
side and a round plate on the other side of the shaft.
One side of the shaft has a screwed part in which
a round plate is inserted permanently. Two wedge

One more round but wide wheel is fastened at one

shaped couplings are inserted in the shaft, one near

the round plate and another at the opposite side of
the reel shaft. In the opposite side, wedge shaped
coupling is loosened or tightened in the shaft by an
alen wrench for adjustments.
First of all, the shaft is inserted in the hole (core) of the
reel. The thinner side of the opposite side coupling,
is inserted in the hole of the reel and hammered a
little. After that it is tightened by alen wrench. Now
the round plate is turned in shaft’s screw, the shaft is
pulled through this and the reel is firmly tightened on

Web Offset Technology Class Notes 41

 end of the reel shaft. The brake jaw is tightened on
this wheel. The brake wheel is made of smooth steel
nearly 15 cm wide and 15 cm in diameter. The brake
is loosened by pressing a paddle and then the reel
with shaft is taken out. The brake wheel and the puller
plate do not come the reel shaft, when the shaft is
taken out after finishing the reel.
Through the continuous brake system, the web does
not become loose when the machine is stopped.
» Tension rollers
Besides that, the web is pulled towards the printing
units in required tension.
» Lifting and lowering the reel
The finished reel of the shaft is lowered for changing
the new. The reel with the shaft is lifted-up after
tightening the reel in the shaft. This function is done
by rotating a large wheel. The brake wheel is set into
the brake jaw and the other end of the rod is set in its
place and tightened firmly.
» Checking of momentum
I n older web-fed printing machines, there is a large
The lock of the brake wheel is tightened with a screw
and bolt by hand. After that the reel along with the
shaft is lifted-up by rotating the wheel.
» Centering the reel shaft
Web-fed machines have a switch board for different
adjustments of the reel after fixing it on the reel stand.
There are switches for shifting the reel both sides. One
switch is provided for slow and one for fast running of
the machine. A small motor is separately provided to
Web Offset Technology Class Notes
perform these functions. This motor is fitted near the
opposite side of reel shaft.
When the reel centerting or shifting switches are
pushed, the mechanism fitted on the opposite side
of the reel shaft pushes or pulls the reel shaft. In this
way, the reel shaft as well as the reel is adjusted
wherever required. This mechanism is meant for
adjusting the side margin in the web in order to
achieve corrent registration.
After the reel is set in its proper place, one end of the
web of the reel is taken out and forwarded through
an idler and tension steel roller. The very important
roller which exerts first tension in the web is called
tension roller. The web is set under this roller. This
roller continuously vibrates up and down. The web
remains in required tension from beginning to the end.
The tension roller adjusts the speed of the revolutions
of the reel gradually from starting a new reel and upto
the last.
A new reel has a large diameter and it gives greater
length of web in one revolution. Gradually, the
diameter of the reel reduces and it gives less length of
web in one revolution. Due to this factor, the tension
of web may have to be adjusted every time which is
not possible. When the speed of the web changes in
the running time, the problem of loosening or excess
tightening of the web occurs. Swinging or vibrating
type or tension roller is fitted in each web-fed machine
to overcome the problem.
leather belt (strap) which continuously presses nearly
the half of the peripheri of the reel. This belt generally
goes towards the feeding side in the similar speed
when the diameter of the reel is reduced. This belt
was used for giving continuous brake to the reel to
maintain even tension in the web and also to control
the momentum of the reel.
The function of the idler and tension roller is done
through a long spring attached with the reel shaft
towards the brake system. Besides the main tension
roller, there are five to six other rollers to maintain the
tension of web as directed by the tension roller. The
42
 web is set on all these rollers to produce even tension
at slow and high speeds. Each of the roller is made of
steel and revolves freely on its bearings by the friction
of the moving web.
• The last and fourth process is to cut the finishing web
All these systems and mechanisms are made for all
the reel stand units. The machines using three or four
reels, have all the same arrangements for each reel
stand.
» Automatic reel changing
The manual reel changing process requires stoppage
of the machine until the next reel is set on the stand.
Therefore, valuable time on the machine is saved by
» Web control unit
changing the reel automatically.
For automatic change of the reel, a new reel is fitted
in its shaft and set on another reel stand which is fixed
similarly as the running reel. When the reel is about to
be finished, the following operations are done by the
operator.
• T
he new reel stand is slowly revolved towards the
finishing web. The new reel and the finishing web are
maintained parallel in the splicing position. Nearly 10
to 15 mm distance should be maintained between the
new reel and the finishing web.
• The speed of the running web and the new reel are
operated in the similar speed. Some of the machines
are equipped with variable speed motor in each reel
stand, which is necessary for correct splicing and
controlling even tensions in both the webs. The cline
system is very suitable for perfect jointing of the
webs. In this system, there are bands which press
the spliced part of the web in running position. In the
cline system, specially prepared powder adhesive is
sprayed on the splicing part of the web. The powder
becomes an active adhesive after spraying a specially
prepared solvent.
• In the third process, automatic gumming in the splicing
Web Offset Technology Class Notes
part of the web is done. The gumming is done by a
brush. The whole width of the splicing web is gummed
automatically.
by a knife. The cutting of the web is so set that the
knife should come into action after one revolution of
splicing the web. After cutting the web, its braking
device stops the reel stand to avoid unwanted opening
the remaining reel. Before cutting the used web, the
spliced web is pressed by an arm to ensure perfect
joining of both the webs.
Some of the machines do not have this system as a
separate unit. They have larger number of forwarding
and tension rollers before the web is fed into the
printing unit.
Generally, such type of printing machines have
crosswise or angular tension rollers and web transfer
rollers. The latest web offset printing machines, which
have blanket to blanket printing principle, are equipped
with the system of separated web control unit.
The purpose of this unit is to create sufficient tension
in the web before it enters the printing cylinder,
because the web may have some looseness when
it rewinds and forwards to the printing units. All
the printing webs have to enter this unit through a
separate set of tension cylinders. The main parts and
adjustments of this unit are as follows.
Tension control unit:
This is the unit through which all the webs have to
enter for the removal of any type of looseness and to
reduce the speed. It has two main cylinders. One is
made of steel and the other is rubber covered.
The steel cylinder is driven through P.I.V. gear system.
The rubber cylinder revolves on its bearings. The web
enters between these two cylinders. The web forwards
under the pressure of both these cylinders. Thus the
speed of the web is reduced. It is necessary that the
speed of the web should be reduced before it enters
the printing unit.
P.I.V. gear system:
The tension of all the webs is reduced or increased
through this system. It has various gears of different
43
 sizes. The mechanism is assembled in a box. The
different switches, adjusting points and tension
denoting dials are set on the box.
The speed of main geared steel cylinder is controlled
by this system. It is fitted before entering the web into
the printing nits. P.I.V. gear boxes are fitted in most
of the web-fed printing machines for each web. The
machines using three webs for printing at a time, are
equipped with three P.I.V. system separately.
The tension of the web is measured in the unit “Kg”
per 15mm. An approximate average of maintaining of
tension in the web through out the machine is given as
under:
1. Infeed unit tension 20-25 kg. per 15 mm
2. Printing unit tension 25-30 kg. per 15 mm
3. Delivery unit tension 30-35 kg. per 15 mm
According to the above facts, the tension in the web
should be adjusted through the P.I.V. gear system to
prevent the tearing of the web.
Some of the machines are equipped with even tension
in all the webs. Speed of each unit is reduced or
increased by a adjusting wheel. The speed adjusting
wheel and round plate are fitted in the outer wall of the
unit to decide the tension of the web. The round plate
is marked from 0 to 80 numbers. A long needle is fitted
in the center of it which shows tension per meter in the
web.
» Web cleaner
A steel strip like blade is fitted along with the rubber
roller. The rollers set in contact with P.I.V. geated
steel roller. The distance of this blade from the rubber
roller is so set that the web should slightly touch it.
The purpose of this blade is to clean the dust, dirt and
other unwanted materials sticking on the surface of
the web. Any unwanted material in the web will reach
upto the blanket and plate cylinders which may bladly
affect the quality of printing.
» Photo-electric cell
The tension controlling unit has a photo-electric
cell fitted near the P.I.V. controlled steel roller. The
machine is stopped automatically if the tearing and
other disturbances occur in the web.
Web Offset Technology Class Notes
» Web infeed system
In multi-web offset printing machines, two or more
webs are used for printing. If all the webs are to be
printed in a single colour, the most distant web is fed
into the first printing unit, the second distant web is
fed into the second unit and so on. For multi-colour
printing, the web enters the next unit and then reaches
upto the kite former.
In the distance between the tension controlling unitand
printing unit, the web moves forwd on steel forwarding
roller. These rollers revolve on theirbearings through
the pulling action of the web. Generally, most of these
rolles are covered with steel grained strips. In some
machines, these rollers have vaccum suction to stick
the web along it. It also maintains the even tension all
through the web upto the delivery unit.
The tension and forwarding rollers may be lifted and
lowered upto some extent. The tension of web is
reduced and increased by this adjustment.
The steel grained rollers pull the web and prevent the
set-off or unwanted markings in the printed web. One
or two grained or plain rollers are fitted there before
entering the web into the printing unit. After printing,
the web forwards on a number of grained rollers and
reaches the kite former.
» Web transfer rollers
These rollers are also called turner bars. The
machines which print only one side of the web by its
one unit, are generally equipped with web transfer
(turner) rollers. For printing the other side of the web,
it has to enter the next printing unit or the next set of
printing cylinders of the same unit.
The blanket to blanket system of printing machines
has straight web feeding device. It does not need the
change of side of the web. The web forwards through
the grained rollers set on top of the printing units or
between the units.
The different types of web turner devices are given in
the diagram.
» Angular turner bars
44
 In this system, the straight web is turned by right angle
on the steel bars. All the bars are fixed at 45º angle
instead of straight travel direction of the web. The side
of the web is turned through this process to print the
other side of the web. These angular turning bars are
set after each printing unit.

