product knowledge edition

7/30/2019 Product Knowledge Edition

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Improve Product knowledge -generally we think we know it issimple & quite confident giving a convincing reply, but at times when a question

thrown at us unexpectedly we tend to stutter... so I have gathered some useful tips

for us to keep in store handy to avoid embarrassment.

Contents - Look for ( new)

* what is vignette...................................................................................................................................3

* What is CMYK......................................................................................................................................3

* What is PMS .......................................................................................................................................4

* Printing processes..............................................................................................................................5

*Iwasaki advantages ( NEW ) .............................................................................................................6

* What is DPI.......................................................................................................................................12

* Measuring Repeat Length .............................................................................................................12

* Convert LM to SQM......................................................................................................................14

* What is a Blanket.............................................................................................................................14

* What is Pre-Press.............................................................................................................................15

* What is UV curing............................................................................................................................16

* What is an Impression.....................................................................................................................16

* Definition of a Self Adhesive Product...........................................................................................16

* Various types of face stock materials ( NEW ).............................................................................17

* QC test methods..............................................................................................................................19

* Theory of Corona treatment..........................................................................................................22

* Positive & Negative plates.............................................................................................................23

* Offset Plates technology................................................................................................................23

* Flexography trouble shooting guide ...........................................................................................23

*Metallization (NEW ).......................................................................................................................28

* 25 simple ways to save money at work place ( NEW )...............................................................28


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* to be continued.............................................................................................................29 onwards


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What is Vignette in printing

Vignette can be used to artistic effect, as demonstrated in this panorama.

In photography and optics,vignette (from French "vignette", pronounced/vnjt/) is

a reduction of an image's brightness or saturation at the periphery compared to the

image center. The word vignette, from the same root as vine, originally referred to a

decorative border in a book. Later, the word came to be used for a photographic

portrait which is clear in the center, and fades off at the edges. It is sometimes purposelyintroduced for creative effect, such as to draw attention to the center of the frame.

What are Process colors

The CMYK color model (process color, four color) is a subtractive color model, used in

color printing, and is also used to describe the printing process itself. CMYKrefers to

the four inks used in some color printing:cyan,magenta,yellow, and key (black).

Though it varies by print house, press operator, press manufacturer and press run, ink is

typically applied in the order of the abbreviation.

The "K" in CMYK stands for keysince in four-color printing cyan, magenta, and yellow

printing plates are carefully keyedor aligned with the keyof the blackkey plate. Somesources suggest that the "K" in CMYK comes from the last letter in "black" and was

chosen because B already means blue. However, this explanation, though plausible and

useful as a mnemonic, is incorrect. The CMYK model works by partially or entirely

masking colors on a lighter, usually white, background. The ink reduces the light that
http://en.wikipedia.org/wiki/Photographyhttp://en.wikipedia.org/wiki/Opticshttp://en.wikipedia.org/wiki/Wikipedia:IPA_for_Englishhttp://en.wikipedia.org/wiki/Wikipedia:IPA_for_Englishhttp://en.wikipedia.org/wiki/Wikipedia:IPA_for_Englishhttp://en.wikipedia.org/wiki/Wikipedia:IPA_for_Englishhttp://en.wikipedia.org/wiki/Wikipedia:IPA_for_Englishhttp://en.wikipedia.org/wiki/Brightnesshttp://en.wikipedia.org/wiki/Saturationhttp://en.wiktionary.org/wiki/peripheryhttp://en.wiktionary.org/wiki/vignettehttp://en.wikipedia.org/wiki/Vinehttp://en.wikipedia.org/wiki/Subtractive_colorhttp://en.wikipedia.org/wiki/Color_modelhttp://en.wikipedia.org/wiki/Color_printinghttp://en.wikipedia.org/wiki/Cyanhttp://en.wikipedia.org/wiki/Cyanhttp://en.wikipedia.org/wiki/Cyanhttp://en.wikipedia.org/wiki/Magentahttp://en.wikipedia.org/wiki/Magentahttp://en.wikipedia.org/wiki/Magentahttp://en.wikipedia.org/wiki/Yellowhttp://en.wikipedia.org/wiki/Yellowhttp://en.wikipedia.org/wiki/Yellowhttp://en.wikipedia.org/wiki/Blackhttp://en.wikipedia.org/wiki/Printing_presshttp://en.wikipedia.org/wiki/Key_platehttp://en.wikipedia.org/wiki/Key_platehttp://en.wikipedia.org/wiki/Key_platehttp://en.wikipedia.org/wiki/Mnemonichttp://en.wikipedia.org/wiki/Mnemonichttp://en.wikipedia.org/wiki/Key_platehttp://en.wikipedia.org/wiki/Printing_presshttp://en.wikipedia.org/wiki/Blackhttp://en.wikipedia.org/wiki/Yellowhttp://en.wikipedia.org/wiki/Magentahttp://en.wikipedia.org/wiki/Cyanhttp://en.wikipedia.org/wiki/Color_printinghttp://en.wikipedia.org/wiki/Color_modelhttp://en.wikipedia.org/wiki/Subtractive_colorhttp://en.wikipedia.org/wiki/Vinehttp://en.wiktionary.org/wiki/vignettehttp://en.wiktionary.org/wiki/peripheryhttp://en.wikipedia.org/wiki/Saturationhttp://en.wikipedia.org/wiki/Brightnesshttp://en.wikipedia.org/wiki/Wikipedia:IPA_for_Englishhttp://en.wikipedia.org/wiki/Opticshttp://en.wikipedia.org/wiki/Photography


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would otherwise be reflected. Such a model is called subtractivebecause inks "subtract"

brightness from white.

In additive color models such as RGB, white is the "additive" combination of all primary

colored lights, while black is the absence of light. In the CMYK model, it is the opposite:

white is the natural color of the paper or other background, while black results from a

full combination of colored inks. To save money on ink, and to produce deeper black

tones, unsaturated and dark colors are produced by using black ink instead of the

combination of cyan, magenta and yellow.

Original Pantone Color Matching System

The Pantone Color Matching System is largely a standardized color reproduction

system. By standardizing the colors, different manufacturers in different locations can all

refer to the Pantone system to make sure colors match without direct contact with one

another.

One such use is standardizing colors in the CMYK process. The CMYK process is a

method of printing color by using four inkscyan, magenta, yellow, and black. A

majority of the world's printed material is produced using the CMYK process, and there

is a special subset of Pantone colors that can be reproduced using CMYK Those that are

possible to simulate through the CMYK process are labeled as such within the

company's guides.

