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Effects on ink setting in flexographic printing:


Coating polarity and dot gain
Robert Olsson, Li Yang, Jan van Stam and Magnus Lestelius, Karlstad University, Karlstad, Sweden

KEYWORDS: Flexography, Coating polarity, Ink setting,


Printing plate deformation, Dot enlargement
yielded a higher print gloss with a waterless offset prin-
ting technique. This was because interaction of the ink
SUMMARY: Ink transfer and the subsequent ink setting are with the high polar latex led to a longer levelling time for
processes that depend on the physical properties of the ink and the ink. On the other hand, Ridgway and Gane (2005)
the substrate, and on the press settings. To gain a better under- found that the ink filtercake build-up is different for dif-
standing of the effects of these factors on printing performance, ferent pigmented inkjet inks. They speculate that there
four coating layers were prepared using calcium carbonates of may be a greater tendency of pigment aggregation for
different particle sizes and latices of different polarities. The some inks than for others which then may lead to diffe-
coating layers were printed with a water-based flexographic ink rent filter cake build-up. The filtercake build-up depends
in a laboratory printing press under different printing pressures. also on an initial separation mechanism, i.e. liquid is
Measurements were made using a white light interference profi- removed faster from the interface than it can be delivered
lometer, an optical densitometer, and an atomic absorption
from the ink bulk. In another publication, Gane and
spectrophotometer to characterize the size and shape of an indi-
Ridgway (2000) used flexographic inks and found that
vidual halftone dot, the print density of the halftone print, and
the amount of ink transferred, respectively. It was found that the the filtercake build-up acted as a “pump” to speed up the
coating layer based on a latex of higher polarity gave a higher ink absorption rate.
print density even though there was no significant increase in In the case of water-based gravure inks, Trianta-
ink transfer. A non-linear relationship between physical dot fillopoulos, et al. (1992) found that alkaline inks penetra-
enlargement and printing pressure was observed, due to increa- ted the base sheet quicker than acidic inks, mainly becau-
sing printing form deformation. The proposed mathematical se the smaller contact angle resulted in good wetting of
model taking into account elastic deformations reveals the rela- the surface. Etzler et al. (1995) reported that the fractio-
tionship between dot enlargement on the printing form and the nal polarity (σ P/σT), where σ P is the surface free energy
printing pressure. The results of the measurements agree quali- related to Lewis acid-base interaction and σT the total sur-
tatively with the theoretical predictions.
face tension, differs considerably among papers of diffe-
ADDRESSES OF THE AUTHORS: Robert Olsson rent grades. Papers with a large fractional polarity may
(robert.olsson@kau.se), Li Yang (li.yang@kau.se) and Magnus exhibit poor ink adhesion due to repulsive polar forces
Lestelius (magnus.lestelius@kau.se): Karlstad University, between the paper and the ink. They also concluded that
Department of Chemical Engineering, SE-651 88 Karlstad, macromolecular rearrangement in the paper surface plays
Sweden. Jan van Stam (jan.van.stam@kau.se): Karlstad an important role in the wetting of paper by alkyd varnis-
University, Department of Physical Chemistry, SE-651 88 hes. The macromolecular rearrangement is responsible
Karlstad, Sweden. for a wetting delay observed with polar fluids, whereas
Corresponding author: Robert Olsson non-polar fluids wet the paper well.
In printing, wettability is an important factor because it
Ink-paper interaction is a complex process depending on affects the ink spreading, as does the force applied in the
the properties of ink and paper. Typical aspects of the printing nip, since this leads to lateral spreading of the
interaction are ink spreading and ink penetration ink on the substrate. The physical dot gain, defined as the
(Oittinen and Saarelma, 1998). Considerable research difference between the size of a printed dot and that on
into these phenomena and related issues has been under- the printing form (without pressure), is a direct consequ-
taken in recent years. Engström and Rigdahl reported ence of the ink substrate interaction and the printing
latex migration to the surface of the coating colour press. Results from an offset printing study presented by
during the drying process (Engström and Rigdahl, 1992). DePaoli (1981) indicate that the dot gain depends prima-
The migration influences the surface properties of a coa- rily on the ink thickness, the physical and chemical cha-
ting which in turn affects the ink-paper interaction. racteristics of the ink and the paper. According to
Rousu et al. (2000) found that a non-polar offset ink DePaoli the length of the ink, which is its ability to be
penetrated deeper than a polar ink into the coating layer. drawn or stretched into a filament before snapping
They also found that a mineral oil exhibited a higher (Finely, 1997), and paper absorption may be critical para-
absorption rate with increasing pore size, whereas linseed meters affecting dot gain. Bohan et al. (2000) investiga-
oil behaved in the opposite manner, at constant latex level ted the effects which printing pressure, viscosity and ink
in the coating. It is suggested that the reason why linseed film thickness had on dot gain. They found that a higher
oil shows a lower absorption rate with increasing pore printing pressure led to a greater dot gain, whereas a hig-
sizes is a decrease in surface energy of the linseed oil, her ink viscosity leads to a smaller dot gain. A third conc-
and thereby a stronger interaction with the latex. In con- lusion from their study was that a thicker ink film gene-
nection to Rousu´s observations, Van Gilder and Smith rated a larger dot gain, as a consequence of the fact that
(1998) concluded that a more polar latex in the coating more ink was transferred. On the other hand, Bould et al.