Besides it, some of the machines have blowing

device, the web is halfed and both the webs are turned
into the same path through turner bars. The webs
forward into the folding unit. This process requires two
turning bars to turn both webs into correct position.

» Printing Units
Principally, all functions of a printing unit of web-fed
machines are nearly similar to the sheet-fed machines,
excepting some of the parts which are designed
according to the path of web direction. Some of the
controls are also of different nature. Most of the web
offset machines are equipped with various controlling
switches fitted on the working side of each printing
unit. There are switches for stop, start, run, slow,
operating the dampeners, ink controlling and reverse
running.

Different designs of units of web-fed offset machines

may be divided into following groups for detailed study.

One side printing units

The older principle of printing units is one side printing.

are holes in the turner bars to create cushion of air

between the web and the turning bars. The air cushion
minimizes the friction of the web and prevents the
breaking and other troubles.

Some of the machines have slitter device after printing Such type of printing machines have been designed
and before reaching the web on the kite former. By this into 2 to 4 units. Each unit is made into separate

Web Offset Technology Class Notes 45

 sections but joined with each other through continuous
gearing systems. It is also called in line or open
system of printing units.
Each unit has one plate cylinder, one impression
cylinder and one blanket cylinder as main parts.
Besides it, each unit consists of one inking and
dampening system as equal. Printing by magnetic
inks, carton printing and moisture-set inks may be
done on these machines. Continuous stationery works
in perfect delivery may also be done on such type of
machines.
One side of the web is printed by one unit and the web
is turned through the turner bars. After changing the
printed side, the web enters in to the other unit and is
» Main Parts of Printing Unit
printed on the other side. For multi-colour printing on
the same side, the web does not turn but it may be set
to go ahead straight to the next unit.
Blanket to blanket printing units
Such type of printing machines are also called both
side printing system of web offset printing unit. The
web forwards straight into all printing units.
Plate cylinder
These machines do not have impression cylinders.
Only two plate and two blanket cylinders
are fitted in one unit. The web passes between two
blanket cylinders and prints both sides of it in one
insertion. In this principle, and extra plate cylinder can
be set to print spot colour. Generally, heat-set inks are
used in these machines. Inking, dampening and web
forwarding systems are almost similar to the others.
Satellite system of units
It is named satellite system of printing units due to its
design of path of web. The web is printed through half
of the circumference of the impression cylinder.
In the next round, the web is printed through the other
half of the circumference of the impression cylinder.
After printing one time, the web passes through the
turner bars and the side of the web is changed. After
that the web enters the printing unit for printing on
its other side. Such type of web-fed offset printing
machines are designed with only one large impression
cylinder. Two, three or four blanket cylinder are fitted
around the common impression cylinder.
All the blanket cyliners are set after some distance
from each other but all the them are set in contact
the common impression cylinder. All the blanket
cylinders are equipped with plate cylinder, inking and
Web Offset Technology Class Notes
dampening systems. These machines have a drying
cylinder which helps in the drying of ink after an
impression and before turning the web.
In this way, the printed ink of one side is perfectly dried
before turning. This is necessary because the wet ink
of the web may create smudging or set-off due to the
friction with the turning bars. Satellite system of web-
fed offset printing units has a device to disconnect
any unit of blanket and plate cylinder. It facilitates
the requirement of selection of multi-colour or single
colour jobs.
Printing unit of web-fed offset machine consists of
three main parts i.e. plate cylinder, blanket cylinder
and impression cylinder. These three main parts of
a printing unit are also equipped with a number of
devices for different purposes. Detailed description of
all the main part is given as follows.
The plate cylinder of web offset machines hold
printing plate. The driving mechinism and bearers
etc. are almost similar to the sheet-fed machines. The
difference is in the gap of both cylinders. The web
offset machine’s plate cylinder has a very small gap
only just to fit the plate clamps at its both edges. It has
plate tension screws and tightening bolts. Cylinder gap
in web machines is nearly three cm.
The gap of the plate cylinder causes white margin
on the head and tail of printed pages after each
impression. Both the longer edges of plate are
screwed with two flat clamping of the plate is done out
side the machine. After that both the clamps along with
the plate are set into the cylinder gap and tightened
with the bolts.
In some of the machines, the plate does not need
any bar or strip. Only the edges of the plateb are bent
and fixed into the cylinder gap. The plate edges are
tightened and stretched as usual. A long steel strip
like a blade is fitted just near the plate cylinder. This
plate is a safety device to prevent the operator’s hand
from accident when dampening or gumming, while the
machine is running.
There is a device for the plate cylinder in lateral and
peripheral direction. It has two handles or levers
for shifting the state of plate cylinder. Some of the
46
 machines have line marks around the projected
shaft of the plate cylinder. These marks are very
successful for registration purpose. The line marks
are considered for shifting the cylinder into lateral and