However, most of the Pantone system's 1,114 spot colors cannot be simulated with

CMYK but with 13 base pigments (15 including white and black) mixed in specifiedamounts.[6]

The Pantone system also allows for many 'special' colors to be produced such as

metallic's and fluorescents. While most of the Pantone system colors are beyond the

printed CMYK gamut, it was only in 2001 that Pantone began providing translations of

their existing system with screen-based colors.
http://en.wikipedia.org/wiki/Brightnesshttp://en.wikipedia.org/wiki/Additive_colorhttp://en.wikipedia.org/wiki/RGB_color_modelhttp://en.wikipedia.org/wiki/Primary_colorshttp://en.wikipedia.org/wiki/Saturation_%28color_theory%29http://en.wikipedia.org/wiki/CMYKhttp://en.wikipedia.org/wiki/Spot_colorhttp://en.wikipedia.org/wiki/Pantone#cite_note-patone2-5http://en.wikipedia.org/wiki/Pantone#cite_note-patone2-5http://en.wikipedia.org/wiki/Pantone#cite_note-patone2-5http://en.wikipedia.org/wiki/Pantone#cite_note-patone2-5http://en.wikipedia.org/wiki/Spot_colorhttp://en.wikipedia.org/wiki/CMYKhttp://en.wikipedia.org/wiki/Saturation_%28color_theory%29http://en.wikipedia.org/wiki/Primary_colorshttp://en.wikipedia.org/wiki/RGB_color_modelhttp://en.wikipedia.org/wiki/Additive_colorhttp://en.wikipedia.org/wiki/Brightness


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Types of Printing processes

1. Offset Lithography the most common printing process today the workhorse! It

offsets ink from metal plates to a rubber blanket (cylinder) to the paper. Almost

every commercial printer does offset printing.

2. Engraving think "fine stationery." Produces the sharpest image of all. Image feels

indented (run your fingers over the back side of the sheet). Most law firms still

use engraving.

3. Thermography raised printing, less expensive than engraving. Uses special

powder thats adhered to any color ink. Mainly used for stationery products.

4. Reprographics general term covering copying and duplicating. Think in-house

copying departments and copy or quick-printing shops. They take your originals

and make duplicates of them.

5. Digital Printing the newest printing process and the least understood! Includes

all processes that use digital imaging to create printed pieces. Doesnt use film.

(Think desktop to the digital press.) For short-run, fast-turnaround jobs.

Limitations include color, paper choices, and quality. But not for long -- the

technology is exploding!

6. Letterpress the original process founded by Gutenberg in 1440. "Relief" printing

(like rubber stamps, images on the plate are higher than the surface). Fine

letterpress is being done by fewer and fewer printers.

7. Screen a.k.a. silk-screening. Ink is forced through a screen following a stencil

pattern. Used for ring binders, t shirts, bumper stickers, billboards.

8. Flexography special type of printing for packaging products. The plates used are

flexible. Products include cardboard boxes, grocery bags, gift wrap, and can and bottle

labels. Frequently used for printing on plastic, foil, acetate film, brown paper, and other

materials used in packaging, flexography uses flexible printing plates made of rubber

or plastic. The inked plates with a slightly raised image are rotated on a cylinder which

transfers the image to the substrate. Flexography uses fast-drying inks, is a high-speed

print process, can print on many types of absorbent and non-absorbent materials, and

can print continuous patterns (such as for gift-wrap and wallpaper).


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8. Gravure prints directly from cylinder to paper. Used when printing for

millions of impressions think magazines, newspapers, and direct mail

catalogs.

Iwasaki advantages

Offset rotary intermittent press for label printers. This intermittent press fits exactly in

the trend toward shorter runs and quick set-up demands. In fact it is the ideal modular

alternative for the printers that consider going digital. This press can combine all used

processes in line such as wet/ dry offset, letterpress, screen-print , hot foil stamping,

embossing, flexo varnishing, laminating and die-cut. next to this backside printing in the

same pass is possible.

The advanced servo system of this press assures a high quality control and print quality.

Objectives

Production for medium to long run

Quality and speed of print

Both Wet and Dry offset versions

Advantages

Robust Construction

Simple set up Reduced waste

High Print Quality

High press performance

Full servo control for registration and control

Options include: Hot Foiling unit, flexo unit, Rotary diecutting, laminating etc...

TR2 DH 330 DH 250

Maximum

repeath

length

50 - 260

mm

50 - 310

mm

50 -310

mm

Web width :

mini-maxi

100 -

330 mm

100 - 330

mm

100 - 330

mm

Maximum

print format

310 x

254 mm

310 x 254

mm

310 x 254

mm


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Maximum

diecutting

format

310 x

254 mm

(opt)

310 x 310

mm

310 x 310

mm

Maximum

foiling format

-310 x 310

mm

Press Speed

30 - 250

rpm ( 50

m/min)

30 - 200

rpm

(40m/min)

30 - 200

rpm

(40m/min)

Number of

colours

1 to 7

colors

Electrical

requirements

26 KW +

5,6 KW

(UV)

12 KW 9 KW

Power source 3 phase200 V

3 phase200 V

3 Phase200 V

IWASAKI (TR2) Contribution courtesy Mr. Sachin Arya - Baddi

Features

New machine IWASAKI TR 2 got the printing features:

1. Waterless offset (Ajantas USP) which gives fantastic half tone quality.

2. Offset with water dampening.

3. Additional advantage over other Iwasaki is that, it has flexo unit.

4. Semi Rotary

5. Online varnish, stamping Die punch (Flatbed), slitting & rewinding.

6. Max Image Area- 320mm

7. Repeat Length- 250mm

8. Halftone -0 to 100%

9. Waterless printing has some advantages over conventional offset as colors are more vibrant andthe printed image sharper; however, the overall cost is slightly higher.


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Offset technology

Offset technology works on the principle that Image Area gets separated from Non Image Area on the

same surface due to chemical applied to develop the silicone coated aluminum plate.

Image area on the plate only catches the Ink & non image area does not take the ink. Then image

area, which holds the required ink dispense the same onto the blanket. From the blanket ink is

transferred onto the substrate. In Iwasaki TR2 , ink is cured through UV lamps.

Iwasaki TR 2 is semi rotary machine.

Flexo Technology

Ink Tray / pan

Through rubber roller Ink is picked

Doctor Blade spreads the evenly.

Anilox picks the evenly spread Ink

Plate Cylinder holds the Nylo Plate


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Nylo plate picks the Ink

Apply on Substrate

Impression cylinder gives pressure from backside.

Ink is cured through U.V lamps

Types of plate

1. For Offset:- Pressure Sensitive Aluminum Plate- Has relatively short life.

Waterless Ink is used.

