The supply chain of gravure printing was the centre of attraction at the event "gravure finished films" to the first international conference of this kind, Innoform Coaching had invited over 150 experts to take part on 5/6 November in Osnabrueck. In 12 top class lectures, the guests gained a deep insight of the update developments and trends in gravure printing, regarding to colour systems, printing plates (cylinders), manufacture quality and security systems and machine technique. Apart from the theory the presentation of a HELIOSTAR G gravure printing machine at the technology center Windmöller & Hölscher, producing with 520 m/min a six colour multilayer lamination, the praxis definitely did not come to short
Karsten Schröder from Innoform Coaching welcomed the guests and promised interesting lectures that would reflect the complete supply chain of gravure print. The large amount of guests from packaging manufactures, users and suppliers have shown that the near enough “hands on” praxis, the suspenseful chosen themes, and the information, were a hit.
After the introduction, James Siever from the European gravure association took over, giving apart from information and details all around gravure printing, in publications and decor-print, furthermore about the image, the chances and the potential of package gravure printing. According to a GFK survey the gravure print method still has the highest printing quality and reliability but they recognise inflexibility in trade mark articles. Therefore the expectations of gravure print as in short handling times and the competitiveness of prices, also in small editions, are high.
Rudi Weis-Schiff from the Janoschka group demonstrated with a diagram, to clarify the average cylinder price, to the supply industry. In Europe in 1990 the price was 1000€ and is now 350€.The prices are not only influenced by production locations, manufacture equipments, automatic grade and contract volume but also the handling time. (Transport time included, all together around two weeks). The challenge and competitiveness of small editions, such as the new hollow cylinder concepts, like the product line CYLIGHT from Janoschka or GELENIUM from Saueressig.
The advantages of light weight, minor transport and storage cost was illuminated by Stefan Beilenhoff, Saueressig GmbH & Co. KG. The in-house development of the Gelenium sleeve was due to the conical principle; the core is of aluminium and an all around chemically nickelized outer layer. It also has a solvent resistance, unlimited usage and can be illustrated in all gravure and laser methods. The technique of the sleeves allows them to be used in different types of printing machines.
An important aspect in gravure print is of course the colour systems that can be applied. Dr. Stefan Häp, Siegwerk print ink AG, confronted the participants with two component and effect inks as a benefit to face printing. The result of his lecture: Against the background of new packaging and materials or regulations, the colour systems offer not only the chance to actualise innovative packaging concepts but also options to increase in efficiency and cost reduction. With a side sealed bag, one could as such exchange a laminate coat with a two component ink and over print lacquer. High standards are also demanded from the colour systems when it has to do with printed film in combination with lamination.
The challenge is the mixture between inks and adhesives and to achieve the best results as Dr. Matthias Henker, Flint Group Germany GmbH, pointed out. He reported about the latest development of this area of pure polyurethane based laminate inks that are not only for flexo and gravure print suitable but adherence on nearly all film types, un-chlorinated and sterilisation application.
If the print and film quality fulfil the customers expectations and how this can be found out was explained by Jochen Mank von Amcor Flexibles Europe Schröder & Wagner GmbH. Apart from the aim to deliver safe products for customers and consumers in the right time, quantity and quality, Amcor have the ambitions of environmental protection, job safety and economy. To achieve their ambitions they have a variety of equipments and various tests. It is also very important to include the staff in quality inspections during the manufacture, independent of what management tool, like the Kaizen or Six-sigma method, to gain a continuous improvement process because in future it will not be possible to win or please certain customers without such a process.
The customer requirements and therefore the packaging manufactures are increasing as Karolina Rosenberger and Micha Weik from Alcan Packaging Kreuzlingen Ltd., for example security systems for pharmaceutical packaging in gravure print, made clear. Not only for the customers are visible security characteristics of the packaging, to protect against counterfeit medication, there are also hidden characteristics that can only be identified under specific conditions. Visual characteristics are fine line prints and holograms, whilst large amounts of colour pigment, that are used for paper money, or printed miore effects stay hidden and can only be controlled with high technique. Gravure print requires for example larger pigments, deeper cells and a very sharp edge. In contrast the in-mould labelling (IML) has to be (so that the message comes across) sharp.
Udo Skopek vom Druckhaus Rahning showed in his practical report that gravure printing is the method for IML with large editions or special requests like solvent/water based colour/lacquers or when difficult materials are used. One of the problems in the making of IML labels is the separation ability and the loading, for the later injection moulding. One technique is for example, the addition of an antiblocker in the lacquer. How good is the loading of the printed substrates? It is not so easy to measure especially when in laminated film, separate loadings are included.
Uwe Matschulat, QUMA Elektronik & Analytik GmbH presented a new developed measuring instrument. The substrate to be measured is contact free deloaded over ionised air and then contact free loaded after, the deloading is to be measured. The data are documentable and can be a basis for quality management for product development and control.
An important part of the supply chain for gravure print machine techniques was the theme from Clemens Brinkmann from the print machine manufacture Windmöller & Hölscher. Varied changeable concepts from slide in charts to cartridge techniques, to sleeve solvents. To have the choice of mixing different needs for different printers, for instance the HELIOSTAR®, innovative and flexible and the most advanced gravure press.
The modular design allows for customized press configurations to meet specific user requirements and additional features can easily be retrofitted any time to extend the machines application possibilities like slide in carts for changing gravure cylinders, the inking system including the ink pan and the ink tank with the ink circulation system an automatic make ready system for an easy, fast change over and the high print quality stays even after years, which was the point that Gerhard Hochstein, Interprint GmbH made. His company, one of the leading decor and gravure printers of the world and his customers expect after years, the stable colour and accuracy. For this they have the most modern finishing technology like laser gravure systems, online colour measuring systems and special deco gravure printing machines.
Udo Linke, Warburger Klischee-Anstalt GmbH with the theme standardisation of flexo helps achieving gravure quality, pointed out to us that the standardization of flexo achieves not the gravure print quality but enables an excellent print quality provided that modern photopolymer and endless sleeves guarantee a high constancy and a high resolution.
The guests were taken to the technology centre of Windmöller & Hölscher so that they could see for themselves what quality results are achieved. A Vistaplex C was demonstrated that with 8 or 10 colours a maximum speed of 800m/min and with endless sleeves a brilliant printing quality was achieved. Also very impressive was the automatic change over of the flexo print machine with extremely short change over times. The maximum output, reduced setup times and minimized waste were the main focus of the gravure printing machine Helioostar G and the fast change over with the help of slide in carts and the automatic make ready systems.
The demonstrations caused for very active conversations at the7 table themes that were held in small groups with a consultant for each group. This innovative and interactive concept showed the innovations esprit of the presenter all the way through the event.
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