peripheral direction.
Some of the latest machines have a device to push
or pull only towards the operating side of the plate
cylinders. The one side tilting of the plate cylinder is
made to equalize the margin of the plate edge. After
correcting the edge of the plate, registration is done as
usual.
Contact of plate cylinder with the blanket cylinder is
made through a switch. The function of it depends
on the air pressure of the compressor. This device
helps the insertion of the web without its receiving any
impression from the plate cylinder.
Besides it, some of the machines do not require
to throw off the plate cylinder. Only inking and
dampening systems are thrown-off. In this way that
plate cylinders are not supplied with water and ink.
The web inserted into the printing unit goes forward to
the next unit without printing.
Plate edge bending
For bending both the edges of the plate, an ordinary
manually operated machine is used. It is equipped
with a steel table and a flat part on which the bending
plate is placed. Two screws on one side are raised are
used as a guide for definite margin in the plate. The
crews are removed and both side pressing handles
are dropped. By this, one edge of the plate is pressed
and bent. Both edges of the plate are bent as required
in the same way.
Generally, the printing plates for web machines
does not require to be punched as in the sheet-fed
machines. The excess length of the plate and the
corner edge are also cut by the bending machine.
Blanket cylinder
The mechanical features of the blanket cylinder are
almost similar to the plate cylinder. Its gap, driving
gears and bearers have this same purpose.
The blanket is cut into a definite size. The larger edges
are punched and then it is placed between the gap of
the clamps. Then the clamping strips are screwed on
both longer edges of the blanket outside the machine.
The screws are provided at 2.5 cm distance nearly.
The blanket is cut slanting under all four corners to
Web Offset Technology Class Notes
avoid creasing, when it is fitted on the blanket cylinder.
One edge of the blanket is clamped and tightened in
the gap and then the machine is slowly run. When
the cylinder gap comes back in position, the other
edge is also clamped. In the end, the blanket clamp
is tightened and tensioned by the screws and bolts.
Generally, most of the bolts are tightened by “L”
wrench.
Blanket to blanket web printing machines have two
blanket cylinders in one unit. Both are set in contact
with each other. Both the cylinders revolve through
their gears. The web passes through both the blanket
cylinders. In this way, both sides of the web are printed
at a time. The surfaces of both the blanket cylinders
receive impression by the plate cylinder. Then the
impression of the blanket cylinder is transferred on
both sides of the web at a time.
Impression cylinder
One side printing machines are equipped with the
impression cylinders in each unit. In this way, such
type of web printing machines are equipped with all
three (Plate, blanket and impression) cylinders similar
to the sheet-fed machines.
The web passes between the blanket and impression
cylinder to receive print only one side of it by one unit.
Such type of web machines have four units to print
both side of the webs of two reels. The impression
cylinder is a plane steel cylinder having driving gear
on its one side. The cylinder revolves along with the
blanket cylinder due to the meshing of this gears.
The impression cylinder may also be called pressure
cylinder because its purpose is only to exert pressure
on the blanket cylinder. Due to its pressure, the
reverse image of the blanket cylinder made by
the plate cylinder is transferred on the web. The
mechanism of bearers, gears and other parts are
generally similar to the sheet-fed printing machines.
The impression cylinder does not need gap like the
plate the blanket cylinders.
» Inking System
The inking system of web-fed offset printing machine
is also similar to the sheet-fed machines. Ink duct,
vibrator, grinders, distributors and all the plate inking
rollers are similar to the similar to the sheet-fed
machines in principle and function. Only the number
of rollers differ from the sheet-fed machines. Web-
fed machines are equipped with a greater number of
47
 rollers for all inking functions. Due to very fast speed
of web-fed machines, they require fast distribution of
ink.
Therefore the inking rollers, riders and oscillators are
made of different diameters in web-fed machines.
Even then the oscillating distance of all the oscillators
differs from each other. The uneven oscillating
distance causes fine and fast distribution of ink.
In web-fed machines, the ink duct fountain roller
revolves continuously. The vibrator touchesthe duct
roller according to the required ink for printing only
one impression. Automatic clearing device is fitted with
each set of printing unit. It can be removed from the
machine and again fitted very easily when required.
The latest web-fed offset printing machines have
» Dampening system
automatic ink control devices. The “Inkatron” and
“idotron” etc. attachment are fitted of automatic control
of the ink density.
Each inking unit has safety guards to avoid the web
from touching the inking rollers. In speedy and latest
web offset machines, the setting screws of the ink duct
fountain are fitted in a half round cover. Each screw is
made as in the shape of a knob. Each knob is fitted in
a cut part. The side strip of the knobs marked from 1
to 10 numbers to locate for adjusting the ink flow. The
blanket to blanket machines are equipped with two
inking systems each set of printing cylinders. Each
plate cylinder requires one complete set of inking
system similar to the sheet-fed machines.
» Chilling device
Heat-set inks need chilling device. A steel roller is
provided for this purpose. Each printing unit has this
roller. There is one pipe for entering the chilled water
into the steel roller. Another pipe is there to drain the
water. In this way, the chilled water circulates in the
roller and the surface of the roller is chilled.