1. For Flexo-Digital Nylo plates - Long Lasting ( It is similar which is used for Varnish)

Flexo Ink is used.

Water less Offset Ink

Waterless Ink,

Silicone Based. Very Thick, High Density

Viscosity Check not applicable.

Preparation of Plate

After graphic is approved.

Negative is prepared at designing Studio.

Aluminum Plate is exposed to 120 pulses with negative to prepare the positive.

(100pulse=1min).

Negative give printing plate with all the specifications of colors & job also depicts the feed

amount.

Plate is initially silicone coated and a film protects it from light.

After exposing it is treated with PTS 2 & WH3.

Plate should be placed very carefully & special attention has to be paid so that there is no

scratch.

Blanket is pasted on Chest with Lohman Tape.

All set-up / environment should be dust free.

Varnishing

Varnish comes in two type (Gloss or matt)

It is done to protect ink on label paper.

UV Curing is done.

Varnish Patch (Nylo Plate) is used to apply varnish evenly.

For all the filmic labels , only varnish is done.

Lamination

Either varnish or lamination is done both cannot be done on same job. Lamination adds strength

to the paper & withstand in wet area better than only varnished labels.


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10-23 mic. (As per customer specs) BOPP film is used for laminating along with glue.

It is not advisable to laminate on IWASAKI, it is better to use separate machine for better results.

But to save time we are using self adhesive laminating film.

We can die cut on IWASAKI after getting lamination done on separate machine that is called

second pass.

Hot Stamping

10-12 mic hot stamping foil is used.

Separate stamping block for each job (made of Copper or Zinc).

Block is pasted with SR 998 adhesive.

Block is pushed downwards apply heat & pressure on foil leaves foil color on specified area on substrate.

Embossing

Its another kind of special effect that can be given to specified area on label.

It is somehow opposite to hot foil stamping and embossing plate is fixed downside and pressureis applied from upside and particular alphabet or picture appears little above over the label.

NOTE: hot stamping & embossing can be done on same job as per requirement.

Die Cutting

All the labels need to be cut according to their specified shape (punch to shape).

Flatbed Die is pasted upwards and pushed downwards onto substrate to cut along the

boundaries of each label.

Downside there is a acrylic sheet (make ready sheet) to adjust the proper half cut & also to

protect 8mm steel plate of machine.

Precautions & Maintenance

While printing temperature has to be maintained at 19 - 21C as to avoid Motelling or scump.

o Motelling- If temp. is low Ink becomes tight and diminishes the effect.

o Scump If temp. is high Ink tends to spread while printing.

If there is any Minor spot on label apparent while printing, the Blanket has to be cleaned with

UV wash

If there is any scratch, either that area has to be removed from Blanket or new plate has to be

prepared/ mounted.

Ink has to be regularly checked and has to be spread with help of spatula as it will leave some

oily substance if contaminated for some while. It can affect the inks effect.

While changing the job, if color sequence has to be changed than Ink tray has to be cleaned with

UV wash. While printing if there is adhesive on roller than, labelstock will stick resulting breakage of roll.

In that case Toluene has to be used to clean the rollers properly.

Preparation of Flexo Plate

StampingBlock


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According to job, Flexo / Nylo plate comes from repro house / studio

Flexo /Nylo Plate is pasted on cylinder with Tessa tape.

In Iwasaki, flexo plate is mounted at first unit.

It can be used to print high opacity on clear labelstock before image is printed.

Quality Checks

1. Scuff Test ( Standard: 50 rounds on 2lbs)

It is a test to check that label does not get affected by rubbing against each other.

2. Tape Test

Ink should not come out with tape from the printed label surface.

3. Fade test / Sun Test

Sun light should not affect / damage the label print. Label is pasted in a area exposed to sunlight

test the effect of the same.

4. Oven Test

Labels adhesive on actual bottle / container is checked. Also Lamination on label is tested.

5. GSM testing GSM of RM is tested as per the specifications.

6. Dynes Treatment- ( 40+ important)

Mainly it is to be done on films as it is difficult to determine the substrate.

Red color solution is applied on substrate, if bubbles appear immediately then it is

wrong, bubbles should appear after 2-3 seconds

Other Important Terms1. Misregister-When printing gets missed and Ink falls on other than specified area.

2. Micro setting- Plate is set through the photocell to ensure proper registration of image.

3. Feed Amount- Amount of paper that is required for single time impression/printing.

4. No. of Ups- No of labels that can be printed at single Impression.

Important Calculation

1. No of Impression= Total Quantity/ No. of Ups

2. Running meter required for one job= Impressions X Feed amount (mm) / 1000

3. Sq.mtrs = Rmtrs X Paper width mm /1000

4. Label size (Sq.inch) = {width (mm) X height (mm)} / 645.

5. GSM= weight(gm) / Area(Sqm) Width

Height


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What is DPI

DPI stands for dots per inch. DPI is a measurement of printer resolution that defines

how many dots of ink are placed on the page when the image is printed. The higher a

printer's DPI, the smoother your printed image will appear. Today's photo-quality ink jet

printers have DPI resolution in the thousands (1200 to 4800 dpi). They will give youacceptable quality photo prints of images with 140-200 ppi resolution, and high quality

prints of images with 200-300 ppi resolution.

A close-up of the dots produced by an inkjet printer. Actual size isapproximately 0.25 inches square (0.635 centimeters square). Individual colored droplets

of ink are visible; this sample is about 150 DPI.

The term DPI is often used interchangeably with PPI, causing a lot of confusion,

however, DPI refers to the resolution of the printing device, where PPI refers to the

resolution of the image itself.

Monitoring Repeat LengthHave you ever had the problem of repeat length varying through a printed roll? You

measure the repeat when you stop the press, and its correct, but when the roll is being

converted, unacceptable variations or shifts in repeat length are encountered

throughout the roll. Perhaps the repeat measures 12 near the core, but measures 13

towards the outside of the roll. Sound familiar? This is not an uncommon problem.

Repeat length can vary when printing on substrates that are stretchy, or have

properties that push the limits of our equipments ability to control web tension or web

speed relative to plate surface speed. With a stretchy or elastic substrate, we often print

on the material while its slightly stretched by excessive tension and end up with a short

repeat when the substrate contracts after printing. With a rigid or stiff substrate, we

may rewind so tightly that we pull the material past the plate at a speed slightly faster

than that of the plates surface and end up with a repeat length thats too long. Or, we

may not be able to pull the material through the press fast enough and end up with a
http://en.wikipedia.org/wiki/Inkjet_printerhttp://graphicssoft.about.com/library/glossary/bldefppi.htmhttp://graphicssoft.about.com/library/glossary/bldefppi.htmhttp://en.wikipedia.org/wiki/Inkjet_printer


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short repeat length. The tension control demands we face when working with touchy

substrates can pose problems with respect to repeat length.

