apex prepared for unprecedented concept launches at drupa · results in uv label, opp polythene and...

Apex International is the leading manufacturer of anilox and metering roll solutions in the world. Apex products are used in the Flexographic printing industry as well as the Offset, Industrial Coating and even the Digital printing industry. Apex International is prepared for several unprecedented concept launches at Stand 11B26 at Drupa 2016.Below you will find a summary:

FLEXO The Fixed palette concept (4C and 7C), which includes patented GTT anilox rolls that have been designed to create the most consistent and controlled laydown in the industry, especially important for optimized Fixed Palette. With Fixed palette, flexo printers can streamline press operations, reduce anilox inventory and variation, and reliably deliver consistent quality from the shortest to the longest of press runs.

Water based inks printed onto foil & film resulting in an extraordinary high-quality print. The future requires from flexo printers to seriously search for an environmentally friendly print solution. With the correct handling production with water-based inks is much more cost-effective than production with solvent-inks (lower costs related to dilution and energy consumption, disposal and storage of hazardous substances). A visit to the Apex stand will be worthwhile, physical proof of water based print jobs from different projects with leading OEM’s and ink manufacturers are on display and they will show there aren’t any difficulties with air nor with re-wetting. Most eye-catching advantage of the GTT anilox technology in combination with water-based inks, is the fact that foaming does not appear, leading to the question whether an anti-foam agent could be redundant.

Apex’ stand will act as a Knowledge Center for printers that come across issues like “Opaque white”, and “UV Spitting”. 40% of all printers have problems like printing an opaque white and use more ink or a 2nd print unit to solve this specific problem. Apex provides efficient anilox solutions that are not necessarily more expensive and at the same time realize a higher quality print result (and thus more revenue).

COATING, OFFSET, PRIMER/DIGITAL PRINTINGThe Coating, Digital and Offset industries will get to know Apex’ smooth, consistent coating transfer solutions. More gloss does not necessarily have to go hand in hand with the application of more lacquer. Nowadays, there is an anilox solution that provides a smoother layer ánd economize on coating. Positive side-effects are that Orange-peel, Pinholing and Micro-foaming are issues of the past.

Last but not least, Apex International will be participating inlive demonstrations at several machine manufacturers in all industries where we supply our products. An up-to-date list will be provided at the Apex stand during the Drupa show and also the samples printed at these demo’s can be collected from the Apex stand.

PRESS DOCUMENTATION - DRUPA 2016

Apex prepared for unprecedented concept launches at Drupa

More information:http://discover.apex-groupofcompanies.com/drupa2016-1

Recent studies and trials aimed at optimizing Pantone simulation suggest that the Fixed Palette approach is ready to revolutionize both the flexo wideweb and label industries. The change is due specifically to advancements allowing for unprecedented process control and consistency as well as the development of new tools designed to pinpoint which process parameters are failing so they may be addressed before problems arise.

4C No limits - No compromiseAccording to Nick Harvey - Print Application Director of Apex International - 4 color fixed palette has many advantages over 7 color simulations in for particular wide web Flexo. First you must understand and consider that existing wide web printers have:• Many existing designs that they hold plates in stock for

(100,000’s Euro’s).• Many ink press returns in stores that require re-formulating for

spot color printing (1000‘s Euro’s). • A number of customers that will not move old designs to Fixed

Palette.

When you understand and consider the above, printers require a transition solution to move over to Fixed Palette. Apex 4C using the GTT technology offers this smooth transition. Harvey states that an estimated 90% of printers only have 8 color presses and therefore 4 color Fixed palette plus White allows for printers to use the spare 3 units for:1. Spot colors that are not possible with 4C simulation and this

gives the possibility to print 100% of the pantone book.2. Printing designs side by side saving set up costs, increasing run

lengths, increasing profits.3. Printing up to 800 colors at the same time (a designer’s dream).4. Printing added value combination lacquers, Gloss, Matt, Tactile.5. Printing up to 800 Metallic colors at the same time just by

backing simulations with silver.

6. You still have the possibility to increase to 5, 6 or 7 C as and when it suits your business needs and your production is comfortable and consistent with 4C.

7. Finally the ability to print all existing designs in the current format without disturbing the 4C fixed process set.

Added to the above moving to Fixed Palette printing in the first instance is a matter of variable elimination in order for printers to make the transition into Fixed Palette Color simulation they need to optimize their internal process control which requires a mind set to remove / eliminate as many process variables as possible.

