The term "Offset" gets its name from the fact that the plate cylinder which holds
the art information does not come in contact with the paper. Procedure Step 1: Making negatives: The first step in the offset process is to create a negative from the original art. From this negative, a printing plate will be made. Figure 1 below represents a digital file; Figure 2 is created inside the image setter.
Step 2: Printing Plates: The negative is then placed in contact with a metal printing plate (fig. 3 below), which is coated with a photosensitive, ink-receptive emulsion. It is exposed to light and the plate is developed, leaving the emulsion (illustrated by the magenta book image) only where it was exposed.
Step 3: Wetting: As in stone lithography, offset lithography uses the water-versus-oil principle to make a print. The plate is first moistened with water. This keeps the non-image areas damp, and therefore more resistant to the oil-based inks used in this process. The plate is now ready to be inked. Step 4: Inking / Offsetting: After the printing plate is developed, it is attached to a cylinder on the printing press. As it turns, the plate offsets this inked image to a rubber blanket, creating a reverse image. The blanket then offsets this image to the paper, reversing it again and making a "right" reading, final print. Step 5: Multiple Passes To Achieve Full Color: Multiple colors are accomplished by changing the color of the ink in each station as it passes through the press. Modern presses not only have 4 color stations but also add a varnish coat to help eliminate finger prints on the paper.
The rubber blanket then transfers the image onto the paper's surface. The printer does not have to be stopped. and printing plates? SBI has a list of vendors for each. large volume. PVC. The oil-based ink "sticks" to the image area. Small quantity can also be printed by offset process. but the cost factor will be on the higher side. magenta.
What is UV offset printing? In this process special UV inks are used which can be dried under UV rays for which special UV lamps are used. it's possible to use offset lithography printing on a wide variety of surfaces and for large quantities. Conversely. yellow. A plate first contacts rollers of a clean solution or water and then is inked by other rollers. The inked image is then transferred from the plate to a rubber blanket. and will help you through the process of ordering. Both spot colors and CMYK colors can be used with this process. What is the advantage of running registration? Running registration is the ability to align printing images to each other while the printer is in operation.An offset lithography (also known as plantographic) printing. By separating the image into small dots called halftone dots. What is 4-color process printing? It is a photo image created by overlaying and blending the 4 process inks . where offset type quality can be achieved. and printing them beside or on top of each other. and black. The principle that oil and water don't mix.cyan. Image areas are photographically transferred to thin metal plates which are treated chemically to accept oil-based ink but repel water on the image areas. What is dry offset printing? The dry offset printing process is indirect printing.
. the SBI Egg Carton Printer and Multiple Product Printer produces high quality process printing. PP material etc. which then prints the product. In this process one can print on MET PET laminated paper. The transfer of ink is controlled by an unlikely principle. The dry offset printing process offers the most efficient method for high speed. Where do I find inks. Because of the resilience of the rubber blanket. which allows quick and precise register of the print colors. high quality printing on pre-formed products.
What is the smallest quantity required for printing of cartons by offset process? The cost of carton is inversely proportional to its quantity. In a dry offset printer. This applies to all types of print jobs. blankets. not just process printing. plates carry both the image and non-image areas on the same level (unlike letterpress where areas are raised to catch ink). non-image areas accept water but repel the oil-based ink. the plate cylinders transfer their inked images to a single blanket cylinder.
It also typically costs less than other types of denesters. How long does it take to set up a printing job? It takes between 15 and 20 minutes per color. smooth and light colored surfaces result in the best quality images. How long do printing plates last? Printing plates last a long time and with proper care. How many products can be printed on one machine? The SBI Egg Carton Printer works most effectively when dedicated to 1 or 2 very similar sized egg cartons. Will my carton work in the printer? Cartons or other types of containers must nest into a stable stack in order to be efficiently fed through our standard printer. To move through the printer. What voltage is required for the printer? The printer is wired to your local power specifications. and moves the product smoothly and quickly. Products that are too flexible. may have problems throughout the printing process. This eliminates smudging. depending upon the technician's experience and the quality of the print plates. Can SBI's Egg Carton Printer or Multiple Product Printer print on products other than hinged-lid cartons?
. and compressed air.What are the advantages of using ultra-violet inks? The ink dries or cures instantly upon exposure to ultra-violet light. a high voltage power supply. adaptable to a wide variety of carton shapes and sizes. What plant services do I need to support a printer? The basics include sufficient floor space. The impression roll squeezes the carton or product against the blanket cylinder. turns with the blanket cylinder. or sag noticeably when held at the ends. the SBI Feedscrew Denester is simple to use. found under the blanket cylinder. What is impression roll tooling? The custom-designed impression roll tooling. cartons must be consistent in design and form. Also. The SBI Multiple Product Printer is designed to print on a variety of hinged-lid containers and flat trays. they will print millions of images. The diameter of the impression roll tooling is slightly smaller than that of the blanket cylinder. What are the advantages of the Scheibler Brothers Feedscrew Denester? With its space-saving and belt-driven design. How long does it take to manufacture the printer? The standard lead-time to manufacture a printer is between 18 and 22 weeks. allowing the ink to contact the product.