Variation in repeat length is often associated with poor tension control. However, even

under the best of tension control conditions, the simultaneously and inversely changing

diameters of the unwinding and rewinding rolls almost certainly guarantee tension

variation throughout the printed roll. With many substrates, this is not a major

problem. But printing on a light gauge low-density polyethylene web with old, cranky

equipment, or pulling heavy gauge material through our presses, for example, can test

the limits of our ability to control repeat length.

Most of us lack the technology to monitor repeat length while the press is running.

However, imagine being able to tell while the press is running that your repeat might be

long or short, simply by analyzing the print with the unaided eye or an average video

inspection device. It could mean a reduction in difficulties and waste associated withrepeat variation. What follows is a way to do just that.

One of the trademark properties of flexographic printing is the appearance of a halo

around the printed image. This halo is mainly caused by slight over-impression of the

plate to the substrate. Keeping this halo to a minimum is a basic goal of quality

flexographic printing, but often we cannot avoid at least some degree of visible halo.

Lets define the leading edge of a printed image as the edge closest to the rewinder,

and the trailing edge as the edge furthest away from it. At times the halo is more

pronounced at either the leading or trailing edge of the printed image. This can result

from a difference in plate surface speed and substrate speed, and can be present

whether or not our plate is over-impressed. Fortunately, its sometimes possible to

interpret the relationship of the substrate speed to the plate surface speed by close

observation of this type of halo, and judge from its asymmetry the likelihood of a

discrepancy in repeat length.

It is found that if the halo is more pronounced at the leading edge of the

image, the substrate is traveling faster than the plate surface and the repeat length is

longer than what it should be. If the halo is more pronounced at the trailing edge of theimage, the substrate is traveling slower that the plate surface and the repeat is short.

Therefore, our goal is to try to avoid halos or keep them equally distributed between the

leading and trailing edges of the images, by making the appropriate adjustments in

tension.


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Conversion of LM to SQM

The conversion goes like this: Area(sq mtr) = L(m) X W(m) .

Area is Length * Width, so just divide area by the Width and you will end up with the linear

meters. All the units need to match so convert millimeters to meters first.

185 / 0.085 = 2176.47 linear meters of paper

What is a Blanket

Printing surface / Fabric ply / Close cell compressible layer / Cord ply / Sealed

bottom fabric

BLANKET BASICS

1. During unpacking and handling, take particular care not to scuff rubber surface or make sharp

bends or creases that might create surface impressions. Check entire blanket for visual defectsor blemishes.

2. Make sure blanket is cut square and properly punched, or where required, bars are parallel

and securely fastened.

3. Check caliper/gauge of each blanket using a deep throat bench micrometer (Cady gauge),

NOT a machinists micrometer or paper micrometer.

4. Establish and maintain usage records for each blanket.

5. New blankets should be washed before use to remove any dust or protective coating appliedduring manufacture. Use clean sponge or soft, lint-free cloth wet with water or water-miscible

blanket wash.

6. Striping on fabric side of blanket must run around cylinder. Striping running across

cylinder identifies a blanket that has been cut in the wrong direction.


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MOUNTING DIRECTIONS

1. Thoroughly clean blanket cylinder and bearers.

2. Mounting a blanket is not the same as mounting a plate ... blankets are elastic. Mounting

procedures and tension are critical to proper performance.

3. Securely lock leading edge of blanket into cylinder. Slowly turn cylinder while pulling blanket

over cylinder. Lock trailing edge in place. Tighten initially only to take up slack.

4. Make final check of printing surface to ensure nothing has been trapped under blanket or

packing. Allow setting by running cylinder on impression, Pre-Press

What is Pre-Press

All activities before commencement of bulk production like preparation of design,

correction / improvement / changes in existing design to initial proofing are carried outin the Pre-Press department. It is further divided into sections;

Computerized Designing Section comprising of Macintosh and advanced PCs

with up to date commercial designing software is manned by experiencedpersonnel. Here the Final CD is prepared to make layouts for production plates /

Cylinders.

Plate Making Section is equipped with computerized plate exposing units and

automatic plate developing machines. Facility to bake the plates for extra long

run life is also available.

What is UV Curing?

Ultraviolet curing (commonly known as UV curing) is a photochemical process in

which high-intensity ultraviolet light is used to instantly cure or dry inks,

coatings or adhesives. Offering many advantages over traditional drying


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methods., UV curing has been shown to increase production speed, reduce reject

rates, improve scratch and solvent resistance, and facilitate superior bonding.

Look What UV Curing Can Do For You

UV curing offers manufacturers many benefits. Below youll find additional informationon some of the most significant ones.

Inks, coatings, and adhesives with dramatically improved physical properties.

Faster production speeds and capacity

Reduction of Work-in-process

Dramatically reduced set-up/clean-up labor

Environmentally Friendly Energy savings, no emissions controls

Less floor space needed

Increase yield and reduce scrap

print impressions

Number ofimages (individual copies) produced in a print run.

Definition of a Self Adhesive Product

Self Adhesive paper is a complex made up of three component parts

1. The Face Stock- this is the part that will finish up as the label. A wide variety of face

stock materials can be chosen depending on quality required. The face stock used in

white, colored, fluorescent, laminated, metalized, thermal and carbonless, film.

2. The Adhesive - it's function it's to keep face material joined to the release liner.

When these two elements are separated, the adhesive stays attached to the face

material forming label.

The quantity of adhesive which is applied to the release liner varies between 10-25gsm depending on the final use to be made of the product.