Therefore starting this journey into Fixed Palette is much smoother when you begin with the already familiar Y M C K process set. When it is understood that 4C brings a possibility of more than 800 colors within a delta e of 2 this is already a huge step forward, whilst at the same time allowing all existing designs to be printed and press return inks to be used away during the transition as stated above.

Printers need to determine if an additional - let’s say - 228 Pantones are worth the inclusion of three additional variables coupled with the inflexibility of having a press fixed and commited to 7C.

The demand for optimized fixed palette is only expected to grow as brand owners demand better color consistency with shorter run lengths and just-in-time production. Chief among these concerns is the ability to create color consistency across multiple markets ensuring that the same values and same Pantones can be printed on labels just as they can on films.

For more than a year, Apex International is involved in a project to prove that Fixed palette printing with only 4 colors is the future for the Flexographic printing industry. At Drupa the results of the trials will be presented to the international Flexographic printing industry.

FIXED PALETTE

blog.apex-groupofcompanies.com/theaniloxrole

The Rise of Pantone Simulation in Flexographic Printing

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What is so special about this project? Fixed palette optimization through advances in color management and process consistency has fundamentally changed flexographic printing in the 21st century. Brand owners around the world have taken notice. In fact, more and more brand owners are choosing printers with a proficiency in fixed palette. Two leading brand owners - Asda/Walmart and Morrisons - have contributed their participation to the project from the start. They have offered designs of some of their packages to be used and printed in the trials.

Secondly, the designs contain packages that were previously printed in various different types of printing techniques, going from Litho to Aluminium foil lidding, from Gravure to Surface Prints in Flexo and from UV Label to UV Shrink sleeves. All these designs are now printed in Reverse on OPP in Flexo!

Third, the number of different designs per printing plate are incredible, all printed with CMYK. For the Morrisons design more than 100 Pantone colors were matched and 28 (!) designs were printed. The Asda printing plate covered 17 designs and also here more than 100 Pantone colors were matched!

“Nothing is impossible”Apex has proven that the impossible is possible by presenting print results in UV label, OPP Polythene and Offset/Litho. Visitors to Drupa can come to the Apex booth and check the color results with their own eyes, as well as with the X-Rite Color management equipment Exact Scan & ColorCert Master. Since it is about matching the original proof that is signed off by the brand owner, the Apex stand will also provide this original proof. And as if that weren’t enough proof, Apex also displays some of the original packaging the way they can be purchased in the supermarket nowadays.

Our Partners in the Fixed Palette 4C Project• ESKO • X-Rite Pantone • BOBST • PPP

The ‘role’ the Anilox played “Achieving color consistency is probably the most difficult component of transitioning to a fixed palette process.” says Bas van der Poel, Technical Sales Director EMEA at Apex International. “Fixed palette is about control: control over variables, control over ink flow and so on. It is this control that has allowed us to hit the number of Pantones we have with these trials and do so while not having to make any changes to plate inventory. It requires a level of control that simply is not possible with conventional anilox rolls.

Apex holds globally recognized patents on the award-winning GTT technology that uses continuous lasers to engrave a slalom pattern onto the anilox. The continuous laser is responsible for creating an anilox product capable of the smooth, consistent and controlled laydown necessary to optimize fixed palette. The Fixed Palette 4C consists of 4 GTT rolls/sleeves and one calibration roll/sleeve for closed-loop control and a guaranteed process stability”.

For more information, visit the Apex International Stand at Drupa 11B26! Or request your Fixed palette

sample pack through: http://discover.apex-groupofcompanies.com/fixedpalettesamplesdrupa

Standard Flexo

Surface Print Flexo Standard Flexo

Standard Flexo Aluminium Foil LiddingUV Label Litho

Litho Gravure

The Morrisons Print Proof with 28 designs previously printed in different printing technologies, now all on OPP Reverse Print in Flexo.

Global Environmental awareness is driving the printing industry to consider other ink systems in order to print more ecological packaging. Water-based inks are often praised as the green solution for a more sustainable product. They are a comparatively eco-friendly product, but when it comes to printing inks on to films and plastics, water creates problems...

