Fingerprinting the Gravure Press. Presented by: Bruce G. Beyer GAA 2008 all rights reserved

Transcription

1 Fingerprinting the Gravure Press Presented by: Bruce G. Beyer GAA 2008 all rights reserved 1

2 What is Fingerprinting? A method or program to quantitatively study a process by examining and recording its input, output and operation. These input, output and operation components are used as variables to establish operational boundaries to control the time, cost and resource consumption of the process. 2

3 Who needs Fingerprinting? Suppliers Printers End users (customers) Can be used for ISO certification Regulatory compliance Training 3

4 Where do I start? How can I collect the information I need? Vendor supplied specifications MSDS Equipment specifications Maintenance logs Running logs QC logs Customer complaint records Survey production personnel 4

5 Designing the Test Run Identify inputs Substrate, ink, press Establish test range Normal operating conditions Build the data collection log Design the image To meet product boundaries Record the inputs 5

6 Conducting the test run Implement a sequential approach Record all operation conditions Run the test to scale (at production speed, etc.) Run one test condition at a time 6

7 Sample collection plan How many samples do I take? Where do I collect the samples from? Do I conduct tests on all samples? Collect enough to get statistically viable data 7

8 Analyze Process Logic Process Correction Statistical Action Path Production Records Logs History Document Printability Printability Data Collection Path Inputs Press Systems Inks Cylinder Substrate Trials Production Operations Path 8

9 Designing the Image Carrier GATF Test Form 9

10 Designing the Image Carrier Solids Tones Process graphics Line graphics Process control targets Process control cmyk photographs Design to represent typical job design 10

11 Process Control Targets Tone wedges Multi step 25 Quarter tone, 25, 50, 75, 100 Vignettes Ladder bars Distortion scales Traps Reverses 11

12 Process Control Targets 12

13 Process Control Targets Web Direction Ladder Lines Test Form 13

14 Process Control Photos Hi Key Low Key 14

15 Process Control Photos Color Skin tones 15

16 Quantifying the Process Tools 16

17 Engraving Quantifying the Process Data Collection Sheet - Engraving Engraving Color N/A Color N/A Unit # N/A Unit # N/A Base # N/A Base # N/A Cylinder Circumference inches Cylinder Circumferenc Inches Date New N/A Date New N/A Screen LPI Screen LPI Cell (Width) Microns Cell (Width) Microns Cell (Length) Microns Cell (Length) Microns Stylus Degrees Stylus Degrees Configuration N/A Configuration N/A Surface Roughness Rz Surface Roughness Rz Engraving Engraving Color N/A Color N/A Unit # N/A Unit # N/A Base # N/A Base # N/A Cylinder Circumference Inches Cylinder Circumferenc Inches Date New N/A Date New N/A Screen LPI Screen LPI Cell (Width) Microns Cell (Width) Microns Cell (Length) Microns Cell (Length) Microns Stylus Degrees Stylus Degrees Configuration N/A Configuration N/A Surface Roughness Rz Surface Roughness Rz 17

18 Cylinder Specifications Cell Angle Diamond Angle Wall Compression Raster (lpi/lpc) Width Length Channel 18

19 Quantifying the Process Cell inspection 19

20 Quantifying the Process Data Collection Sheet - Substrates Units Film Manufacture ID # N/A ID # N/A Type N/A Gauge Treat Type Flame/Chemical/Corona Surface Energy Dynes Smoothness Readings Substrate Units Readings Coated Manufacturer N/A ID # N/A Basis Weight Pounds Ink Receptivity Caliper Inches Surface Smoothness Brightness Absorbtivity Porosity Moisture Content % Compressibility Uncoated Unit Number Units Readings Manufacture ID # Basis Weight Pounds Ink Receptivity Caliper.001" Surface Smoothness microns PPS Brightness % Absorbtivity angle Porosity ml/min Moisture Content % Compressibility pps10/pps5 20

21 Substrate Properties Paper & Board Smoothness Compressibility Porosity Basis weight Caliper Moisture Wetability 21

22 Paper Properties Smoothness Parker (PPS) Sheffield Emvico 22

23 Paper Properties Emvico Smoothness 23

24 Quantifying the Process Vendor Information 24

25 Substrate Properties Non paper Surface tension COF Gloss Sealability Opacity / clarity Elasticity 25

26 Substrate Properties Contact Angle 85 degrees 26

27 Quantifying the Process Data Collection Sheet - Ink & Ink systems Ink System Components Units Measurement Condition Location Pump Flow Gallons/min Outside The Unit Position Of Nozzle Inches Outside The Unit Ink Pan System Low Medium High Outside The Unit INK Unit Number Units Readings Notes Manufacturer N/A Identification numbers Formula/Batch Color N/A Solids % Dilution Ratio MLS/100 Grams Weight Per Gallon Pounds Solvent Type(s) N/A Press Viscosity Seconds Ink Temperature F Extender % 27