Depending on the composition, adhesives can be found in 3 main types
http://www.fusionuv.com/uvlearningcenter.aspx?id=206#Inks,_coatingshttp://www.fusionuv.com/uvlearningcenter.aspx?id=206#Faster_production_speeds_and_capacityhttp://www.fusionuv.com/uvlearningcenter.aspx?id=206#Reduction_of_Work-in-processhttp://www.fusionuv.com/uvlearningcenter.aspx?id=206#Dramatically_reduced_set-up_&_clean-up_laborhttp://www.fusionuv.com/WorkArea/linkit.aspx?LinkIdentifier=id&ItemID=208http://www.fusionuv.com/WorkArea/linkit.aspx?LinkIdentifier=id&ItemID=208http://www.fusionuv.com/WorkArea/linkit.aspx?LinkIdentifier=id&ItemID=208http://www.fusionuv.com/uvlearningcenter.aspx?id=206#Less_floor_space_neededhttp://www.fusionuv.com/uvlearningcenter.aspx?id=206#Increase_yield_and_reduce_scraphttp://www.investorwords.com/10438/number.htmlhttp://www.businessdictionary.com/definition/image.htmlhttp://www.businessdictionary.com/definition/individual.htmlhttp://www.businessdictionary.com/definition/copy.htmlhttp://www.businessdictionary.com/definition/printrun.htmlhttp://www.businessdictionary.com/definition/printrun.htmlhttp://www.businessdictionary.com/definition/copy.htmlhttp://www.businessdictionary.com/definition/individual.htmlhttp://www.businessdictionary.com/definition/image.htmlhttp://www.investorwords.com/10438/number.htmlhttp://www.fusionuv.com/uvlearningcenter.aspx?id=206#Increase_yield_and_reduce_scraphttp://www.fusionuv.com/uvlearningcenter.aspx?id=206#Less_floor_space_neededhttp://www.fusionuv.com/WorkArea/linkit.aspx?LinkIdentifier=id&ItemID=208http://www.fusionuv.com/uvlearningcenter.aspx?id=206#Dramatically_reduced_set-up_&_clean-up_laborhttp://www.fusionuv.com/uvlearningcenter.aspx?id=206#Reduction_of_Work-in-processhttp://www.fusionuv.com/uvlearningcenter.aspx?id=206#Faster_production_speeds_and_capacityhttp://www.fusionuv.com/uvlearningcenter.aspx?id=206#Inks,_coatings


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1. Water based Emulsion ( or Acrylic ) adhesives - These are made up polymers dissolved

in water. Most widely used types are acryl ate dispersions ( water based acrylic adhesive

)

2. Solvent Based Adhesive - These are made up of solutions in a organic dissolvent with

different components ( rubber , resin etc. )

3. Hot melt adhesive - These are made up of rubber with resins, plasticizers and other

additives which, when producing the self adhesive complex in melted form are applied

by means of heat ( with temperatures of higher than 120c ) neither dissolvent nor

water are used.

3. The Silicon coated Release Liner - This is the part which is eliminated after the label

has been attached to the appropriate surface. The coating of silicon ensures that the

adhesive will only be attached to the material. The Silicon coating that is applied tothe release liner usually around the 1.2 gsm range depending on the type of

release liner and final product.

* ( contribution courtesy Mr.Manoj Kumar - Daman 12/12/2011 )

Various types of Self Adhesive Stock materials used in Printing

Description Substrate Adhesive Liner / Release paper Application

Fascoat (Avery) Chromo Hot melt

Silicone coated Release

liner

Used where Paper label is

required with UV /

Lamination


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80 GSM 18 (+-2) 62 GSM

Clear on Clear PP Transparent Acrylic PET transparent

where absolute

transparency is required

60 micron 19 GSM 36 mic

PE 85 White

Opaque

Polyethylene Acrylic


liner

Used for squeezablecontainers / bottles /

tubes

85 micron 19 GSM 62 GSM

PE 85

Transparent

Transparent

Polyethylene Acrylic


liner

Used for squeezable

containers / bottles /

tubes

85 micron 19 GSM 62 GSM

PP White

Biaxially

Oriented

PolypropyleneWhite Hot melt

Silicone coated Releaseliner

Used where Opaque

Filmic Label Required (

but not suitable forsqueezable Bottle)

50 micron 15.5 Gsm 62 GSM

PP transparent

Biaxially

Oriented

Polypropylene

transparent Hot melt


liner

Used where Opaque


but not suitable for

squeezable Bottle)


PET White

Biaxially

Oriented Poly

Ethylene White Hot melt


liner

Used where Opaque


Suitable for Oil Product)50 micron 15.5 Gsm 62 GSM

PET Clear

Biaxially

Oriented Poly

Ethylene

Transparent Hot melt


liner

Used where Transparent


Suitable for Oil Product)


PP metallic

Biaxially

Oriented

Polypropylene

metallic Hotmelt


liner

Used where metallic

Effect Filmic Label

Required


Ultra

Destructive

Surface Paper

is made out of

Egg Cell Hot melt


liner

Used where Tamper

Evident Label Required

18 GSM 62 GSM


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Direct Thermal


liner

Used where Thermal Ptg

on Label Required

62 GSM

Thermal

Transfer


liner

Used where Thermal Ptg

on Label Required

62 GSM

Quality Control carried out on adhesive complex

1. Peel or Adhesive Capacity Test

- according to the adhesive capacity, adhesives are commonly classified of ;

Removable - adhesive that can be taken off after they have been stuck on.

Permanent - adhesive that cannot be taken off after they have been stuck.

Super Permanent - these are used when there are problems with the adhesive capacity

of the release liner which the label is attached.

The peeling or adhesive capacity test is a way of measuring the products adhesive

capacity. According to the result the adhesive will be defined as Super permanent,

Permanent, Removable.

Characteristics of Peeling test - The force required to remove at 180 and 300mm/min

a sticker 25mm wide attached to the pressure exercised by a roller weighing 2kg on a

plate of various different materials after specific periods of attachment ( 20 min, 24

hours, 1 week ) (Ref/Std:FINAT FTM-1)


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2. Quick Stick Test ;

This test measures the tack ( or stickiness ) of the adhesive. Tack is very important for

automatic application. A high level of tack means that the adhesive will be attached as

soon as it touches the release liner.

For manual application tack is less important since the person who stick on the label can

subsequently apply the pressure for it to remain attached. For example, for stickers it is

better to have a low tack which makes it possible to un-stuck if stuck in the wrong place.

Logically this will always be for a short space of time, since the adhesive will increase

their adhesive capacity over time.


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Characteristics of Quick Stick test - The force required to remove immediately at

300mm/ min a 190c25mm strip of adhesive face material attached to a plate of

stainless steel measuring 25x25mm (Ref/Std:FINAT FTM-9)

3. Rolling Ball Test:

This test also designed test Tack.

Characteristics of Rolling Ball test - The distance ( in CM) covered by a stainless steel

ball 11.1mm in diameter that falls onto a flat surface inclined at an angle of 30 and

which rolls on to a sample, it's movement then being restrained by the sample's

adhesive film. The slower the rolling ball move the greater the tack.(Ref/Std: PSTC 6M )

4. Cohesion Test:

Cohesion of a adhesive gives us an idea of it's resistance to fluidity. This is classic

problem when we try to guillotine self adhesive sheets or die cut stickers. Since if the

adhesive does not have sufficient cohesion it can flow over the edges and the sheets /

labels will stick to one another.

