Cylinder engraving traditional technology with future potential

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Sheena Harmon
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1 Cylinder engraving traditional technology with future potential Dr.Ernst-Rudolf Weidlich GRT GmbH&Co.KG ERA Conference Dortmund

Established markets (also by quality enhancement) Routine in production

2 Roto Gravure Packaging : Tradition Market concentrations (mergers, competition changes) High grade of standardization (cheaper production) Established markets (also by quality enhancement) Routine in production (profit orientation) Manifold technical pool available (also for print form production) all set 2

3 Market Requests marketing design politics Market split : mass vs. exclusive products Complexity of products Product attraction (image, LW, haptic) Brand names : better design, creating added value, brand protection Products : faster design changes, shorter runs Customer : f.e. nutrition lists, QR codes Environmental aspects : sustainability (f.e. Cr), material and energy effiency Product informations : nutrition list, Restrictions in design : f.e. cigarette box roto gravure : challenges and potential for new business 3

storage of informations / instructions adding of security codes information Embossing : macro : haptics

4 Package : Component Change Hidden informations : line shifts (: security market) Moiree-effects (reading pen) via QR-codes : net connection attraction Printed electronics : electro-luminiscence storage of informations / instructions adding of security codes information Embossing : macro : haptics nano : holographic security/safety Functional inks : metallic inks nano : ink doting new / additional orientations 4

5 Packaging : Information Densities static flexible dynamic print network connection printed electronics QR sensoric soric roto gravure : package as a vessel 5

6 Creating Added Value Implementation of QR codes gives : Adapting to new plattforms : via cell phone app to internet webside of brand names informations via web : pictures / movies / sounds / smells (?) Practical purposes : transmission of recepices / instructions / warnings / advertisement brand protection : originality, consumer safety,... tracability : country of origin, trade routes,... Technical needs : high resolution codes scaling dimensions (information density) innovative implementation for adding values to packages

Orientation Packaging printing : Evaluating technical potentials Definition of limiting parameters Optimization of processes Innovation strategies

7 Orientation Packaging printing : Evaluating technical potentials Definition of limiting parameters Optimization of processes Innovation strategies Printing new functions : Market requests Future tendencies Scientific network Diversification concepts Focused investments GRT GRT : creating innovations 7

Roto Gravure : Technical Possibilities writing resolution / µme2 1 10 100 1000 10000 1980 1985 1990 1995 20000

direct lasers Xtreme -engraving Markets / Applications : very high resolution applications high definition

8 Roto Gravure : Technical Possibilities writing resolution / µme Argon laser laser ablation High Res laser TSER laser MDC Zinc laser mechanical engraving direct lasers Xtreme -engraving Markets / Applications : very high resolution applications high definition objects complex linework objects big area objects GRT : most wide spread technical possibilities in one location 8

9 Mechanical Engravings Advantage : very good halftone reproduction Additional equipment Xtreme-engraving : offset-approach for stylus engraving engraving resolution : 100µm to 5µm reproduction of linework GRT : 50% of cylinder production Option #1 : mechnical engravings 9

10 Direct Laser GRT : first in technology Pulsed direct laser from Schepers Resolution 12µm Objects : linework and functional designs Opening of new applications in packaging markets GRT : process optimization done, production Option #2 : direct laser engravings 10

11 HighResLaser Production Lines Option #3 : indirect laser engravings 11

12 HighResLaser GRT : first installation worldwide (2007) Most smallest laser resolution (indirect laser plus etching) : 2µm Best screen definition (honey comb, line, quadratic screen, individual screens) Moiree-free halftone reproduction Shaft- and hollow cylinders Automatic production lines GRT : 45% of cylinder production Advantages : high resolution, eveness HighResLaser : best definition 12

13 World Record Smallest character height in print form Print resolution / µm text / geometr.elements Writing resolution / µm Micro text : min. 35µm height

14 Security Features Cost temperature sensitive colors micro text micro embossing holograph. elements security screens optical pigments hidden immages IR-, UVcolors GRT Security strength HighResLaser : increase of security strength for micro text 14

15 Value Strength by Brand Protection Plagiat production : 9 of 10 companies effected Demage : 8 Billion in Germany, 40 k jobs, increasing tendency Countries of origine : Asia (65%), Europe (29%), Americas (5%) Markets for : Asia (51%), Europe (32%), Americas (14%) Packaging : 10% fake production Protection applyed : 56% of companies, used technical features : product marking, embedded security,... Security features NOT used, because : technical possibilities not useful, unknown, too expensive Planing to incorporate security features : 43% of companies requests for brand protection in packaging industry 15

16 Security Features : Synergy Effects Conversion : from : security features (micro text, geometric micro elements, micro embossing) for HighSecurity applications (holograms, tax banderoles, passports, driver licenses,...) to : secure packages, especially for high price and exclusive products (cigarette, pharma, cosmetics, liquids,...) micro structures

Generating Added Value Implementation of printed electronics to packaging products Analog technical requests Packaging printing : Detail contrast Edge definition Eveness Colour match Contrast

17 Generating Added Value Implementation of printed electronics to packaging products Analog technical requests Packaging printing : Detail contrast Edge definition Eveness Colour match Contrast strength Colour superposition Printing electrical functions : Fine resolution Smallest gap dimensions and variations Homogeneous layer thickness (100nm to 40µm) Multi layer built-ups converting of print parameters 17

Printed Electronics : Historical Situation Microelectronics Printed electronics Micro electronics actual : market penetration miniaturization high integration rate 40nm structure size 1950 20000 2050

18 Printed Electronics : Historical Situation Microelectronics Printed electronics Micro electronics actual : market penetration miniaturization high integration rate 40nm structure size Printing of electrical components : New technical approach Potential : opening of new markets printed electronics actual : lab status / optimizations successful prototyping pre-series, first factories solutions for basic problems 18

19 Printed Electronics : Perspectives micro electronics printed electronics printing input electrical functions new applications added value design adaption production tolerances definition of new markets! cheap mass production flexible surfaces electr. conducting liquids Print applications : solar cell, OLED, battery, electr.paper, flat screen...

20 Printed Electronics : Techniques roto gravure offset flexo screen pr. printed elecronics Differences in : through-put printed matter liquids, pigments lateral resolution layer built up eveness... inkjet Use of potentials! Challenges become perspectives! roto gravure : strong potential for future markets 20

21 Printed Electronics : Becoming Real Mass production for printed electronics Scaling potential for future developments 14 to 50µm objects

Best technologies available for future applications.

22 iroto Conclusion : Roto gravure is capable, to give answers to actual questions of new markets - and opens new potential for brand name products. Best technologies available for future applications. The future package will have more added value. Go for roto gravure! Go for GRT as your partner in cylinder making! 22

23 Contact GRT GmbH & Co. KG Goorweg Hamm Germany Member of Tel.: +49-(0) Fax: +49-(0) ISDN : +49-(0) Internet : grt@grt-gmbh.de 23

Printing versus coating technology Which way Printed Electronics with solution coating will go?

Printing versus coating technology Which way Printed Electronics with solution coating will go? Frank Schäfer, Andrea Glawe, Dr. Daniel Eggerath, KROENERT GmbH& Co KG, Schuetzenstrasse 105, 22761 Hamburg