Generally, the chilling steel roller is of oscillating type.
These are controlled similarly to the inking rollers.
The chilled roller prevents the drying of ink on the
inking when the machine is stopped for mark ready
pruposes.
Between the printing units
Besides all the above designs of web-fed printing
machines, there is a small platform, made of steel
Web Offset Technology Class Notes
covers, to stand and to sit for working between the
printing units. The operator stands on the steel cover
to adjust and control the ink duct, dampening unit and
preparation of plate and blanket cylinder. In one side
of the printing units, the web path is made under these
covers to feed one unit to other. These covers may
also be opened for inserting the web from one unit to
other.
Some of the machines have various set of grained
steel rollers to pull and forward the web between
printing units. The grained steel rollers do not create
set-off due to the wet printed ink. The grained flexible
steel strips and fitted on the roller which revolve on
ball bearings.
The necessity of moisture on the non-image areas of
the printing plate, is an obvious necessity similar to
the sheet-fed offset printing machines. In web offset
printing machines, the dampening system consists
of a water fountain as fountain solution tray. The
dampening solution remains at a constant level in the
fountain. The water in the fountain comes through a
pump system. In the side opposite to the operator,
there are small water tanks fitted with each printing
unit.
A thick rubber tube is connected between the fountain
and water tank. The water (dampening solution)
of the tank is pumped to the fountain by the pump
system. The working side of each printing unit has
a separate operating pump, its motor, switches and
other mechanism. Each one side printing unit has one
dampening system. Two dampening systems are fitted
in both side blanket to blanket printing units.
A fountain with a roller, distributors and plate
dampeners are the main parts of the dampening
system. The system does not have a vibrator, instead
of it, the fountain round. Both the ridges of the roller
touch the distributor in turn. Such fountain roller is
used as vibrator in this process.
The fountain roller of web offset machines is made of
rubber cotton tape is wrapped on the whole rubber
surface and sewn at both ends. The cotton tape
absorbs the water and when its ridge touches the
distributor, water is supplied automatically. In this
way, two ridge of a fountain roller supply water to the
printing plate continuously.
The dampening solution is provided in a storage tank
48
 from where it is supplied to the fountain by means of a
pump system. An exit pipe in the fountain continuously
drains-off the solution back to the storage tank. In this
way, fresh solution is always available in the fountain
and is maintained at the desired level.
To reduce and increase the quantity of dampening
water, the revolution of the fountain roller are reduced
or increased by two different switches. There is a
small separate motor to operate all the functions of the
dampening system.
Spray fountain system
The latest and very fast web offset machines have
spray fountain system. It has a fountain or tray to store
the dampening solution. The fountain water remains
at constant level. A long round brush is fitted on the
fountain steel roller. When the fountain roller revolves,
the water applied on its surface, is taken by the hairs
of the round brush. Hence the brush applies water on
the distributing steel rollers. The fountain roller and
other distributing steel rollers are chromium plated.
Chromium is water receptive. Hence the train of
dampening system remains in correct and continuous
process.
In this process, the brush is set at slight pressure on
the fountain steel roller. Therefore the hairs of the
brush spray water on the fountain roller surface. The
sprayed drops of water moisten the steel distributor.
Various steel distributors are set in contact with the
plate dampening rollers and thus the plate is damped
properly.
The fountain has a cover to increase and reduce the
quantity of water. The fountain cover has various
adjustable strips in the fore edge. Each strip may be
pushed forward and pulled back through its separate
knob. The strips are pushed to reduce or stop the
sprayed water from reaching the steel distributor. The
excess sprayed water is stopped by the cover strips
and returns back into the fountain. Each pushed strip
affects only the front surface which is about one inch
wide.
Some of the machines are so equipped that the
hairs of this type of fountain, spray water directly to
the plate of the plate of the plate cylinder but this
does not work satisfactorily. General reduction and
increase of water all over the fountain, is adjusted by
increasing or reducing the revolutions of the brush.
The speed of its revolution is controlled through a
Web Offset Technology Class Notes
manual switch fitted near the dampening system.
Some of the latest machines have automatic control
switches for increasing and reducing the revolutions
of the dampening brush. The switches are set in the
automatic control box.
» Delivery operations
When all the webs have passed through the printing
units, all of them forward on the grained steel rollers,
and reach the delivery part of the machine. The
advantages of grained forwarding rollers are:
• To avoid set-off in the web due to the wet printed
ink.
• To help in pulling and forwarding the web at an
even speed.
• To avoid air gap in the moving web which may
cause creasing defect.
The next operation on the printed web is to set and dry
the newly printed ink to prevent set-off.
» Ink drying unit
Generally, the sheet-fed offset printing machines, do
not have any extra attachment for drying the printed
ink because the inks used in sheet-fed machines dry
by cold-duct process. Besides it, most of the web-fed
offset printing machines have a drying chamber as
an extra attachment. Some machines have a device
for blowing hot air on the printed web for setting and
drying the ink.