Litho overprint varnishing does not offer an instantly dry print at delivery in contrast with UV and aqueous. Conventional ink/litho varnish. the SBI Multiple Product Printer lends itself to printing on non-hinged products. the development of these aqueous coatings. Conventional ink/aqueous varnish. Litho overprint has been around the longest and is still the most widely used means of improving gloss and print protection. printed stocks can be immediately processed. How many people are required to operate the printer? Two people are typically needed to operate the printer. offering improvements in application. The resultant necessity to use spray powder sometimes causes the characteristic "rough" feel. 2.5 Wm and. ensures that cracking on carton and cover creases or folds is not a problem. Most recently. litho varnishing provides the ideal means of "spot" or pattern varnishing at high speed. Maximum 2 film weights of litho varnish which can be applied are as low as 0. Almost instant drying at the delivery. They dry partially by absorption into the paper or board. However. Although considerable progress has been made over the years. Gloss level and scuff resistance is lower than UV. Conventional ink/UV varnish.
1. The higher viscosity reduces the amount of penetration and "greying" of lower quality boards. litho varnishes have a tendency to yellow and. Litho overprint varnishes are generally solutions of solid resins in vegetable drying oils. 2. The in-line coaters as optional extras to multicolor litho presses have kept pace with. depending on substrate. The SBI Egg Carton Printer has an average production speed of 200 cartons per minute. and storage stability.8-1. The advantages and benefits of aqueous coatings are: 1. acrylic dispersions have replaced the old emulsions. Material unit costs are lower than any of the other processes by a factor of 2. The SBI Multiple Product Printer has a speed range of 50-100 products per minute.
Aqueous coatings Glossy aqueous in-line coatings are relative newcomers compared to litho varnishes. is generally similar to aqueous. One person feeds the cartons into the denester and monitors the dry offset printers. although mild.Of the two printers in our line. but mainly by oxidation which crosslinks the vegetable oil component to a tough flexible film. or perhaps even led. and wetting characteristics. The second person separates and bags the printed bundles of product. do have a distinctive odor on dried print. UV ink/UV varnish.
. What is the average production speed of the printers? Production speed is a function of operator experience and product consistency. 4. coupled with the flexibility of the resin/oil combination. 3. The aqueous coatings of today are quite different from those available even five years ago. and. Little or no spray powder imparts improved feel and a cleaner environment.
2. either in-line or dried. The perceived drawback is of coating as a "too hard" process and being problematic. The reason for this is that aqueous coatings are only 40-45% solids and more wet coating must be applied to achieve the same dry film weight. gluing performance will be affected. less spray-related damage and improved product are considered. However. Aqueous coatings are water white. but not necessarily adversely. Aqueous coatings have been developed to achieve a number of specialized purposes such as: In-line heatseal (blister-pack) coatings. In-line calendering coating. The advantages of UV cure systems are therefore:
Acrylic aqueous coatings are compatible with most glues. However. but on more absorbent carton boards. if not correctly formulated. Suitable for food packaging. film lamination. The two advantages perceived with aqueous coatings are: 1. Specially formulated aqueous coatings can provide an ideal base for subsequent processes. the film may crack on folds and may not adhere to unsuitable substrates. once the operators have mastered the technique they are reluctant to forego the security of running aqueous on almost every job. foil blocking. e.g. are odorless. plus instant curing at the press delivery. Special "Tie-Coats" are available for in-line web heatset coating. 6.B. usage is 2-1/2 times as much. Gloss on quality coated paper can be expected to be superior to litho varnish. This ability to apply heavy film weights of a hard glossy film when cured is also responsible for one of the disadvantages of UV coatings. They are 100% solids systems which crosslink to form a hard plastic film. the extra material costs are negligible. gloss is reduced and similar results can be anticipated. Economics: Although unit costs are similar to conventional litho varnishes. clear. Aqueous coating applied as a sealer over conventional inks will enhance the appearance of any subsequent UV coating application and reduce UV coating usage. gluing. opaque and pearlescent to upgrade low quality board. Love. 5. Tie coats (sealers) to enhance gluing. but when savings due to quicker turn-around. and. This is an added cost when viewed in isolation. Grease resistant barrier coats (for food contact). Prime coats. This has been confirmed in tests carried out with National Adhesives and N. Completely matte finish coatings. That is. etc. as the application of aqueous coatings reduces the absorbency of the board. once dried. The dried coating film is tougher and generally more scuff resistant than a litho varnish. These negative and positive factors need to be weighed against the product being produced and the advantages gained
UV cure UV inks and coatings do produce the ultimate gloss and film hardness. including PVA's and EVA's. 4.3. film lamination and UV varnishing over conventional inks. UV roller coat or screen gloss varnishing.
viscosity is one of the rheological core sizes determinating the ink’s behaviour in the printing machine. Film flexibility has been a problem. They can be formulated as “wax-free” to accept hot foil stamping. the permutations may seem infinite. Excellent abrasion resistance. Fast turn-around with in-line processing possible.