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(2004a) found that in flexographic printing presses ink


spreading had a large effect on the final dot size.
Printing plate deformation, as one of the causes of
physical dot gain, has been investigated by Bould et al.
(2004b), who conclude that there are basically two
mechanisms of plate deformation of flexographic
printing which leads to in dot gain. The first is a lateral
expansion of the dot surface under compression, which
depends on the material’s Poisson´s Ratio. The second
mechanism is a “barrelling” effect where a part of the dot
sides becomes in touch with the substrate. The Young´s
modulus of the material determines to what extent
“barrelling” occurs.
The objective of the present work has been to study the Fig 1. The spectral reflectance of the coating layers of different compositions.
factors that affect ink setting. The effects of coating pola-
rity and the printing pressure in flexographic printing had essentially the same reflectance factor spectra in the
have been especially emphasized. visible wavelength band.
Two latex films were prepared to characterize the sur-
face tension properties through contact angle measure-
Materials and Methods ments employing a FTA200 instrument from First Ten
Coating layer preparation Ångström, USA. Deionised water, ethyleneglycol
Different coating layers were used to study whether the (>99,5% from Merck, Germany) and diiodomethane
pore structure or the surface chemistry affects properties (≤98% from Fluka Chemie GmbH, Switzerland) were
such as print density. Coating layers were prepared on used for the characterization. Small drops of the fluids
non-porous polyester films to minimize any possible were placed on the latex film surface and the contact
influence of the base paper. The coating colours were angles were captured with a CCD camera (Sanyo VCB-
based on calcium carbonates of different particle sizes, 3512T). The contact angle measurements were repeated
latices of different polarities and a CMC thickener. The at least seven times for each latex film and testing fluid.
calcium carbonates slurries: Hydrocarb 90, denoted I, Components of the surface tension van Oss (1994) were
and Hydrocarb 60, denoted II, supplied by Omya Plüss- calculated from the contact angle data, the acid-base, γ AB,
Stauffer AG, Switzerland, also contained dispersant agent and the Lifshitz-van der Waals component, γLW , are listed
(<1%) and preservative (<200 ppm). The latices, DL950 in Table 2. The surface tension components of the fluids
(a styrene-butadiene latex with a Tg of 7ºC, denoted A) used for the calculation are found in Table 3, γ + and γ - are
and HPP88 (an acrylate latex with a Tg of 4ºC, denoted the electron acceptor and electron donor parameter
B) were supplied by Dow Europe S.A., Switzerland, and respectively, and γ l is the surface tension.
the thickener FinnFix 10 by Noviant Oy, Finland. The
pigment slurries were first mixed thoroughly and latex, Table 2. The surface tension components of the latices.
thickener and deionised water were then added to achieve
a final dry content of 57± 3%. The mixture was stirred Latex γ LW γ AB
mJ m -2 mJ m -2
until no visible floc was present. The pH was adjusted to
a final value of 8.5. Four coating layers of the four A DL950 41 2.0
possible combinations, Table 1, of different calcium B HPP88 35 0.5
carbonates and latices were prepared using a K Control
Coater K101, from R K Print-Coat Instruments Ltd, UK, Table 3. The surface tension components (in mJ m-2) of the fluids used for charac-
terisation of the latex films, data from van Oss (1994).
with bar number 8. The wet deposited coating layers were
100 µm thick, and they were dried in air of 23ºC. Liquid γl γ LW γ+ γ-
Mercury porosimetry and interference profilometry were
Water 72.8 21.8 25.5 25.5
used to characterize the porosities and the surface
Ethylene glycol 48 29 1.92 47
roughnesses of the coating layers. The reflectance of the Methyleneiodide 50.8 50.8 0 0
coating layers, Fig 1, was measured with a spectro-
photometer (CM-3630 from Minolta Co., Ltd., Osaka,
Japan). The measurements showed that the coating layers Printing
For the laboratory printing, an IGT-F1 from IGT Testing
Table 1, The coating layer compositions (pph = parts per hundred parts of dry pig-
ments). System, Amsterdam, NL, was used together with a cyan
ink from ANI Printing Inks AB, Sweden. The printing
Coating layer Calcium carbonate – 100 pph Latex – 12 pph CMC – 0.5 pph plate had a thickness of 1.7 mm and a hardness of 70º
I-A HC90 DL950 FinnFix 10 Shore A. The printing plate was designed with dot diame-
I-B HC90 HPP88 FinnFix 10 ters of 0.12, 0.25, 0.49, 0.73 and 1.01 mm for the 40%
II-A HC60 DL950 FinnFix 10 tone value and 0.12, 0.25, 0.51, 0.74 and 1.01 mm for the
II-B HC60 HPP88 FinnFix 10 60% tone value. The four coating layers were printed

