Printing and Graphics
CORDES PORCHER, BOBST GROUP USA INC HELPS CORRUGATED
PRINTERS IDENTIFY PROBLEMS AND OFFERS SOLUTIONS.
The Printing Process
Cordes Porcher is a
technical specialist in high
graphics on corrugated for
Bobst Group USA. He
travels the continent
helping the post-print
industry improve and
understand the printing
process. Porcher has 15
years of teaching
experience, with the last 13
spent in printing. He can
be reached at
888-226-8800 or
973-226-8000 ext. 5270.
To mail him your problems
and samples, send them to
Bobst Group USA Inc.,
146 Harrison Ave.,
Roseland, N.J. 07068
cordes.porcher@bobstgroup.com
Air Bubble
Problem extra ink applied to the plate as a result of the
raised plate surface contacting the anilox roll and
Name: Air Bubble gathering extra ink when sheets are not feeding
Also known as: Halation, Hot Spots through the machine. The floor of the plate has ink
See also: Halation (Jan/Feb issue) applied to it and may print in undesired areas.
Location on sheet and/or printed elements: Can Cause:
be anywhere on the sheet. The problem will be ■ Air bubble trapped under plate when it is
localized and will be relatively small in comparison mounted to carrier sheet.
to the entire job.
■ Air bubble trapped under the plate as a result of
Signs and symptoms: Air Bubbles are most
improper storage of plates. The plate has started
notable in screens in the shape of an oval or circle.
to delaminate from carrier sheet.
Positives will appear distorted or bulging. Reverses
■ Air bubble trapped under the plate as a result of
will appear filled in. Solids will appear to have dark
improper handling of plates. This is commonly
ovals or circles in comparison to the same
the result of laying plates flat when they have
adjacent color during the press setup procedure.
been mounted in the round. The plate has
Air bubbles also can be found in non-printing
started to delaminate from carrier sheet.
areas.
Description: Dark spots found in the print, which Collateral effects:
are most notable in the screens from three- ■ Color shifts in the image as a result of more ink
quarter tones to on the printed sheet than
highlights. intended.
Positives will ■ Ink printing in areas intended
appear to be void of ink.
distorted or
bulging. Diagnostic Process
Reverses will
Evaluation:
appear filled in.
■ With your fingers, start above
Solids will
appear to have the suspect area on the plate
dark ovals or and drag them across the
circles in suspect area feeling for a
comparison to lump. If no lump is found,
the adjacent refer to the Halation
colors. This is AIR BUBBLE UNDER FLOOR OF YELLOW PLATE column in the Jan./Feb.
IN A NONPRINTING AREA
the result of issue.
Corrugated Today March/April 2005 13
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Printing and Graphics
AIR BUBBLE UNDER FLOOR OF MAGENTA PLATE IN
PRINTING AREA
AIR BUBBLES ARE ■ The anilox to plate impression can be backed
away from the plate in small increments.
MOST NOTABLE IN
Since the air bubbles have lifted the surface
SCREENS IN THE
of the plate, these raised areas will print on
SHAPE OF AN OVAL the sheet. This is a good technique for
OR CIRCLE. determining where bubbles are located
A SEWING MACHINE across an entire sheet very quickly and will
NEEDLE CAN BE provide a map for removal.
■ The floor of the plate will have ovals or
USED TO LANCE THE
circles in nonprinting areas.
BUBBLE AND THE Tools: Fingers, magnifying glass 10X-12X,
AIR WILL ESCAPE UP sewing machine needle and/or Dremel tool
THE GROOVE IN THE
NEEDLE ORIGINALLY Treatment
INTENDED FOR THE
General Measures:
THREAD. A sewing machine needle can be used to lance
the bubble and the air will escape up the groove
in the needle originally intended for the thread.
Care should be taken in the choice of needle size
and insertion point of the needle. The plate
image can be damaged and the damaged area
will appear in the printed product. In the screen
areas, the needle should be inserted between
dots. For solids, insert the needle into the
shoulder or at the base. If this cannot be
achieved in the screened areas or solids, a
Dremel tool can be used to drill a small hole
through the back of the carrier sheet.This drilling
technique is also suggested for solid areas as the
19 Corrugated Today March/April 2005
insertion of the needle into the
face of the plate will leave a divot
or dimple. Whatever the
technique chosen to remove the
air under the plate, the technique
should be tested in a non-critical
printing area to see the results of
the intervention. If the needle is
inserted into the floor of the plate
to remove an air bubble in a non-
printing area, a small amount of
edge sealer should be placed over
the hole to prevent liquid from
migrating under the plate. It is
almost impossible to apply edge
sealer to a screened area or to the
edge of a solid without influencing
the print quality.
Chemicals: Edge sealer
Extreme measures: Plate may need to be
demounted from carrier sheet and reapplied, or a
new plate package may need to be
manufactured.
Prevention
Proactive steps:
■ Review all plates prior to going to press
against a proof of the image to be printed.
Compare the screens on the plate to the
proof. Look for deformed, dark areas and
areas of unwanted print.
■ Avoid placing plates on a flat surface if they
were mounted in the round.
Where to seek help: Prepress/plate supplier —
review plate manufacturing, storage and
handling options with your plate supplier.
Editor’s Note: In every issue, Cordes Porcher will
identify ways to diagnose a specific printing problem
and recommend how to treat and prevent it. These
are only suggestions and have been shown to solve
problems in other corrugated plants. In the process of
fixing a printing problem it is important not to
override safety mechanisms or operate equipment in
such a way that you run the risk of injuring personnel
or damaging materials or equipment.