1. Unless we print on high absorbency substrates, water inks require significant heat to dry and to leave a cured ink film on the substrate. In other words, they require energy that negates any positive ecological benefits from the use of water-based inks.

2. Water has a high surface tension, which can print beautiful perfect dots however creates mottled/pinholed solids, which means that in order to ‘wet out’ on most plastic surfaces, the surface tension has to be reduced considerably in order to achieve good print quality and smooth laydown of ink.

That is done by adding a surfactant or a solvent, which contaminates the water immediately. Depending on the substrate, the type of press, the printing speed, the amount of solvent can range between 2 – 20% of the press-ready ink.

3. Waterbased ink is also susceptible to foaming creating micro bumbles which thickens the ink and creates a reduced ink transfer. In order to solve this, the ink can be adjusted with anti-foam agents which in turn create drying issues and trapping problems.

4. Water has to be combined with solvents in order to dissolve the kinds of resins that provide good adhesion on packaging films. Read: more chemicals!

5. Switching from a solvent based ink to a water based ink cannot be done overnight, because of the different transferring capabilities. It often means modification to the anilox rolls because a shallower, more open cell structure is required to print water based inks.

6. Contamination between solvent inks and waterbased inks creates an adversus chemical reaction that can result in the ink setting solid and then a major cleaning of anilox, pumps, pipes is required. Therefore, a press is required to be dedicated to waterbased inks to ensure press efficiency is maintained and waterbased ink print is viable.

Having touched on the characteristics of water based inks here above, it cannot be left unmentioned, that critics have doubts on the printability of water based inks as well...

They appear to result in:

1. Poor scratch and rub resistance (especially shortly after printing)2. More difficult to re-wet3. More difficult to clean4. Comparatively lower gloss and poorer color strength5. Ink sets onto the plates creating ink build up and an inconsistent print6. Slow drying and therefore more heat/energy required7. Highest risk of clogging inside the anilox cells (especially with low-volume anilox rolls)8. Very difficult to control and guarantee a consistent and repeatable ink transfer (because of the pH and viscosity)

WATER-BASED FLEXO INKS


How to Supercharge Your Water-Based Flexo Inks


Side view of GTT: Channels are up to 30% shallower and land mass is reduced by more than 60%

Water based inks - the future of printing!

Still, ink suppliers and also machine manufacturers dare to announce that water based inks are the future of printing. And a major part of the success of printing water based inks, lies in the actual transfer of the ink. Many of the above print issues can easily be solved when the right configurated anilox roll is used.

Apex International have performed several successful trials together with different ink brands in combination with leading machine manufacturers. The results reported by the ink manufacturers was:

The shallow surface structure of the open-slalom laser engraving technology developed by Apex, results in no clogging. The most effective ink transfer allowing for the maximum ink replenishment within the Anilox surface compared to the restricted limits of any conventional engraving is realized. A very thin layer of ink can be transferred and less drying time is needed (energy savings!).

Major advantages with no air inside the print process.In a closed-cell structure (image left), air gets trapped inside the cells and especially with waterbased inks, that is a disastrous combination. With the open-slalom structure (image right), the ink flows freely and the air will not get stuck inside the cell, it simply flows away.

Less air simply means a better lay down of ink and better results on gloss and color strength. A side effect of having no air inside the print process, is the fact that a defoamer is no longer needed, which makes water-based printing an even more ‘green’ way of printing packages.

With an open structure, the phenomen Dot Dipping does not occur. The explanation is simple: pressure causes counter-pressure, ink escapes through the opening and the result is over-inking. The water-based ink does not set onto the plates and will not cause ink build up and therefore inconsistent print is no longer an issue. The below image shows this:

Ink-Dipping-Anilox.jpg

The key to the success of waterbased inks is to control the viscosity and the pH and the key benefit of the open-slalom surface structure is a consistent ink transfer and the ability to print repeatable results with no air inside.

PLATE

ANILOX

CONCLUSIONThe last 5 print issues (out of the 8 mentioned)

caused by waterbased inks, can be improvedby using Apex GTT Anilox technology,

which is a very good step in the rightdirection of a greener Flexo future.

Samples of waterbased prints performed by different ink brands on 3 different machine types will be available in the ‘Green - Waterbased Area’ at the Apex stand (11B26). Receiving your samples by visiting the Drupa stand, or by requesting your sample pack here.:http://discover.apex-groupofcompanies.com/flexo-waterbased-samples

See physical proof of state-of-the art ink-transfer technologies that obviously supercharge your water based inks!