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with printing forces of 25, 60, 125, 225 and 375 N. An


anilox roll with an ink volume of 2.7 g/m2 and a screen
ruling of 180 lines/cm was used, with forces of 35, 75,
150, 250 and 400 N between the anilox and the printing
cylinder. The printing speed was 0.6 m/s in all cases. To
be able to calculate the printing pressure, the contact area
in the nip had to be measured. This was determined by
pressing the printing plate (with ink applied to it) against
the substrate, with the relevant forces applied, with the
IGT-F1. The result was a “footprint” of the printing form
in contact, the area of which could easily be measured
manually. For forces of 25, 60, 125, 225 and 375 N, the
nip length obtained was 8, 12, 16, 18 and 19 mm
respectively. The width of the printing nip was 35 mm.
Fig 2. The cumulative pore volume as a function of pore radius of the different
coating layers.
Print characterization
To characterize the printed dots and the full-tone ink film Table 5. The gloss values of the unprinted coating layers and for coating layers printed
roughness, a profilometer based on white light interfero- (under different applied printing forces). ∆gloss shows the gloss variation between the
metry (WYKO NT3300 from Vecco Instruments Inc., printed and the unprinted coating layer.
AZ, USA) was used. The scanning depth was 90 µm and Gloss 75º 25 N 60 N 125 N 225 N 375 N Substrate
a magnification of 5 was used. The scanning area was
1.24 x 0.94 mm except in the case of the halftone dots I-A 76.0±1.1 77.4±0.6 76.4±1.2 77.3±0.1 77.6±0.8 32.4±0.7
I-B 62.9±1.2 65.9±0.5 65.3±1.2 63.3±1.3 60.9±0.2 25.4±0.1
with a diameter of 1.01 mm, when the scanning area was
II-A 33.1±0.6 33.2±0.3 34.0±1.7 34.4±0.3 33.7±0.9 7.9±0.2
1.2 x 1.24 mm. The print density was measured 20 times II-B 28.8±0.6 28.2±0.7 29.2±0.3 28.8±0.4 27.7±0.2 6.9±0.1
for every sample with a GretagMacbeth densitometer
(Gretag-Macbeth AG, Switzerland). A ZGM 1022 gloss- ∆Gloss