The latest high speed machines have a large drying
chamber, this chamber has a device to blow hot air on
both sides of the printed web. For creating hot blowing
air into the drying chamber, diesel or liquid petroleum
gas (cooking gas) is continuously burnt into its firing
box. The firing box is joined with the pipes coming
from the compressor unit.
The drying chamber has various pipes joined with the
firing box. These pipes have holes through which the
hot air coming from the firing box blows continuously,
when the drying chamber is closed, the air blowing
pipes on the upper and lower side blow hot air.
The hot air blowing pipes are set about 4 mm away
from both sides of the web. The hot air blowing
49
 pressure form both sides of the web should be
perfectly equal. The uneven pressure may cause
uneven drying of printed ink or the web to be
damaged. The hot air generating box has two main
pipes. Each pipe has a stop cock with a pressure
measuring gauge. The quantity of hot blowing air and
its pressure may be increased or decreased through
the key of the stop cock.
The temperature
The temperature of the heating chamber is maintained
at 170º to 210º celcious. The temperature is reduced
for thin ink films and increased for thick films.
Consideration should also be given for the coverage
of ink on paper. Excess temperature may damage the
printed paper. Low temperature will not dry the printed
ink sufficiently.
For operating the heat drying chamber, the control
console has different switches and adjustments.
Opening of the heating chamber for inserting and
passing the web through it and all other controls are
adjusted by the switches of the control console.
The pressure of hot air on both sides of the web is
generally maintained at 10-12 kg per square cm. It
may be changed according to the bursting strength of
paper and the structure of fibers of the web.
» Chilling unit
After passing the printed web through the heating
chamber, it is necessary to cool it. The surface of the
web, structure of the fibers and the newly printed ink
densit yare affected when the web is passed through
the heating chamber. All these factors of the web
become normal when the web is passed through the
chilling unit.
There are two large cylinders for chilling the web.
Both cylinders are set away from each other. One side
of the web passes on contact with one cylinder and
the other side with the second cylinder. There are six
rubber wheels set for pressing the web against the
chilling cylinder to ensure perfect contact of the web
with chilling cylinders.
Droplets of water are formed on the surface of the
chilling cylinders. Due to condensation of atmospheric
moisture on the cold surface of the cylinder through
which ice cold water is circulated. Outer surface of
Web Offset Technology Class Notes
the cylinder is highly glazed. The chilled drops of
water vapour on the glazed cylinder normalize the
heated web by this process. The cold water enters
the cylinder towards the operating side and drains out
towards the gear (rear) side of the machine.
Such machines are equipped with separate air
conditioning plant. The air conditioning plant is
maintained by the engineering department, huge and
large steel pipe are carried up to the different chilling
units of the web offset printing machine. The steel
pipes are joined with all the main pipes. Stop cocks
are fitted at various places to increase and reduce
the chilling capacity. Normally the chilling unit is
maintained at a temperature of 15 to 15.5ºC.
» Silicon applicating unit
This unit of the machine is fitted just after the chilling
rolls. There are two fountains each fitted with a steel
roller similar to the water (dampening) fountain. The
fountain is filled automatically through a pump device.
Nearly half of the steel roller is always immersed in
the silicone solution. Both the sides of the web come
into contact
with both the
steel rollers
of the silicone
fountain. In this
way a layer
of silicone
solution is
applied on both
sides of the
printed web.
The surface
of web and
its fibers are
changed due
to the heat
and chill treatment. The layer of silicone makes the
web surface glazed. The web surface on both side
looks as polished. This unit is mostly used in web
offset machines which are specially made for printing
magazines and periodicals.
The silicone solution is available in plastic cans. This
solution is of milky white colour. The solution supplied
by the manufacturer is mixed with water in the ratio of
1 : 1. The proportion of water depends on the surface
of the web. Rough surface of paper requires less
dilution with water while smooth surface requires less
50
 silicone.
» Delivery Unit
When all the webs have been subjected to the
processes described earlier, to the folding unit. This
unit is also called the finishing unit of the machine
because the web is converted into the form of book
through this unit. This unit has more complicated
mechanisms and is equipped with different
attachments. Various operations of folding unit may be
classified as under for detailed study.
Forwarding cylinders
» Former
After printing and post treatments, each web is
forwarded on separate steel cylinders and rollers. One
or more plane steel cylinders are fitted in some of the
machines. Some machines have grained cylinders.
The forwarding cylinders and rollers pull the webs
from the printing units and forward them towards the
folding unit.
P.I.V. gear mechanism
It is a mechanism which controls the tension of the
web before it is fed into the folding unit. Here the
web needs greater pulling tension. Therefore this
gear mechanism increases the speed of the web
by increasing the speed of any one cylinder. The
driving gear of this cylinder is driven by the P.I.V. gear
mechanism. The function of this mechanism is similar
Web Offset Technology Class Notes
to that which is fitted before the web enters the printing
unit. It is interesting to know that the speed of the web
does not remain the same through out the machine.
The principle of controlling the tension of the web
through out the machine is that, the speed of the web