Characteristics of Cohesion test - Interconnecting or fragmentation force of an

adhesive film in two parts when two different forces are applied. This test is based on

the time required for a 1kg weight to produce an internal fracture in the adhesive film of

a sample strip stuck to a plate of glass at an inclination of 2 from the vertical. (Ref/Std:

FINAT FTM8 )

5. Release Test :

Release is the force that separates the face material and the release liner, and is a very

important factor in the printing process and process of matrix stripping ( reels) and also

for the automatic application of labels. release test carried out at two different speeds.

Low speed - 300mm/ min.

High speed - 150mtr/min.

Characteristics of Release test - The force required to un-stick adhesive applied face

stock material from the silicon coated release liner to which it is attached as part of a

single adhesive complex. Low speed - sample 5cm width x 19cm long / High speed -

sample 3cm width x 70cm long. (Ref/Std: low speed - FINAT FTM3 / high speed -

FINAT FTM4 )


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Theory of Corona Treatment:

The surface tension of plastic films is not sufficiently high to permit good adhesion of

print ink with plastic film . In case of lamination , it prevents better bonding between

two or more materials. Hence, for better quality of printing, lamination and coating

processes , surface tension of the plastic films should be increased. The Corona

Treatment method is widely used nowadays to increase the surface tension of the films.

The Corona Treatment of plastic film is done by passing the film through the corona

discharge created between electrode and dielectric covered ( usually Silicone Rubber

Sleeve) earthed roller as shown in Fig. 1. The air gap between electrode & roller is 2-3

mm. The electrode is connected to electrical supply having high voltage & high

frequency. As film passes through the corona discharge, molecules of surface gets

oxidizes which has more surface tension. The corona discharge between electrode and

roller is visible by violet color flame between them.

Positive & Negative Plates

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 whenexposed 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.
http://www.etind.com/corona-treatment-tech-info.htmlhttp://www.etind.com/corona-treatment-tech-info.htmlhttp://www.etind.com/corona-treatment-tech-info.htmlhttp://www.etind.com/corona-treatment-tech-info.html


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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 sheet fed 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

( * contribution courtesy Mr. Prashant Kulkarni - Daman 13/12/2011 )

Flexography Troubleshooting GuideAdhes ion

Problem: Ink flakes off substrate, comes off when crinkled, or isremoved easily in tape test.Cause:1. Viscosity too high


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2. Viscosity too low3. Ink surface tension too high4. Incorrect ink system for substrate5. Poor film treatment6. Ink drying too slow7. Substrate surface contamination8. Insufficient web temperature

Solution:1. Reduce viscosity consistent with acceptable printability2. Add virgin ink to fountain3. Consult your technical sales representative4. Ensure that the correct ink for the substrate is being used5. Check surface of film for adequate treatment; treat in-line, if possible6. Check driers for heat and airflow; consult your ink manufacturerSolvent Flexo: Reduce with faster solvent blend

7. Check with film supplier as to advisability of applying a primer before printing, use in-line treater8. Increase temperature settings of driers, check drier balance

BleedProblem: Color spreads into subsequently applied coating oradhesiveCause:1. Improper pigment use in ink formulation2. Coating or adhesive may be rewetting the dried inkSolution:1. Consult your ink manufacturer to reformulate using resistant pigment2. Consult your ink manufacturer to reformulate using resistant pigment

Blus hing (Hazing, Fogging )Problem: Milky, foggy or matte appearance in an ink or coating.Cause:1. Solvent Flexo: High humidity causing excess moisture build-up in ink2. Solvent Flexo: Moisture condensation on surface of drying inkSolution:

1. Solvent Flexo: Consult your ink manufacturer for properly balanced solvent blend for specific ink and printingconditions2. Solvent Flexo: Use less hygroscopic solvent blend for ink reduction; coordinate with your ink manufacturer

Color Too StrongProblem: Visual color different from standard.Cause:1. Solvent Flexo: Ink viscosity too highWater Flexo: Ink pH too high2. Ink pigmentation too high3. Inappropriate anilox roll; cell volume too great or cell count too low4. Inadequate pressure setting on impression roll5. Plate and/or ink metering roll durometer too low6. Inadequate impression on doctor blade

Solution:1. Solvent Flexo: Reduce viscosity to proper level with recommended solvent blendWater Flexo: Check and adjust pH then reduce viscosity to proper level2. Reduce ink colorant strength with balanced extender3. Replace anilox roller with one of higher line. Adjust impression for optimum printability5. Consult plate and/or roller manufacturer6. Adjust doctor blade to recommended pressure

Color Var iations Among Same Color Jobs


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Being Run in a PlantCause:

1. Poor viscosity controlWater Flexo: Lack of pH control2. Variation in substrate porosity or surface treatment3. Previously used ink4. Inadequate amount of ink in fountain or doctor blade chamber5. Different suppliers of same color6. Variation in ink batches7. Non-standard process designSolution:1. Establish set procedures for viscosity controlWater Flexo: Maintain proper pH2. Consult with ink and substrate manufacturers for proper measures to be taken3. Replace or add virgin ink4. Add ink to fountain or ensure adequate ink pressure into enclosed doctor blade assembly5. Run only one suppliers ink on a given color6. Consult your ink manufacturer7. Inks must be modified to matched print station; recommend match visual standard on-site

Dir ty Pr int ingProblem: Fuzzy extensions of image into non-image area. Impressionincrease or change in plate durometer during run. Recovers when taken offpress; sometimes results in cracks in plate during storage.Cause:1. Excess ink being applied to plate2. Excess impression between plate and substrate3. Ink viscosity too high4. Accumulation of paper dust (lint)5. Ink drying too fast6. Water Flexo: Ink pH too low7. Excessive anilox volume8. Excess anilox impression9. Plate swell caused by use of materials not compatible with printing plates

Solution:1. Adjust anilox/fountain roller impression; adjust doctor blade pressure2. Reduce to kiss impression for type and minimize impression consistent with acceptable printability for reverses3. Adjust to lowest viscosity consistent with acceptable printability4. Improve housekeeping, vacuum paper dust and filter ink5. Check air flow at between-deck driers; consult your technical service representativeSolvent Flexo: Use slower solvent blend to reduce ink6. Water Flexo: Raise pH as instructed to by ink manufacturer

7. Use lower volume anilox8. Back off impression of anilox to plate9. Confer with plate and ink suppliers

Excessive Ink Consumpt ionProblem: Too few impressions per pound of ink.Cause:1. Ink viscosity too high2. Ink color acceptable, but stronger than standard3. Weak ink4. Excessive anilox volume5. 2 Roll: Soft metering roller6. Excess loss on start up or shutdownSolution:1. Reduce ink to lowest viscosity consistent with acceptable printability2. Use balanced extender to weaken range