meter from Zehntner GmbH Testing Instruments, I-A 43.6±1.8 45.0±1.3 44.0±1.9 44.9±0.8 45.2±1.5
Switzerland, was used to determine the gloss values at I-B 37.5±1.3 40.5±0.6 39.9±1.3 37.9±1.4 35.5±0.3
75º of the printed and unprinted coating layers, the mea- II-A 25.2±0.8 25.3±0.5 26.1±1.8 26.5±0.5 25.8±1.1
surements were repeated three times. These data were II-B 21.9±0.9 21.7±0.8 22.3±0.4 21.9±0.5 20.8±0.3
used to calculate ∆Gloss (=Glossprinted-Glossunprinted).
To estimate the amount of ink transferred, two measu-
rements per sample were made using a Perkin Elmer In Table 5 the gloss of the printed surface after printing at
Atomic Absorption Spectrophotometer 4100 (Perkin different press loads from 25 to 375N and also the
Elmer, Wellesley, MA, USA) with a slit width of 0.7 mm. ∆Gloss values, i.e. the differences in gloss between the
Prior to these measurements, the printed samples were printed and unprinted coating layers, are shown. As
treated according to SCAN-CM 38:96 and burnt using a expected, the printed surfaces exhibit higher gloss values
mixture of acetylene and air as fuel. The flame was then than the unprinted coating layer, since the ink may fill in
scanned with a light beam and the characteristic absorp- rough places on the surface. Interestingly, the differences
tion spectrum of copper atoms at a wavelength of 324.8 between the print gloss on different substrates are signifi-
nm was recorded. It is assumed that the intensity of the cantly greater than the differences in gloss between the
absorption line is proportional to the amount of copper unprinted coating layers. Nevertheless, the surface rough-
atoms and thus to the ink amount. The measurements ness of the substrate appears to influence the print gloss,
were performed at Stora Enso Research Centre, Karlstad, since, e.g., the print on the smoothest surface (I-A) has
Sweden. the highest print gloss. As in the case of the unprinted
coating layers, the gloss values of the prints are also
dependent on the particle size of the calcium carbonate.
Results and Discussion The press loads had little influence on the print gloss.
Fig 2 shows for the four coating layers the cumulative pore
volume as a function of pore radius, where it is evident that Print density
the finer calcium carbonate particles generate smaller pores, Fig 3 shows the print densities of the full tone prints on
but that the pore size distribution is also affected by the latex the different substrates at the different printing forces.
used. Table 4 shows that the coating layers with finer pores The figure shows on all substrates a maximum at an
also had smoother surfaces. Table 5 shows that the gloss of intermediate force. It also reveals a stronger influence on
the unprinted coating layers also follows the same trend. the latex than of the pigment size. The print density was
higher on the coating layers containing latex A than latex
Table 4. The roughness values, Ra, of the substrates characterized with interferen-
B. The influence of the pigment particle size was relative-
ce profilometry. The values are based on four measurements.
ly limited. The fact that I-B and II-B give similar print
Substrate I-A I-B II-A II-B densities suggests that the porosity has no great influence
Roughness, Ra [nm] 680 ± 11 800 ± 37 865 ± 6 909 ± 10 on print density. Intuitively, one might relate the higher

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print density to a larger ink volume transferred, as sug-


gested by Tollenaar and Ernst (1961), but the atomic
absorption spectroscopy measurements, Table 6, seem to
exclude this possibility since there are essentially no
differences in the amounts of copper on the different
printed samples. This suggests that the differences in
print density have other origins than the amount of ink
transferred. Since the substrates have essentially the same
reflectivity the difference in print density cannot be an
optical effect of the substrate. This implies that the
differences are due to different ink-substrate interaction,
probably due to the polarity of the substrates.
Fig 3. The print density of the full-tone print on the different coating layers (error
Table 6. The amount of copper in the printed sample measured by atomic absorp- bars shows the 95% confidence interval) as a function of printing force.
tion spectroscopy (flame).