UV inks are considered by many to be the most popular in the narrow-web space. And for good reason. Print results with UV inks are consistently better than those using water or solvent-based inks. But the use of UV inks is not without its challenges. Chief among those challenges is the issue of spitting.

There are several theories as to why spitting occurs with UV inks and not with water or solvent inks. Generally, these revolve around the higher viscosity of UV inks comparied to water or solvent and the impact it has on the doctor blade. Specifically, the higher viscosity can move the blade just enough to allow more ink than is intended to slip through. Other theories suggest that anilox cell type, viscosity, press speed and doctor blade specifications all play a role. Regardless, the results can be a disaster, particularly at high speeds.While exactly why spitting occurs is a subject for debate, what is not in dispute is that the relationship between doctor blade and anilox is at the core. If spitting is creating a challenge in your shop, try these tips for better print results:

1. A stiffer doctor blade may prevent excess ink from getting under and transfering to the plate and substrate. Testing shows a thicker blade will minimize UV spitting

because they resists hydroplaning and do not allow texcess ink to transfer to the anilox.

2. Try a 30° anilox cell with openings The ink can move through the openings in the anilox cell

walls preventing ink from being built up onto the back of the doctor blade. (Situation 1a).

A word of caution: This solution is only temporary. Because the roll will wear

over time, the openings will become smaller and eventually disappear. So over time you will get the same situation as with the regular anilox roll. Ink will built up at the back of the doctor blade (situation 1b).

UV INK SPITTING


3 Tips to PreventUV Ink Spitting

1 2


3. Try GTT Channel engravings. There is no pressure built up at the doctor blade because

the ink can move through the GTT channels. Therefore no ink builds up onto the back of the doctor blade and no ink drops from the doctor blade onto the flexographic plate or substrate.

“The S-flow channel enables the ink to flow freely creating a very positiveside-effect: no UV spitting! Ever since we use GTT (for almost 2 years), we have

not had to clean the plates in between jobs. This means: a significant longer plate life as well as a huge decrease in machine down time.”Daragh Whelan, Technical Director Americk Advantage

CONCLUSION

An ‘open-cell’ engraving is the solution to UV spitting. However, you have to be aware that some solutions are only

temporary until wear of the cell walls occurs. The GTT open-slalom surface is a permanent solution, because no ink is

built up through pressure at the back of the doctor blade and no ink drops from the blade onto the plate or surface.

1a 1b

1


CONCLUSION

Reflex Label recently conducted a series of trials designed to optimize their opaque whites process. The company, which is one of the largest label and flexible packaging companies in the UK with global customer base, has a history of being

at the forefront of innovation and has consistently invested in new and emerging technologies. For this reason, Reflex approached Apex International to help them define a new process for opaque whites that would produce results normally seen using a double hit method with only one hit.

Using benchmarks established through trials with another label printing company in the UK, Apex suggested that a single anilox engraved with GTT, the company’s proprietary channel engraving technology, would lay down as good or better opacity with a single hit than with a double hit using any other anilox. With a press speed of 60mpm using inks from UK-based Pulse Roll Label Products, Reflex conducted comparative testing to produce both promotional labels and for use on an order they recently won that required a full wrap around label using a specialized polyethylene substrate.

The trial compared a single GTT C21 anilox with two conventionally engraved anilox rolls, including one with 300 LPI and a volume of 8.5cm3 and one with 500 LPI and 7.5cm3. The one hit method using GTT produced significantly better opacity with less ink than the double hit method. The difference is so clear that it can be seen without magnification.

“I am very happy with the results using the C21 anilox and have achieved very good densities on the material we are using for our new project. It has also been used on other jobs which had been double hit with opaque white and are now just been hit once using the GTT C21 Anilox.”Michael Preston of Reflex Labels.

“Apex has worked closely with Reflex labels to achieve a solution for opaque whites, the results have proven to be massively positive for both parties. Not only has this beena victory for Apex and Reflex but I’m confident we have solved a problem for the label industry in general.”Matthew Turner, Technical Representative for Apex.

OPAQUE WHITES WITH GTT

Reflex Label Unlocks Secret to Opaque Whites with GTT

A one hit, single anilox engraved with GTT, Apex’ proprietary channel engraving technology, produced a significantly

better opacity with a single hit than with a double hit using any other anilox and even with less ink than the double hit

method. The difference is so clear that it can be seen without magnification.