remains higher at the reel shaft, slower before entering
the printing units, higher after printing units and again
slower before entering the folding unit.
The higher working speed of web forwarding rollers
and cylinders is derived through the main driving gears
of the machine. The P.I.V. gear machanism reduces
the web speed. By this mechanism, the required
tension of the web is controlled in this way described
as above.
Some of the latest web machines have electronic
controlling box to adjust the P.I.V. gear system.
Generally, this part is called kite former. However,
the design of this part is not the same as it is named.
It is of the shape of a triangle and it forms the first
fold in the web. It has two thick steel pipes in V shap.
In the upper open part, there is a steel forwarding
roller. Three guide wheels are set on this roller. All the
overlapped webs forward on the steel roller. The guide
wheels are set on the non-image areas of the printed
web. They should not be set on the image areas to
avoid smudging of the newly printed ink.
Both the pipes of the ‘V’ shaped part, have holes for
sucking air. The web remains fully in contact with the
thick pipes and ensures the correct first half fold of the
web. When the web reached the bottom pointed edge
of the V part, it is converted into first fold.
The “V” shapped thick pipes of first folder (kite former)
are covered with a steel sheet, on which the web
slides easily. Some of the machines have half or
quarter or three fourth steel covering on the former.
Some of the machine do not have any steel covering
on this former (folder).
51
Adjustment of the former
Generally, the first former does not need any
adjustment in normal routine jobs. It only needs
adjustment when the width of the web is increased or
reduced. When the size of the web is changed, a large
screwed rod is tightened or loosened. The bottom
edge of this part is pulled back or pushed forward
by loosening or tightening the screwed rod. This
adjustment is needed to set the correct half fold of the
web and easy entering into the next folding cylinders
and rollers.
Centre indicator
There is a steel strip nearly 2.5 cm wide. It is set in
front of center of white space in the printed web. The
center indicator and the central guide wheel, set on
the upper forwarding steel roller are adjusted in an
alignment. Such adjustment ensures the correct first
half fold of the printed web.
Pulling rollers
Some of the old web offset printing machines are
only equipped with these rollers. These rollers are
also called draw rollers. One or two set of two rollers
are there in the folding unit. The pulling rollers are
wrapped with a grained steel strip. Due to it the web
is pulled and makes the first fold very correctly. The
grained surface of the rollers pulls the web in pressure
but it does not affect the undried printed ink on the
web. Pulling rollers are meant to ensure correct
feeding of the first folded web between then next
folding cylinders.
Folding Unit
When all the webs have been printed on both sides
and passed through the first former, they have to
enter the second folding unit. Generally, the complete
folding unit is made glass covered and various safety
guards are fitted there.
Second folder
The web now enters two rollers. These rollers
are covered with grained steel strip. The grained
rollers pull the web and make the second half fold.
Newspaper printing machines have only two folding
units but the magazines and book printing machines
are equipped with more than two folding devices
(units).
Third folder
For third folding, the twice folded web turns towards
Web Offset Technology Class Notes
the left direction and enters a set of two small
cylinders. These cylinders are covered with grained
steel strips in some machines. But others have plain
(grainless) cylinders. The control of margin and pulling
action in the folded web is made through the rubber
wheels in plain cylinders. These wheels are two or four
in number and set with pressure on the folded web.
The principle obtaining third fold through the cylinders,
is known as buckle folding system. Besides this, some
of the machines are also equipped with knife folding
systems, which has been described in the fourth folder
unit.
Cutting device
Each type of web printing machines has a cylinder for
cutting the folded web into the size of a book. There
are one or two cutting blades fitted in the length of the
cylinder. The cutting cylinder has one blade which cuts
one section in its one revolution. The cylinder having
two blades, cuts two sections in its one revolution.
In front of the cutting cylinders, each machine has
another cylinder parallel to it. This cylinder has a
wooden strip along its length which remains at the
back of the web and supports the cutting blade of the
cutting cylinder. Due to the wooden strip, the edge of
the blade does not get damaged.
Some machines do not have cutting blades. Instead of
that there is a stretch system of cutting. When the web
remains at heavy tension. The projected edge of the
cylinder cuts the web sharply.
After this, all the folded sections are dropped in
overlapped state on the continuous moving tapes.
The sections are collected by hand in some of the
machines and placed on the table. Generally, two
to four persons are needed at delivery part of the
machine for collecting, jogging and placing the printed
sections.
Section counter
Section counter machine is also fitted at the folding
part, through which the number of printed copies
becomes known. Slow speed machines have single
section counter but the high speed machines have two
section counters. For example, if the counter shows
the number 000100, it means that 200 copies have
been printed.
In latest web machines, the counter fitted at the folding
part, through which the number of printed copies
becomes known. Slow speed machines have single
52
 section counter but the high speed machines have two Ancillary Operations by Delivery Unit
section counters. The web offset machine made for stationery work are
equipped with numbering, perforating stitching and
cutting devices.
Fourth folder