Substrate I-A I-B II-A II-B


Amount of Cu [mg/kg] 61 ± 0 61 ± 2 59 ± 2 63 ± 1

Here we will give a tentative explanation to the pheno-


mena observed from an ink-substrate interaction point of
view. Substrates with a higher polarity, γAB, may promote
easier penetration of the fluid phase, water in this case,
and this may result in a different build-up of the ink layer
structure than in a latex with less polar surface properti-
es. This will thereby result in different dewatering of the
wet ink film. A higher rate of dewatering of the ink film
may draw the ink pigment particle together and form a
Fig 4. The roughness of the full-tone print (error bars shows the 95% confidence
more tight and dense ink layer. This in turn may lead to a interval based on 6 individual measurements).
higher print density. Olsson et al. (2006) studied the
imbibition of fluids with different viscosities, dipole in a higher gloss than latex B, which may be an effect of
moments and surface tensions into different model their different chemical properties. After printing, the
coatings. They showed that the polarity of the fluid percentage increase in gloss is considerably higher for
influenced the depth of penetration of the fluid. the calcium carbonate II than I coatings. The calcium
This tentative explanation is supported by the gloss carbonate II coatings have a rougher surface than I, and
and roughness measurements, since the driving force this can more easily be improved if the ink fills larger
forming a more tight and dense ink layer may also contri- pits and thereby gives a smooth surface. However, the
bute to form a smoother (Fig 4) ink layer and thereby a calcium carbonate I give a final gloss value higher than
higher print gloss (Table 5) and a greater gloss improve- the calcium carbonate II coating layers.
ment (∆Gloss in Table 5). The ink film roughness, Fig 4,
shows a behaviour similar to that of the printing density. Dot geometry
The A latices both gave higher printing densities and The geometry of the individual dots was characterized
smoother surfaces than the B latices. Latex A also results using interference profilometry. The diameters of dots in

tion (left) and the cross printing direction (right). Filled characters represent 40% tone values and unfilled 60% tone values. ♦ I-A; g I-B; 5 II-A; X II-B 40%; + II-B 60%.
Fig 5. The calculated dot enlargement of a 0.73 (40%) and 0.74 (60%) mm, in diameter, dot on the printing form measured with interference profilometry in the printing direc-

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both the printing and cross-printing directions were deter-


