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FLEXO Magazine : October 2009
www.flexography.org OCTOBER 2009 FLEXO 47 HOW IT WORKS This new patented technology utilizes a solid elastomer built into a pattern that expands into open areas engineered into the design. Traditional stickyback problems are elimi- nated. At the same time, displacement cushioning maintains exceptional print performance and increases press speeds, while remaining virtually crush proof. This technology has been referred to as revolutionary, not evolutionary" because of its unique structure and print performance. The micrographs in Figure 1 and 2 show the product's structure. The ribs are made from an engineered elastomer, without a cell structure to deteriorate. It is specifi- cally designed to create the ideal physical properties (using durometer and resilience) necessary to print combined copy at press speeds in excess of 30 percent faster than conven- tional foam tapes. THE RESULT The dots depicted in Figure 3 were printed using soft density foam, while the dots in Figure 4 were printed using displacement cushioning. Notice the difference in the size of the dots and the density of the dots. The dots printed using cellular foam are nearly transparent in the middle. The graphic element e" depicted in Figure 5 was printed using a medium density foam, while the graphic element e" in Figure 6 was printed using displacement cushioning. Notice the difference in the sharpness and density of the text. In order for cellular foam to print dense solids, higher density tapes are used at the sacrifice of dot reproduction. Results show that the unique properties of displacement cushioning allow the use of one mounting tape regardless of the job being printed. Line or type, combination work or the most difficult process work can be printed without mixing vari- ous density tapes or utilizing special make ready. Press dampening provided by displacement technology allows an increase in press speed far beyond the point where many printers experience bounce today. This is combined with plates running cleaner for longer periods of time, providing higher press up time. Reportedly, these two factors alone pro- vide an increase in press productivity greater than 15 percent. Additional benefits are increased solid ink density at lower impression levels on solids, reverses, text, and tones while add- ing confidence in UPC scanning consistency. With initial results in from flexible packing test sites reporting the same promis- ing results experienced in newsprint, concerns of consistency throughout a run may rapidly become a distant memory. ABOUT THE AUTHOR: John R. Rastetter has accumulated more than 25 years of experience in the global printing and packaging industry after receiving his Bachelors in Printing Science from R.I.T. As vice president of sales and marketing for Controlled Displacement Technologies LLC, John will focus on introducing ChannalBAC Controlled Displacement Tech- nology throughout the newspaper and packaging industry. FIGURE 3. Printed using cellular foam. FIGURE 4. Printed using displacement cushioning. FIGURE 5. Cellular foam results. FIGURE 6. Displacement cushioning results. TECHNOLOGIES & TECHNIQUES
Sustainable Fall 2009