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3. Check ink for strength vs. original standard4. Finer/shallower anilox5. Check durometer; extend or reduce ink6. Additional care in ink handling; can be due to large amount of ink required for inking station

Foaming

Problem: Voids in printing, foam visible in sumps, or inkoverflowing sump.Cause:1. Too much air being introduced into ink2. Ink level in fountain below pump intake level3. Ink falls excessive distance when recycled into reservoir4. Ink viscosity too high5. Improperly formulated ink6. Water Flexo: Poor cleanup proceduresSolution:1. Check for leaks in hoses and pumps. Adjust pump speed to reduce agitation2. Fill fountain with ink well above intake level3. Use hose or pipe to eliminate long ink falls into pan4. Reduce viscosity to allow any bubbles to rise and break at surface

5. Consult your ink manufacturer6. Water Flexo: Ensure that no detergent from clean-up has contaminated ink

Ghost ing

Problem: Part of image not printing; resembles an offset of sameimage. (See also Tracking)Cause:1. Ink dries too fast for anilox volume, does not adequately replenish aniloxSolution:1. Slow ink down Add extender Use coarser anilox Reduce press speed

Mott le

Problem: Random light and dark spots. May cause color toappear dirty.Cause:1. Substrate has non-uniform caliper or absorption characteristics2. Ink viscosity too low3. Improper impression. Can be caused by uneven plates, surface dirt on plates or dirty impression cylinder4. Non-optimal plate selection5. Contaminated plates6. Transparent colorSolution:1. Try lower durometer plate; try opaque ink2. Add fresh ink and maintain proper viscosity3. Clean plates and impression cylinder; adjust impression; check and adjust plate cushion or mounting materials;remake plates

4. Consult plate manufacturer5. Wash plates with appropriate solvent or replace plate if cannot be cleaned6. Transparent color does not cause problem, but increasing opacity of the color match may mask the problem

Set-of f and/or Bloc kingProblem: Ink transfers from image side to back side of substratewhen unrolled; inability to separate printed sheets or to unroll web.Cause:1. Drying too slow


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2. Excess pressure in re-wound roll3. Film substrate treated on both sides4. Film substrate heavily plasticized5. Web too warm when rewound6. Web rewound with too much surface moisture7. Solvent Flexo: Trapped solvent in printed ink film8. Water Flexo: Trapped amine in printed ink film

Solution:1. Check driers for heat and air flow; reduce ink viscosity consistent with acceptable printability; consult your inkmanufacturer2. Reduce rewind tension3. Avoid excessive pressure in rewind; apply offset powdero web prior to rewind; overprint with non-blocking clearvarnish, if necessary4. Avoid excessive pressure in rewind; apply offset powder to web prior to rewind; overprint with non-blocking clearvarnish; consult your ink manufacturer for different ink5. Reduce web temperature by chilling within 10 F of ambient temperature6. Avoid over chilling which allows condensation to form on film surface7. Solvent Flexo: Check driers for heat and airflow; consult your ink manufacturer8. Water Flexo: Check driers for heat and airflow; consult your ink manufacturer

TrackingProblem: Ink appears in area where there is no print.(See Ghost ing)Cause:1. Ink film too heavy2. Ink drying too slow3. Mechanical problems4. Difficult design due to extreme color coverage, degree of trapping and/or die cut positioningSolution:1. Reduce viscosity consistent with acceptable color and printability; have ink reformulated for stronger color to permitthinner film; adjust to proper pressure at all roller nips2. Solvent Flexo: Adjust ink drying speed with supplier-recommended solvent blendWater Flexo: Adjust ink drying speed based on instructions from supplier3. Adjust and clean all belt and idler roller surfaces that are in contact with the printed substrate

4. Change layout of design and/or consult your ink manufacturer

TrappingProblem: Cannot achieve good coverage in areas where more thanone color is applied.Cause:1. First-down color drying too slow2. Subsequent colors drying too fast3. Improper pressure setting on Impression cylinder4. Water Flexo: Improper viscosity5. Incorrect plate or backingSolution:1. Consult your ink manufacturer; check drier capacity; Solvent Flexo: Use faster-drying reducing solvent

2. Check air flow in between-color driers. Consult your ink manufacturer; SolventFlexo: Use slower drying reducing solvent3. Adjust impression on first- and second down inks4. Water Flexo: In general, each succeeding color requires slightly higher viscosity; adjust accordingly5. Use optimal plate, firmer backing

Weak Colo rProblem: Visual color different from standard.Cause:


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1. Ink viscosity too lowSolvent/Water Flexo:a. Too much solvent added to cut inkb. Excess clean-up solvent in systemWater Flexo: pH too low2. Worn anilox roller3. Plugged anilox roller

4. Plate durometer too high5. Improper pressure setting on impression and/or anilox roller6. Ink too weak for anilox roller volume7. Inadequate ink in fountain or in doctor blade chamber8. Solvent Flexo: Dirty plates9. Water Flexo: Glazed or dirty plates10.Water Flexo: Glazed metering roll

Solution:1. Replace ink totally or add virgin ink to fountain2. Consult anilox roller manufacturer to verify; replace if necessary3. Use brass bristled brush for chrome rollers; stainless steel bristled brush for ceramic rollersSolvent Flexo: Clean with recommended solvent to remove dry ink from cellsWater Flexo: Clean with brush, hot water (140 F) and detergent to remove dry ink from cells4. Remake plates to proper specifications and replace

5. Re-adjust impression for optimum printability6. Consult your ink manufacturer to strengthen ink if at all possible. If this is not possible, replace anilox roller withone having a deeper etch7. Add ink to fountain or ensure adequate ink pressure into enclosed doctor blade assembly8. Solvent Flexo: Wash plates with recommended solvent and, if necessary, a moderately stiff non-metallic brush9. Water Flexo: Wash plates with warm water, a mild detergent and a moderately stiff nonmetallic brush10.Water Flexo: Wash with warm water, a mild detergent and a moderately stiff non-metallic brush

Metallization

Metallization is performed using aphysical vapor depositionprocess. Aluminum is the most

common metal used for deposition, but other metals such as nickel or chromium are also used.