Offset professionals know that coatings and varnishes can bring a printed piece to life, or ruin it completely. Whether you use a high-gloss UV lacquer, a drip-off or soft-touch coating, an acquous lacquer for protection, all coatings are applied in order to create some additional value to a print.

The application of offset coating is done by an anilox roll, it transfers the right amount of lacquer from A to B. Nevertheless, the right amount of lacquer requires a very accurate approach and printers who properly manage this process can provide additional value to a simple print and command higher margins for the entire operation.

1. More lacquer isn’t necessary for a more glossy appearance. But it will hurt your bottom line.

It is a misunderstanding to think that ‘more gloss’ automatically means ‘apply more lacquer’. Gloss is measured using a Gloss Meter which directs a light at a specific angle to the test surface and simultaneously measures the amount of reflection. The more light is reflected, the more glossy the appearance of the surface.

It is not about the amount of lacquer applied onto a print, which determines the level of gloss you achieve. It is all about creating a smooth and consistent layer that reflects the light in a homogenous way. The images below show this in practice, whereas the below example results in a higher # gloss points, because more light is reflected.

2. Maximize visual coating results To maximize visual coating results, avoid issues like (micro-)

foaming, orange-peel and pinholing from the start. Orange peel effect refers to a coating layer that can be characterized by a surface that is similar to an orange peel and the reason for this almost always is too much volume. Pinholes (trapped pockets of air within the conformal coating) and foam (extreme bubbling) are similar defects that should be avoided in order to maximize the visual coating result.

OFFSET COATING


3 Tips for Improving the Margins of Your Offset Coating Operation

Gloss Checker

Gloss Checker

Gloss Checker

Gloss Checker


Non-homogenous coating layer (reason: air inclusion) Homogenous and even coating layer (no air)

However, this is a very complicated process as it is highlydependent on many variables: the type of coating (lacquous, UV, dispersion), the substrate to apply the coating onto and the drying equipment. The anilox manufacturer needs to take all these parameters into consideration while giving proper volume advice for the transfer of wet coating. The below micro-photographs show the difference between non-homogenous and homogenous coating application.

3. Avoid press downtime Want to ensure longer print cycles without having to stop

the press? There are various ways to achieve this:

• Make use of standardized anilox rolls that are suitable for applying different types of coating. • Keep your rolls clean on a regular basis in order to avoid having to deep-clean them. • Keep your rolls in good shape, avoid damages while changing them.

Bringing all these tips into practice means your cost go down and your print quality is increasing in quality, automatically resulting in a better price.

Ask your Anilox manufacturer for advice on the right amount of coating to be transferred, and the correct

surface profile.

Second-Generation Anilox Rolls versus New technology Anilox rolls

Many Offset printers today rely on second-generation anilox surfaces made up of closed-cell geometry, basically holes into which coating is doctored. Problem is, this geometry can create turbulence, foaming and uneven coating release. The result is a disturbed laydown and pinholing among others. GTT’s new Open Slalom Ink Channel geometry instead allows coating to flow calmly and transfer precisely with stunning results. This technology is approved and embraced by all leading Offset Coating Machine manufacturers.

CONCLUSION

GTT’s new Open Slalom Ink Channel geometry allows coating to flow calmly and transfer precisely with stunning

results. A smoother layer is the result, often with savings on coating. Positive side-effects are that orange-peel,

pinholing and micro-foaming are issues of the past. This technology is approved and embraced by all leading

Offset Coating Machine manufacturers.

More information:http://discover.apex-groupofcompanies.com/drupa2016-1

ABOUT APEX INTERNATIONAL

Apex International employs approximately 300 people and serves over 5,000 active customers in all markets

(corrugated, narrow-web, wide-web, offset and coating applications) on a global scale. Apex operates five production

facilities and seven sales offices worldwide, providing a local presence for customers and a global network to serve

multi-location businesses and multi-national corporations. Apex anilox products are approved and deployed by all

leading machine manufacturers in the flexo and offset industry.

“Apex anilox products are approved and deployed by all leading machine manufacturers in the flexoand offset industry.”

apex prepared for unprecedented concept launches at drupa · results in uv label, opp polythene and...

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