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FLEXO Magazine : July 2013
of the most high-end graphics in a controlled and repeat- able manner. The trend to the higher anilox cell counts is noticeably increasing in both the narrow web market and the wide web market. This trend mirrors the increased graphics improvements with higher plate lpi and the increased use of color and print targets. Across both narrow web and wide web markets, printers are using print targets that range in density numbers, dot gain tolerances, L*a*b*, and G7 tolerances. The complexity of the color separations and builds require precise ink delivery speci- fications. The XLT-60° hexagonal has precise structure and shape, for this reason it is the ideal anilox to meet today ’s tight print requirements. Engraving of the hexagonal shape can be orchestrated with extreme accuracy, provided the anilox bases and ceramic are precisely and consistently prepared. HIGH OPACITY WHITES Traditionally, in order to achieve high opaque white in flexography, it was necessary to use a rotary screen station. While this approach is effective, it does require setup time and limits the production speed of the press. In addition, should the rotary screen get damaged at any time during pro- duction, the change out and re-setup of a replacement screen can be quite time consuming. Fortunately, today ’s anilox technologies offer a great option for achieving the same results in a fast paced productive manner. Channeled engravings such as 30°, 75°, 89°, 45° and weave can efficiently deliver heavy opacity whites for any ink system in use. Using the right anilox engraving, it is entirely possible to achieve opacity levels with solvent inks in the mid to upper 60 percentile, water-based inks in the mid 60 percen- tile and with UV inks, opacity in the mid to upper 80 percentile. These channel engravings, can de- liver a much greater level of ink, almost pouring the ink on to your substrate. These engravings have large open- ings and with the right engraving specifications, white inks can flow freely in and out of the channels. Chan- neled anilox rolls are available to deliver just about any level of opacity you may be looking to achieve. The only question is, “Can you dry or cure it?” Channeled anilox engravings can be available with vol- umes ranging from heavy volume — 20 bcm to 40 bcm + — to low volumes of 20 bcm or lower. Having the right setup makes the biggest difference. Using water-based inks to achieve high opaque whites may require installing high capacity dryers and possible changing the web path to extend the drying time before laying down the second color on top of the white. Channeled engravings such as 30°, 75°, 89°, 45° and weave can efficiently deliver high opacity whites for any ink system in use, especially with UV inks. Engravings have been used with UV inks that have achieved opacity of 70 percent or better. Engage your ink supplier and anilox supplier in a discus- sion of your goal and define the percentage opacity you want to achieve. Using the right ink formulation and anilox specifi- cation to conduct tests, you will find the right combination that will meet your goal. VARNISHES Matte and gloss varnishes have been used effectively in the offset industry for years. There has been an increased interest and subsequent use of these varnishes in the flexographic industry as work has transferred to in-line processes. Using new channeling engravings — XTR 89° & 75° — has resulted in smooth laydown of both matte and gloss varnish coatings. These new type of engravings enable the varnish to flow smoothly from the anilox rolls in the web direction. The benefit of not having cross supports in the 89° XTR engraving and the shape of the channels — large channel opening — enables any coating to flow effortlessly in and out of the channels with minimal disturbance that would result in agitation and foam- ing. With the XTR engravings, it is common to engrave heavy volumes that can deliver a specified amount of coating, while the anilox remains clean during long pressruns. Using the right anilox specification and a spot plate, it is possible to create dynamic effects by combining matte and gloss effects in the same graphics. Many ink suppliers have tested the technology and have ready-made recommenda- tions for these applications. Having the matte and gloss varnish can create increased visual depth in your graphics that allows the product to stand out. The sheen of the gloss spot varnish tends to pull that area to the eye. METALLIC/FLUORESCENT INKS Solids or combination – using metallic inks and fluores- cent inks—can truly enhance your product, but have often Channeled anilox roll engraving patterns. Photos/illustrations: Harper Corporation of America. With XTR engravings, it is common to engrave heavy volumes that can deliver a specified amount of coating, while the anilox remains clean during long pressruns. See Who’s FIRST Certified Your name not here? Visit www.flexography.org to learn more about FTA’s FIRST Operator Certification Program Company Name Certification Type Ms. Ali Reslan Press Operator, Implementation Specialist AGFA Pitman Implementation Specialist American Packaging Corporation Press Operator (17) Amspak Press Operator Anagram International Prepress Operator Anderson & Vreeland, Inc. Implementation Specialist (6) Belmark, Inc. Implementation Specialist (3) Bemis Company, Inc. Press Operator Berry Plastics Corporation, Evansville, IN Company Certification Berry Plastics Corporation Press Operator (52), Prepress Operator (11), Implementation Specialist (27) Best Label Inc, Union City, CA Company Certification Best Label Inc. Press Operator (11), Prepress Operator (2), Implementation Specialist (7) Mr. Brett Angel Press Operator Coastal Packaging Co. Inc. Implementation Specialist Central Piedmont Community College Prepress Operator Clark Container Inc. Press Operator (10) Colormasters, LLC Implementation Specialist Cryovac Press Operator Emerald Packaging, Inc. Press Operator (22), Prepress Operator, Implementation Specialist (5) Esko Implementation Specialist (5) Farnell Packaging Ltd. Press Operator (10), Prepress Operator (3), Implementation Specialist (2) Georgia-Pacific Corporation Press Operator (6), Implementation Specialist (5) Harper Corporation of America Implementation Specialist (11) Hood Packaging Corporation Press Operator (10), Implementation Specialist (5) InterFlex Group Press Operator (30), Implementation Specialist (11) International Paper Company Press Operator (3) INX International Ink Co. Implementation Specialist Johnson Bryce, Inc. Press Operator (2), Implementation Specialist Labeltape, Inc. Prepress Operator Lintec Label Solutions Press Operator Matthews Brand Solutions Implementation Specialist (2) Nosco, Inc. Press Operator Pemla Ink Technologies Implementation Specialist (5) Plastic Packaging, Inc. Press Operator (33), Implementation Specialist (28) Poly Print Inc. Press Operator (4) Portco Packaging Press Operator (3), Implementation Specialist (5) Prairie State Group Press Operator (5), Prepress Operator (2), Implementation Specialist (4) Printpack, Inc. Press Operator, Implementation Specialist Shields Bag & Printing Company Implementation Specialist (5) Smyth Companies Press Operator (21), Prepress Operator (3), Implementation Specialist (13) Spear Implementation Specialist (2) Star Packaging Press Operator (12), Implementation Specialist (2) Stevenson, The Color Company Implementation Specialist Sun Chemical Corporation Implementation Specialist (3) Trinity Packaging Corporation Press Operator, Prepress Operator Turner Labels Implementation Specialist Walter G. Anderson Press Operator (10) Winterfield LLC Press Operator (5), Implementation Specialist (2) 56 FLEXO July 2013 www.flexography.org