Highest gloss results for very acceptable print appearance. taint problems are reduced although UV does have a characteristic odor. the transfer onto the cartonboard and the quality of the completed printing units. High gloss box varnish provides moderate rub resistance. to sheet. but caution should be used in shipping heavy products in varnished
. The varnish may either be applied directly to the folding box during the printing process itself or in separate varnishing machine. to blanket. Possibly the most relevant way to explore the alternatives is from the viewpoint of the practical print application. The UV varnish is either applied directly in the printing machine or in a separate varnishing machine. but these are partially cancelled out by better mileage. They come in gloss or dull finish and are most adaptable to creative design effects using combination spot finishes to contrast and highlight images.
The disadvantages are: Higher unit costs. Varnishes are applied like ink. all these options in practice prove to be complementary rather than competitive. In fact.
UV curing has established a firm niche in the high quality packaging field and for printing on nonabsorbent substrates. to plate. Good product resistance. and protect the carton during the final finishing stages and on the shelf. Press varnishes are solvent-based and dry relatively fast by oxidation. As mentioned earlier. Viscosity Item for: Besides yield strength and adhesiveness. is usually designed to seal the ink. on press.
UV varnish Item for: This type of varnish adds to the surface great gloss and rub resistance. if we consider the number of combinations. VARNISH Varnishes are essentially “clear inks” with the same viscous quality as press inks. Substrate or dried ink surface has to have sufficiently high surface energy levels to be UV receptive. from roller. No spray powder required. Immediate cure. Being solvent free. Varnish Item for: Varnishing the folding box’s surface protects the cartonboard against scratches or contamination and accentuates partially or totally the gloss of the printed product. although this is being constantly improved. For hardening (drying) photo initiators are required. Varnish. the least expensive final finish. but will have less rub resistance that standard high gloss varnishes. in-line.
V. Other than film lamination. it often affects the final color. It is higher in cost than regular press varnish. liquid coatings.
. U. or if spot U. moisture and scuff-resistance and actually strengthens the sheet. Film lamination is the most expensive of all the final coatings mentioned. Aqueous is typically glueable and therefore can be applied to the sheet as an overall coating. is necessary can be applied by a type of silk screen process. of usually . on press. laminated. We will take every precaution to minimize this change. even when specially formulated inks are used. but not even the coater can predict the final result since the color may change up to 12 hours after the coating is applied. ONE NOTE OF CAUTION: While UV coating will generally enhance the look of the colors on the printed sheet. FILM LAMINATION A full-coverage. It is a liquid coating that uses U. and the same ink on the same board will often come out a somewhat different color on different runs. Available in gloss and matte finishes. This process gives the greatest level of gloss. Gloss U. gives cartons their highest rub resistance and highest gloss.V. Aqueous dries by oxidation and with the use of heated air can dry as quickly as 10-15 seconds. as well as a greater rub resistance. lamination process versus the roller-applied. and Sierra Packaging cannot accept responsibility for UV caused color changes.V. or as a separate off-line coating.V. UV coating is used for its high gloss and excellent rub resistance. It is also available in matte finish. It is generally either roller applied off press. COATING This is Ultra-violet cured coating. it can be used on folding cartons up to . lights to harden the coating as opposed to drying by oxidation. The matte finish is more velvety than other matte finishes and imparts a “cloudy” effect softening the printed colors.0015” thickness is pulled over the sheet.cartons to prevent scuffing. which reduces the need for non-offset powders.024. but it can also be applied as a “spot” coating with the use of a relief plate or blanket. and specially formulated inks must be used if the colors would normally contain Rhodamine red or Reflex blue. The film. and adhered to the stock. These coatings can be applied either in-line. film-to-sheet. These are changes that the existing technology cannot yet overcome. AQUEOUS COATING Aqueous coatings are waterbased liquid coatings similar to varnishes but with harder resins. The white of a board can also turn slightly yellow after UV coating. Aqueous coatings provide a slightly higher gloss finish and smoother feel than gloss varnish. PMS or specially matched colors are at particular risk.