mined. As shown in Fig 5, the halftone dots tend to have
a greater diameter in the printing direction than in the
cross printing direction. At low pressures, there is in fact
a contraction in the cross direction. This is probably a
consequence of a combined effect where the substrate is
pulled through the printing nip at the same time as the
printing plate is pressed against the substrate causing a
deformation of the circular dot on the plate. Similar
observations have been reported by Lagerstedt and
Fig 6. Schematic figure of dot deformation on a printing plate. Left: the original
Kolseth (1995) who shows that the printed dots were dimensions of the dot. Right: the dimension of the dot under pressure.
mangled out and even merged together in the printing
direction when the printing pressure was increased. They deforms under pressure and its dimensions become R, R1,
also reported that the printing speed had no effect on the and H-d, respectively (Fig 6b). Due to the constraint of
shape of the observed printed dots. the printing plate base, the radius at the top of the dot
Another possible reason, although not investigated in (R1) remains unchanged (or the deformation is negligible)
this study, for the heterogeneous deformation, and especi- during printing. According to Hooke’s law, the height
ally for the contraction observed in the cross printing deformation of the dot, d, caused by the pressure, P, is
direction, is the ink elongation (and splitting) producing a P
retraction motion. d= [1]
k
It was also found that the dot enlargement in both the
printing and cross printing direction was non-linear with where k is the elastic stiffness of the printing plate.
respect to printing pressure. To be able to compare diffe- Assuming that the material is incompressible, the fol-
rent dot sizes as well as different tone values, the printing lowing relation applies due to volume conservation:
pressure rather than the printing force is used. The pres-
1 1
sure was calculated from the printing force, the nip
3
( ) ( )(
π H R12 + R0 R1 + R02 = π H − d R12 + RR1 + R2 [2]
3
)
length, number of dots and the individual dot area on the
printing plate. It is evident in Fig 5 the dot enlargement Let ∆R=R-R0 be the dot enlargement. The relative dot
increases approximately linearly at low printing pressu- enlargement, ∆R/R0 , can then be expressed as:
res, but that it deviates from linearity when the pressure
 2 
becomes higher. This is probably due to the deformation ∆R 1  R1  R1   R2 R  P kH 
of the printing plate and its increasing contact area with = −2 − +  2 +  + 4  2 + + 1
1 1
[3]
R0 2  R0  R0   R0 R0  1 − P kH 
the coating layer.  
Bould et al. (2004b) studied the plate deformation and
they concluded that the dot gain is an effect of the Eq 3 shows that the relative dot enlargement depends
printing plate deformation. They suggested two forms of nonlinearly on the relative height deformation,
deformation of the printing plate, i.e. either dot P/(kH)=d/H, unless the pressure is small. It is easy to
expansion or sides collapsing. The non-linear behaviour prove that when P/(kH)<<1,
evident in our measurements may be a combined effect of
these deformation mechanisms. It is possible that the dot R12 R1
2
+ +1
is able to maintain its form at low pressures but at higher ∆R R0 R0 P
= [4]
pressures the dot deformation through side collapse or R0 R kH
dot expansion begins to be visible. One should, however, 2+ 1
R0
remember that ink spreading on the surface also
contributes to the final dot gain, and this has not been In other words, the relative dot enlargement, considered
considered here. as a diameter increase, increases linearly with respect to
the increasing pressure when the pressure is small, but
A mathematical model of printing plate deformation non-linearly when the pressure is further increased.
To further understand the dot enlargement process, we Secondly, the relative dot enlargement depends on the
have made an effort to develop a mathematical model ratio of the radii, R1/R0. A typical height of a flexographic
that describes the relationship between the dot deforma- printing plate is 0.8-1 mm with an angle to the printing
tion and the pressure exerted on the printing plate. The plate base of 10-15º. This means that the ratio (R1/R0) for
printing plate is made of a polymeric material which different dots will, in our case, be 1.2 to 2.8 for both 60
undergoes deformation under the pressure to which it is and 40% tone values.
subjected in the printing nip. Fig 7 depicts the relative dot enlargement caused by
Fig 6 is a diagram of a dot with (right) and without dot deformation, calculated according to Eq 3 (solid line)
(left) pressure being exerted on it. The dot is attached to and by Eq 4 (dashed line). The computation agrees
the printing plate base on the top side. We assume that qualitatively with the experimental observation, Fig 5,
the dot has a truncated conical structure and that its suggesting that dot deformation is the factor responsible
original dimensions are R0, R1, and H (Fig 6a). The dot for the non-linear dot enlargement. However, it should be

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is gratefully acknowledged. We would also like to thank Noviant Oy for the CMC,
DOW Europe for the latex, Omya AB for the calcium carbonates and ANI Printing
Inks, now XSYS Print Solutions, for the flexographic ink.

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with the experiments, for printing plate deformation has polymer suitable for waterless sheetfed offset paper coatings, 1998 Pan-Pacific
been presented. The diameter of the printed halftone dot and International Printing and Graphic Arts Conference, Québec City, Québec,
was shown to be larger in the print direction than in the van Oss, C. J. (1994): Interfacial Forces in Aqueous Media, Marcel Dekker, Inc.
cross print direction. Canada, p. 440.

Acknowledgments Manuscript received May 16, 2006


Accepted September 29, 2006
The financial support of the Swedish Pulp and Paper Research Foundation, the
Knowledge Foundation and the Swedish Agency for Innovation System (VINNOVA)

574 Nordic Pulp and Paper Research Journal Vol 21 no. 5/2006

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