I-95 Flexo Seminar Draws Large Crowd, Features Presentations on Ink Density, Expanded Gamut

I-95 Event 1PHILADELPHIA, PA—Nearly 70 flexographers attended the inaugural I-95 Flexo Seminar Sept. 16 at FTA member Gallus‘ Philadelphia, PA location. Much like the road from which the group derives its name, attendees came from all along the East Coast to hear presentations addressing solid ink coverage, digital printing’s complementary nature to flexography and expanded gamut printing.

Sponsors of the event included:

  • ACTEGA Coatings & Sealants
  • Daetwyler
  • FLXON Inc.
  • Gallus
  • DuPont
  • Harper Corporation of America

FTA Hall of Fame member Mark Mazur—formerly of DuPont Packaging Graphics and current self described “old retired guy”—began the day by discussing how to improve solid ink coverage. When printers need to decide whether to use standard digital or flat top dots, Mazur said there is no “one solution for everyone” and that the question is best answered by looking at the market segment. However, when it comes to plate surface, either an engineered surface or solid screening is a big improvement over the standard variety.

He continued by running through different microcell patterns before providing a simple explanation for ablation: Consider a door opening and closing, with a flashlight trying to shine through it. If the door opens and closes too quickly, Mazur noted, not enough light gets through to form a full beam of light. Similarly, if the laser or energy source isn’t given the power or time, the rotating drum will “smear” the effect of the energy on the mask. To improve this, either the energy or pulse amplitude can be increased, or the “door” or pulse length can be increased. He supported this by detailing the results of imaging done with various combinations of pulse length and amplitude, showing an optimal area where ink density improves.

Mazur
Mazur

Following Mazur, Gallus’ Product Director Harold Jacob spoke on differentiating digital technologies. “You need to get into digital, if you aren’t already,” Jacob implored. He then analyzed three technologies in the digital world—dry toner, liquid toner and inkjet. After categorizing the first two techs as being quite mature, Jacob noted that inkjet, despite being the youngest, has seen a high rate of development and is now capable of 2-pl. size droplets and 1,200 by 1,200 dpi resolution. Continuing to discuss droplet size, Jacob noted that smaller size equates to better adhesion, better curing power, less gloss and less ink consumption, all wins for printers.

Wrapping up the day was another FTA Hall of Famer, Esko Product Specialist – Color Mark Samworth, who talked about expanded gamut for packaging. Providing a brief history of color evolution in packaging, Samworth said he believes this decade will be remembered for the rise in 7-color printing, revealing it’s believed that by 2020, 50 percent of the market is projected to be utilizing expanded gamut.

He cited two primary reasons for its growth: quality and economics. Looking to quality, Samworth compared the achievable color gamuts with 4- and 7-color printing, passing around several printed samples that included the FLEXO Magazine October 2014 cover project. On the subject of economics, Samworth was blunt, saying the cost of spot colors is “unbelievably expensive” and that running with a fixed ink set delivers increasing makeready savings based on the number of jobs ganged.