Numbering
For numbering, cylindrical numbering machines are
provided, through which numbers in a sequence are
printed on the web wherever required. Number printing
machines are fitted in the grooves of the cylinder.
Number printing machines are fitted in the grooves
of the cylinder. Inking system is fitted along with the
cylinder. All the numbering machines are inked in each
turn of the cylinder and print numbers on the web in
Fourth fold required only in book printing but very the usual manner.
rarely. Generally, in the machines having fourth folding
unit, it is not utilized regularly. There fore the fourth Perforating
folding unit is disconnected from the third folding unit.
For perfotating a cylinder holds serrated steel strips at
The fourth attachment is connected to the third folding
various distances. When the web enters the cylinder,
unit by revolving a wheel through hands. The cut
the serrated teeth of steel strips perforate the web.
sections are forwarded on the tapes and guided by
The perforations in the paper are done for easy
various wheels.
tearing. Receipt books etc. need this operation.
The section strikes a stopper and at the same time,
a knife presses it exactly in the center of the section.
The blade of the knife pushes the section between two
steel rollers and the fourth fold is made. There are also
front and side lays (stoppers) to adjust the center and
side margins of the section.

Section separator
After fourth folding, all the sections are dropped one
by one within the steel fingers of the section separator.
The separator remains in revolving state and it
turns the sections on the moving belts one by one.
Here also, the delivery of printed sections is done in
overlapping position.

