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FLEXO Magazine : December 2011
Rest in peace. 866-APEX-USA gtt@ apexnorthamerica.com www.byebyeanilox.com UniFlexGTT for Wide Web | UniFliGTT for Narrow Web | UniCorrGTT for Corrugated | UniCoatGTT for Coatings/Offset Bye bye, anilox. Adios, unwieldy anilox inventories. Sayonara, BCM/LPI math. Bon voyage, sleeve and roll changes. So long, pinholes, dot gain, mottling and haloing. See ya later, downtime. INNOVATION Learn more from Apex today: call 866-APEX -USA gtt@ apexnorthamerica.com · www.apexnorthamerica.com Apex North America · 65 Washington Street · Donora, PA 15033-1391 USA BEYOND EVOLUTION GTT iS NOThiNG ShORT OF A REvOlUTiON iN FlEXOGRAPhY. Bold words? You bet. And here’s why: Apex reinvented the very concept of ink-to-plate transfer and, from the ground up, perfected a whole new surface geometry, a whole new ceramic composition — and a whole new world of flexographic printing possibilities. We call it GTT: Genetic Transfer Technology. Dot gain, pinholing, haloing, mottling. You’ve come to expect these foes on-press and you do your best to combat them, but because flexo is an imperfect art, your results often vary. Wouldn’t it be nice to master one problematic variable: ink-to-plate transfer? Historically, a prime limiting factor in print quality, press speed, and workflow is the anilox surface where ink meets plate. Apex has met that challenge head-on. Just like the mechanically-engraved chrome anilox before it, the capabilities of the conventional hexcell anilox have been outpaced by advances in presses, plates and inks — and by customer expectations. It’s time to evolve. And Apex leads the way with the invention of GTT, the patented successor to conventional anilox surfaces. The GTT ink metering surface is the proven evolution for this century. The GTT series includes UniFlexGTT for wide web, UniFliGTT for narrow web, UniCorrGTT for corrugated applications, and UniCoatGTT for coatings/offset. Discover how our three revolutionary technical innovations deliver unrivaled precision, durability and the freedom to consistently print your best work every day without sacrificing time, focus or profitability. Bye bye, anilox. hello GTT. GTT DEFiNED GENETiC TRANSFER TEChNOlOGY iS ThE NEXT GENERATiON OF iNk mETERiNG TEChNOlOGY: A PRECiSiON iNSTRUmENT whOSE TEChNOlOGY EmPOw ERS YOUR hiGhEST FlEXO POTENTiAl. ThE GTT PRODUCT liNE iS OPTimizED FOR EACh Fl EXOGRAPhiC SPECiAlTY: UniFlexGTT for wide web UniFliGTT for narrow web and label UniCorrGTT for corrugated UniCoatGTT for coatings/offset THE CHALLENGE THE SOLUTION GTT, the GTT oval symbol, UniFlex, Unicorr, and UniCoat are registered trademarks ofthe Apex Group of Companies. © 2011 Genetic Transfer Technology (GTT) European patent issued and granted: EP 2121339. US and other foreign patents pending. ® OUTSIDE FOLDOUT COVER: FOLD BACK COVER PANEL SPINE/BINDINGEDGE FOLDOUT PANEL OUTSIDE FOLDOUT COVER: FOLD hello, GTT When the world’s largest anilox manufacturer rewrites the flexo rulebook with an invention that renders obsolete conventional hexcell anilox technology, you know it’s got to be a pretty big deal. Meet UniFlexGTT for wide web and UniFliGTT for narrow web — the future of flexographic ink metering technology. Imagine requiring just two or three GTT surfaces to replace your entire stockpile of hexcell anilox rolls/sleeves. Imagine: use the same surface for fine screens and stronger solids — on fewer ink stations at higher speeds. Go ahead and streamline your pressroom. Gain unparalleled print quality and consistency. Free your bottom line to soar. And re-imagine your future. Is this an evolution in flexo? More like a revolution. Bold words? You bet. And here’s why: Apex reinvented the very concept of ink-to-plate transfer and, from the ground up, perfected a whole new Slalom Ink Channel surface geometry, a new hybrid ceramic composition and a new laser engraving process. So save time. Save ink. And save money. Let us prove it: turn the page and read the facts — and then ask for your quote today. ® SEEFORYOURSElFTurnthepageandlearnhowtochangeyourgamewithGTT.YOUSAYYOUwANTAhi-DEFREvOlUTiON?Reliable,repeatablehighDefinitionFlexoiswithinreach.GTTdeliversthepowertomaximizeyourhigh-definitionplateinvestment. APEX Covers-Flaps 11-11.indd 1 12/2/11 2:07:39 PM Conventional anilox cup geometry creates aeration and turbulence within the ink fluid at doctoring. Ink can “mist” or “spit” after doctoring Deep conventional anilox cells trap ink while cell wall surface mass reduces ink area, thus inhibiting reliable ink replenishment. GTT channels are 40-60% shallower and land mass is reduced by 66% for greater ink surface area. Since the channels are narrower than hexcells, greater dot support is delivered. GTT slalom channels reduce ink stress at the doctoring phase for a more controlled ink-to-plate transfer. iNk vESSEl GEOmETRY COmPARiSON BLADE DIRECTION CROSS-SECTiON OF ANilOX ANilOX