28 Ink Properties Weight per gallon Dilution ratio L*a*b* Density Viscosity 28

29 Quantifying the Process Ink viscosity 29

30 Quantifying the Process Press Set-up Information 30

31 Quantifying the Process Press Set-up Systems Doctor Blade Angles Impression Pressure, nip, hardness Drying Temperature, velocity, dwell Web controls Tension, registration treatment 31

32 Quantifying the Process Data Collection Sheet - Doctor Blade Doctor Blade Component Units Measurement Condition Location Manufacturer N/A Style N/A Composition N/A Thickness Inches Tip Size Microns Back Up Blade Thickness Inches Blade Extension (Holder) Inches Backup Blade Extension (Holder) Inches Torque On Bolts Ft-LB Level Inches Oscillation Range Inches Outside The Unit Set Angle Degrees Outside The Unit Contact Angle Degrees Outside The Unit Blade Tip to Nip Distance Inches Outside The Unit Pneumatic Pressure At Control Panel PSI Unit Panel Pneumatic Pressure At Piston PSI Outside The Unit Length Of Blade Inches 32

33 Doctor Blade Angle Blade to nip distance 2. Set angle 3. Contact Angle w & w/o pressure 1 33

34 Quantifying the Process Doctor Blade Angle 34

35 Set Angle Chart Doctor Blade Angle Holder angle Doctor blade angle Holder height (cm) Holder height (inch)

36 Quantifying the Process Data Collection Sheet - Impression Impression System Unit Number Units Readings Notes Manufacturer Material Durometer Pressure Contact Flat Esa N/A N/A Shore A PLI Inches voltage / current 36

37 Impression Durometer - Shore A (75-90) Impression Flat (3/8-5/8 ) Loading (pli) (75-250) 37

38 Quantifying the Process Pressure vs. Load impression D-blade impression 38

39 Quantifying the Process Data Collection Sheet - Dryers Components Units Measurement Condition Location Dryer Zone #1 Control Panel Temperature F Main Panel Actual Reading Temperature F Inside The Unit Nozzle Velocity Ft/Min Inside The Unit Input Flow Gauge Inside The Unit Output Flow Gauge Roller Condition N/A Inside The Unit Balance N/A Enter Web Temperature F Burner Zone #2 Control Panel Temperature F Main Panel Actual Reading Temperature F Inside The Unit Nozzle Velocity Ft/Min Inside The Unit Input Flow Gauge Inside The Unit Output Flow Gauge Roller Condition N/A Inside The Unit Balance N/A Exit Web Temperature F Temperature F 39

40 Dryers Time Speed and length Temperature Turbulence Air flow (ft/min) 40

41 flow Quantifying Dryer nozzle the Process Dryer Nozzle Air Flow 41

42 Quantifying the Process Dryers Zone Temperature Readout I II I II I II I II 42

43 Quantifying the Process Web Temperature in out 43

44 Quantifying the Process Dryers Analog set Recirculation 44

45 Quantifying the Process Data Collection Sheet - Press Controls Press Zone Components Units Measurement Condition Location Unwind Unit Rewind Unit Dancer Roller Air Pressure PSI. Unwind Control Panel Unwind Tension Reading PLI Main Control Panel Main Tension Control PSI Unwind Control Panel Nip Roller On/Off Switch N/A Unwind Control Panel Nip Roller Pressure PLI Unwind Control Panel Motor Tension Control Low Medium High Unwind Control Panel Unwind Tension Unit On/Off N/A Unwind Control Panel Width Of Roll Inches Unwind Control Panel Dancer Roller Air Pressure PSI Unwind Control Panel Unwind Tension Reading PLI Main Control Panel Main Tension Control PSI Unwind Control Panel Nip Roller On/Off Unwind Control Panel Nip Roller Pressure PLI Unwind Control Panel Motor Tension Control Low/Medium/High Unwind Control Panel Unwind Tension Unit On/Off Unwind Control Panel Width Of The Roll Inches Unwind Control Panel 45

46 Quantifying the Process Web Controls Unwind tension Main tension Nip load 46

47 Quantifying the Process Pressroom Environment 47

48 Quantifying the Process Printability Quantifying Print Quality 48

49 Printability Print Density Color Mottle Image analysis Tone response Trap Gloss Rub, scuff 49

50 Printability Gloss, Density 50

51 Printability Color Space 51

52 Printability Mottle sample 52

53 Image Analysis 53

54 Printability Image Analysis Camera software microscope 54

55 Printability Image Analysis 55

56 Processing the Data Collecting Results Analyzing the Data 56

57 Mottle, non uniform image formation 57