Section gathering
In old machines, the delivery men used to collect the
sections in lots by hands. For this purpose, about 3 to
4 persons were employed. In modern machines, there
is an automatic gathering divice.

The moving and overlapped sections on forwarding

tapes, are jogged from both sides. After this, all the
sections forward between two tapes and collect at a
table one by one. Here the springed stopper is pushed
continuously by the pressure of increasing number of
sections. The jogged sections are taken out by hand
and sent to binding department for bounding.

Web Offset Technology Class Notes 53

 plates, inserts or other advertising products need not
be a regular part of the book. They have to be cut into
sheets after printing.

Some web offset machines do not have sheeting

(sheeter) device as an ancillary attachment Therefore,
the printed web is taken out and set on a sheeter
(sheeting machine) by which the web is converted into
sheets.

Stitching
Stitching divice is the last operation of the delivery
unit. Here, each book is trimmed at the edges. The
sequence of trimming is fore-edge, tail and finally the
head. Sharp edged blades are fitted for trimming the
edges of the books.

Lastly the printed and bound books or magazines are

placed on the conveying tapes in overlapping position
and carried up to the dispatch department.
Slitting device
The cutting of the web in its longer side into one or
more parts is called slitting. Some of the web printing
machines are equipped with slitting device in the
delivery part. Slitting wheels, having sharp edged
blades are fitted in a rod. The wheels are set on the
web at required distances. The sharp edge of the
wheels slit the running web continuously.

The slitted parts of the printed web are again wrapped

into reel. After that, the unprinted slitted reels may
be used for printing another impression on any small
sized machine. It is printed, it may be cut into sheets
and used as inserts or plates.

Sheeting device
Cutting of web along the width or converting the web
into sheets, is called sheeting. Some of the machines
XTRA NOTES
are also equipped with sheeting device. The posters,
Web Offset Technology Class Notes 54
Web Offset Technology Class Notes 55