The metal is heated and evaporated under vacuum. This condenses on the cold polymer film,which is unwound near the metal vapor source. This coating is much thinner than a metal foilcould be made, in the range of 0.5 micrometres

[1]. This coating will not fade or discolor over

time. While orientedpolypropyleneandPETare the most common films used for metallization,

nylon,polyethyleneand cast polypropylene are also used.[2]

25 simple ways to save money in the workplace and reduceclimate changeThe rate at which the climate is changing is directly attributable to the activities of humans. The

burning of fossil fuels, such as coal and gas, for our electricity, heating and transportrequirements emits potent greenhouse gases, in particular carbon dioxide. This warms theEarth by trapping heat from the sun within the atmosphere, a process known as the greenhouseeffect.In Torbay, the average annual temperature will be up to 4C higher by 2080 than it was in 1990.This will lead to a 50% reduction in summer rainfall and a 20% increase in winter rainfall as wellas an increase in sea level of up to 90cm. Storm events will also become more common andintense.
http://en.wikipedia.org/wiki/Physical_vapor_depositionhttp://en.wikipedia.org/wiki/Physical_vapor_depositionhttp://en.wikipedia.org/wiki/Physical_vapor_depositionhttp://en.wikipedia.org/wiki/Metallised_film#cite_note-Hanlon-0http://en.wikipedia.org/wiki/Metallised_film#cite_note-Hanlon-0http://en.wikipedia.org/wiki/Metallised_film#cite_note-Hanlon-0http://en.wikipedia.org/wiki/Polypropylenehttp://en.wikipedia.org/wiki/Polypropylenehttp://en.wikipedia.org/wiki/Polypropylenehttp://en.wikipedia.org/wiki/Polyethylene_terephthalatehttp://en.wikipedia.org/wiki/Polyethylene_terephthalatehttp://en.wikipedia.org/wiki/Polyethylene_terephthalatehttp://en.wikipedia.org/wiki/Nylonhttp://en.wikipedia.org/wiki/Nylonhttp://en.wikipedia.org/wiki/Polyethylenehttp://en.wikipedia.org/wiki/Polyethylenehttp://en.wikipedia.org/wiki/Polyethylenehttp://en.wikipedia.org/wiki/Metallised_film#cite_note-1http://en.wikipedia.org/wiki/Metallised_film#cite_note-1http://en.wikipedia.org/wiki/Metallised_film#cite_note-1http://en.wikipedia.org/wiki/Metallised_film#cite_note-1http://en.wikipedia.org/wiki/Polyethylenehttp://en.wikipedia.org/wiki/Nylonhttp://en.wikipedia.org/wiki/Polyethylene_terephthalatehttp://en.wikipedia.org/wiki/Polypropylenehttp://en.wikipedia.org/wiki/Metallised_film#cite_note-Hanlon-0http://en.wikipedia.org/wiki/Physical_vapor_deposition


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Changes to our climate on this scale will have wide ranging impacts upon food supplies, waterresources, coastal defenses, transport and communication networks, public health, wildlife,landscape, and the make-up ofTorbays economy.Forty percent of Torbays carbon emissionscome from the energy needed to power our businesses. If we all make changes in ourworkplaces to reduce carbon emissions by saving energy we will make a difference. Whetherits an office, a workshop or a retail outlet, there are many ways you can reduce the amount of

energy used in your workplace. Most of these are easy and will not cost you a penny in facttheyll save you money on your energy bills! Saving energy means extra profit or more moneywhich can be reinvested in staff, training or improved facilities.

Lighting1. Switch off lights when theyre not required and when daylight is adequate. Consider fittinglight switches that work through sensing movement, which can prevent lights being left on forlonger than is necessary.

2. Save 125 per year by switching off lights at night and weekends.

3. Replace halogen and incandescent lighting with energy saving fluorescent types. They will

reduce energy use by up to 80% and can pay for themselves in less than a year.

Appliances4. Dont leave PCs on overnight. Switching off one PC and flat panel monitor when not in usecan save 100 each year and the same amount of carbon each year that is emitted from drivinga car 3,000 miles. Thats 1000 for every 10 PCs in your office!

5. Switch off printers, photocopiers and suitable water coolers and vending machines at nightand weekends using time switches to save up to 500 a year.

6. Set your printers and photocopiers to use double sided printing to halve your paper costs,reduce waste and save energy.

7. Enable automatic power saving features on IT equipment. Screen Savers dont save energy.Instead, set your PC to automatically put the monitor into standby when youre unexpectedlyaway from your desk.

8. Label equipment and switches so that it is clear how to switch something on when it isneeded

9. Only fill the kettle with the amount of water you need. The kettle will boil faster and youll besaving about 45 of electricity each year.

10. When replacing appliances try and buy the most energy efficient models. An energy efficientPC and printer will use 200 less electricity each year than an inefficient model. Look for the Arating on kitchen appliances, the Energy Star logo on IT equipment and the Energy SavingRecommended logo - visit www.eu-energystar.org to view approved products.

11. Use electricity-powered tools in preference to compressed air versions as they use onetenth of the energy. Check for leaks in any hoses and repair them immediately.

Heating, Cooling and Ventilation


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12. Air conditioning typically accounts for 30% of the energy used in an office. Only use it whennecessary and keep doors and windows closed.

13. Reduce the need for air conditioning and lighting by using window blinds to reduce theamount of heat entering the building and to direct strong sunlight up towards the ceiling.

14. Turn off extraction, compression ventilation units whenever theres nobody in the workplaceto benefit from their use.

15. Install insulation where possible. Loft, cavity wall and draught proofing can reduce yourheating and air conditioning bills by up to 15%.

16. Installing a timer to turn off heating overnight and at weekends could save up to 350 eachyear.

17. Ensure the heating thermostat is set no higher than 21C and avoid positioning yourthermostat in draughts, in direct sunlight or near to equipment or machinery that gives off heatas this can result in over or under heated areas.

18. How hot do you need your water? You only need to heat water to 60C to avoid the riskof Legionnaires Disease. Any higher might be a waste of energy.

Transport19. Use sustainable transport (walking, cycling, or public transport) one day per week andencourage your colleagues to do the same.

20. If you need to use your car to commute to work, why not car share?find people who make the same journey as you and are willing to share the costs

21. Organize meetings at venues that allow all participants to arrive by sustainable transport.

22. Use telephone or web conferencing as often as possible to avoid travelling to unnecessarymeetings.

23. Consider working from home occasionally. This removes the need to travel to workcompletely. Make sure youre saving energy whilst at home

Organisational24. Monitor your workplace energy use by reading your utility meters at regular intervals andplace Energy as an agenda item for team meetings.

25. Assign somebody to be responsible for switching off lights and appliances at the end of theday - rotate this responsibility between colleagues. Show your commitment to tackling climatechange

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