SURFACE PRINTING PLATE iNk DOCTORiNG ChARACTERiSTiCS COmPARiSON CROSS-SECTiON OF GTT BLADE DIRECTION PRINTING PLATE GTT SURFACE i Nk -TO-Pl ATE TRANSFER Ch ARACTERiSTiCS COmPARiSON GEOMETRY GTT SlA l O m iNk ChANNEl GEOm ETRY imPROvED hYDRAUliC FlOw SETS YOUR iNk FREE Smooth operator. In another first, Apex employs a new low-power, high-efficiency laser engraving process to eliminate the problems of rough, uneven ceramic recast caused by the unavoidable jackham- mer effect of conventional pulse lasers creating closed cells. Because our laser is always “on,” the walls and floor of the ink channels created by the laser ablation are consistently smoother and more uniform. Count on superior ink release. Competitor YAG pulse laser leaves uneven recast throughout the cell engraving. Inferior channel surfacing results from pulse laser engraving. Competitor pre- engraving porosity of conventional ceramic layer typically ranges from 2% to 15%. Constant Beam laser technology surgically removes the ceramic, revealing smooth and even channels time after time. Apex ultra-dense ReleasAll v1500 ceramic porosity is less than 1% before engraving. 80/20 molecular hybrid ceramic lowers surface energy for better ink release. REiNvENTiNG INK TRANSFER LASER ENGRAVING CERAMIC C ONSTANT BEAm lASER ENGRAviNG ABlATiNG A CONSiSTENT, PRECiSE ChANNEl RElEASAll v1500TM hiGh-DENSiTY NON-wETTiNG CERAmiC SUPERh ARD hYBRi D CERAmiC TROUNCES POROSi TY CERAmiC POROSiTY COmPARiSON Real slick. Real hard. GTT’s “non-wetting” hybrid ceramic composition – ReleasAll v1500 – is for- mulated to provide the highest-density, hardest and most ink-repellent surface layer available. While con- ventional ceramic is 99% pure Chromium Oxide (CrO2), our GTT hybrid uses 80% pure CrO2 and adds 20% Titanium Dioxide particles to lower the ceramic’s surface energy. Structural pores and voids all but vanish to produce an ultrahard layer (1500 Vickers rating) that controls and releases ink like no one else. Count on easier cleaning, greater score-line and damage resistance, not to mention near-complete ink release. ENGRAviNG lASER BEAm APPliCATiON COm PARiSON INSIDE FOLDOUT COVER: FOLD INSIDE FOLDOUT COVER: FOLD SPINE/BINDINGEDGE Surface Geometry Ceramic Composition Laser Engraving 1 1 2 2 3 3 ThREE INNOvATIvE fEATURES DEfINE ThE GTT REvOLUTION IN INk mETERING: let it flow. The breakthrough idea behind the GTT revolution is our patented open slalom channel surface geometry which finally enables a precise hydraulic method for metering ink onto your plate. With GTT, because the ink now flows into a precisely-engineered curved channel and is no longer captured and trapped in a confining cell, less blade and plate pressure is required for the ink to release to the printing plate. Thus you gain more efficiency and control over your entire inking process, including subsequent plate-to-substrate transfer. iNk “STRESS REliEF” The elimination of closed hexcell cups means ink turbulence and aeration (known as “ink stress,” “pressurization,” or “foaming”) are relieved, resulting in a far more controlled and complete ink-to-plate transfer. Stressed ink is unpredictable ink. iNk REPlENiShmENT With GTT, pressurised ink no longer “explodes” out of the doctor blade chamber as it does with 60° hexcell anilox, no matter the depth or extended length of the hexcell. Nor is air trapped into hexcells as the roller surface re- enters the blade chamber to be re-inked. GTT slalom channels give ink and air an “escape route” that enables calmed ink to release and replenish more completely, giving you repeatable results over long press runs. TRANSFER TO PlATE Furthermore, GTT’s open-ended channel design removes 66% of the non-inked cell-wall “land” area of a conventional anilox design meaning still more ink surface area is evenly exposed to the plate, thus maximizing uniform plate inking. What’s more, GTT open channels are narrower in width than closed hexcells for greater dot support on finer screens. ShAllOw ChANNElS Since the GTT open channel is 40-60% shallower than a conventional hexcell cup, the ink achieves more complete release from the roll surface. Thus less ink volume and lower viscosities are required at the critical kiss- point of ink-to-plate transfer, meaning you may run thinner inks while achieving amazing density on solids and dots. Also minimized are mottling, pinholing and dot gain. Shallower GTT slalom channels enable ink to flow along the blade path, reducing stress. The ink itself encounters no blockages along the blade path and thus emerges from the chamber in a “calmer” state. Stressed ink and cell land areas create uneven plate inking in conventional geometry, forcing ink up between plate dots and remaining within the cell cups. GTT open geometry allows calm, consistent ink transfer. Less aeration, shallow and narrow wavy channels, and thinner land areas all serve to deliver ideal ink volume to plate. APEX Covers-Flaps 11-11.indd 2 12/2/11 2:08:01 PM