The Power of Print in Laminated Card Manufacturing

Transcription

1 The Power of Print in Laminated Card Manufacturing ICMA EuroForum th / 10 th October Robin McMillan & John Schneiderhan working for you.

2 Overview Current print processes and related inks Introduction to UV curing process Features, benefits and impact of UV curing technology Hidden magnetic stripe cards Added value security features 2

3 Divider page Printing Ink Developments

4 Introduction and Scope Major advances have been made in UV ink technology through a greater understanding of the basic chemistry and the processes involved Wider adoption of UV curing ink technology across a growing number of industries 4

5 Inks and associated products used in card production Screen printing inks Solid colours ) Metallic shades ) Pearlescent / iridescent effects ) Usually solvent based technology Transparent shades ) Security effects ) Offset printing inks Spot colour ) CMYK process inks ) Usually UV curing technology Security effects ) Digital printing inks Thermal ) Depends on print technology Ink Jet ) of the printer Adhesives Screen printing ) Usually water based technology Roller coating ) 5

6 Solvent Based, Conventional Drying Inks Typical Formulation Pigment Resin Solvent Additives Surface active agents Plasticisers Dries by simple evaporation of solvent Can be in air or forced Causes printed film to shrink significantly Release of solvent from wet ink Evaporation Release of solvent from wet ink 6

7 An introduction to UV curing The Electromagnetic Spectrum Radiation is often used to cure coatings: Microwave, Ultraviolet (UV), Infra-red, Electron Beam (EB) 7

8 UV Curing Polymerisation, not drying E.G. Polymerisation of a multifunctional acrylate species Polymerisation reaction Liquid to solid Almost instantaneous No loss of mass Other reaction methods exist 8

9 UV curing Inks Typical Formulation Pigment Similar to solvent based inks Prepolymer In place of resin Inert resins can also be included Monomer Usually the solvent of the formulation Photoinitiator Additional component to initiate cure Additives Surface active agents Plasticisers As solvent based inks 9

10 Printed film properties of UV inks Wet printed ink film No change in mass Minimal shrinkage Fully dry and resistant film UV radiation Cured ink film 10

11 Factors Affecting UV Cure UV cure is however effected by a number of factors. UV Lamp choice Spectral output UV dose Reflector Ink Composition Photoinitiator selection Functionality of system Pigmentation Coating Properties Film thickness Substrate Interrelated However, cure properties are more easily measured and thus controlled, but are more numerous Interrelated Oxygen Inhibition 11

12 Divider page Laminated Card Production

13 UV curing inks Features Main Features: No volatile solvents Instant curing Little or no shrinkage Improved and wider adhesion range 13

14 UV curing screen inks Impact Improved efficiency Less press downtime Lower costs Higher ink mileage Faster print speeds Lower consumable use Reduced space requirement Improved quality Higher quality print Colour consistency Superior adhesion Peace of mind New opportunities New substrates Greater design freedom 14

15 UV curing screen inks Impact Customer satisfaction Higher quality images Improved colour consistency Greater security Increased print robustness Improved competitiveness Reduced costs Increased service capability Greener products Reduced VOC Lower energy consumption Less waste generation 15

16 Printing Ink Development Summary Advantage Feature How / Why Reduced Costs Higher ink mileage Lower ink useage Lower energy requirement UV driers are cheaper to run Time savings Increased press speeds Fewer wash ups / stops Infinite screen stability Redcued wash up solvent No mid run wash ups Multi substrate Fewer inks stocks Improved Sustainability Lower energy requirement UV driers cheaper to run Reduced VOC emissions 100% solvent free inks Reduction in floor space Smaller driers / footprints Reduction in floor space Immediate stacking Future substrate ready Suitable for PET and PC substrates Higher Quality Increased print definition Finer stencils used No loss of detail Infinite screen stability Finer half tones Finer stencils used Consistent colour reproduction Consistent ink rheology Higher degree of process control UV curing more controlable Security Immediate post processing Reduced number of prints awaiting further processing Improved ink adhesion More robust prints post curing Immediate lamination Reduced number of prints awaiting further processing Future Developments Most research in UV curing systems Future proof facilities 16

17 Key Conclusions Adoption of UV technology benefits all Manufacturers Issuers Consumers Future opportunities 17

18 Divider page Hidden Magnetic

19 Description of the Hidden Magnetic Stripe Card 19

20 Japanese Double Magnetic Stripe Card 20

21 Japanese Double Magnetic Stripe Card 21

22 Printing Construction 22

23 Hyundai Card 23

24 Hidden Magnetic Stripe Card 24

25 Printing Image Printing Step Test Process 25

26 Divider page Enhanced Security

27 Printable Security Levels Assume 3 levels of printable feature Contained within the ink Printed effects Combinations of above Overt technologies Thermochromic Colour shift Print effects or patterns Simple covert technologies Colour change UV responsive IR responsive Bespoke machine readable solutions Magnetic resonance 27

28 Enhanced Security Features Ultra Violet (UV) Infrared (IR) Security Features Color Shift 3D Effect Metallic Security Features 28

29 Laminated Card Manufacturing Hidden Magnetic Tape Potential Uses and Markets Enhanced Security Inks and Coatings 29

30 Questions? working for you.