7-RSP Gravure and Flexo Printing Process Print cost and Migration cost To Non tol.ppt

All about deception and incepted knowledge about printing

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SAKATA INX SAKATA INX
Visual Communication Technology
TECHNICAL SESSION 15
th
-16
th
December 2023
Rotogravure and Flexo Printing Process – Print
Cost Comparison
Migration Cost from Toluene base to Non
Toluene Ink System
Presenter : R.S. PRASAD
Co-Presenter : MR. Anupam Roy
Expert : MR. M. MURAKAMI

2. . . .. . . SAKATA INXSAKATA INX
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Rotogravure and Flexo Printing Process
Plate
roller
Press
roller
Anilox
roller
Gravure Printing Process Flexo Printing Process

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Gravure and Flexo Printing : Variables
Gravure Printing Process Flexo Printing Process

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Rotogravure and CI Flexo Printing Machine
Gravure Printing Machine
Flexo Printing Machine
In Line
Press
Stack Press
CI Press

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Gravure and Flexo : Image Carrier
Gravure Cylinder Engraved Image Flexo Plate Raised Image

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Electromechanical Cell
Laser Cell
100% 5% 50%
Gravure and Flexo : Image Carrier

7. . . .. . . SAKATA INXSAKATA INX
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Rotogravure cylinder Specification

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Photopolymer Plate: Final Image

9. . . .. . . SAKATA INXSAKATA INX
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Flexo Plates
The printing
plates, which have
a thickness of
approx 3.9 mm
are pasted on
Steel cylinder with
two sided self-
adhesive tapes
(sticky back
Tapes).
Plate lining for wide web flexo is 120 to
133 lines/inch and for narrow web 120 to
150 lines /inch.

10. . . .. . . SAKATA INXSAKATA INX
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Flexo Plate Mounting

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Inking System
Flexo Inking System Gravure Inking System

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Drying Mechanism
Gravure Print Drying System
Flexo Print Drying System

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Gravure Print Identification

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Flexo Print Identification

15. . . .. . . SAKATA INXSAKATA INX
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Flexo Plate Image:
Printing unit and Anilox
ink transfer principle.
Relief printing plate
micro photo.

16. . . .. . . SAKATA INXSAKATA INX
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Anilox: Ink Provider to plate

17. . . .. . . SAKATA INXSAKATA INX
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Anilox Geometry
Surface Geometry Other than random patterns, anilox cell
angles include the 60° hex pattern, the 30° hex pattern,
and the 45° diamond pattern.

18. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Anilox Geometry
Today, the 60° hex pattern is recommended for most flexo
printing applications for the following reasons::
Cells can be nested more tightly together, allowing for
approximately 15% more cells in a given area.
Post areas are eliminated due to the placement of the
cells during laser engraving.
Cells can be shallower while still releasing the same
amount of ink because more cells fit into a square inch
area.
Channeling is avoided (as compared to the 30°) because
the straight side of the cell wall is not positioned
horizontally.
The 60° hex pattern is most easily reproducible from a
manufacturing standpoint. Therefore, you will see greater
consistency from roll to roll.

19. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Anilox Geometry
45° and 30° patterns may be preferable in non-printing flexo
applications (such as coatings, laminations, and specialty
printing), but ordinarily are not recommended for general
flexo printing applications.
Calculating the Number of Cells per Square Inch There
are two calculations for determining the number of cells
per square inch of your anilox roll. One calculation is
specifically for 45° cell patterns, and the other accounts
for both 60° or 30° anilox configurations. Following are
the calculations:

20. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Anilox Geometry
For 45° Cell Patterns:
Line Screen X Line Screen = # of Cells per Square Inch
Example: For a 500 Line Screen, 45° anilox roll:500 line
screen X 500 line screen = 250,000 cells per sq. inch
For 60° and 30° Cell Patterns:
(Line Screen X Line Screen) X 1.15 = # of Cells per Square
Inch
Example: For a 500 Line Screen 60° or 30° anilox roll:
(500 line screen X 500 line screen) X 1.15= 287,500 cells
per sq. inch
Conclusion In today's flexo marketplace, it is vital that you
understand the impact of your anilox line screen and cell
geometry.

21. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Flexo Anilox Volume
In addition, you need a basic understanding of the carrying
capacity of the cell or cell volume. Knowledge of these
three components will give you the ability to choose the
anilox inventory best suited to your printing operation.

22. . . .. . . SAKATA INXSAKATA INX
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Understanding Flexo Anilox Line Screen : Ink Volume
•Line screen of 500 LPI is equivalent to cell volume of
3.2 BCMs.
•We can have 1000 LPI line screen with 3.2 BCM cell
volume but the depth of cell will have to be deep.
•Similarly, we can have 3.2 BCM cell volume with 120
line screen anilox with cells being much too shallow.
•With higher ink strength, printer uses higher line screen
anilox with lower anilox volume to reach for higher
graphics reproduction with finer vignettes, line and
process work.
•Following, is a rough outline of printing applications
matched with appropriate line screens and cell
volumes:

23. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Understanding Flexo Anilox Line Screen : Ink Volume
Application
Appropriate Anilox Line
Screen (LPI)
Appropriate Anilox Volume
Heavy line and solids 180 - 330 9 - 4 BCMs
Line and type 200 - 400 8 - 3 BCMs
Vignettes 360 - 500 3.6 - 2.8 BCMs
Process 500 - 1200 2.8 - 0.9 BCMs
UV Flexo ultra-low viscosity pourable system can be printed
with aniloxes up to 1800-line screen with 1.0-1.2 BCM.

24. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Flexo Colour Shade
A banded roll contains actual bands of different line screen
and volume combinations. A banded roll test helps
determine the correct line screen and volume
combination for printing the thinnest ink film possible and
still delivering the color strength required.

25. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Plate Image Making : Analog and Digital (CTP)
In Conventional photo-
polymer flexo-graphic plates
required a high-contrast film
negative that is positioned
over the photo-polymer plate.
The two materials are then
placed under vacuum to
ensure the film image is in
intimate contact with the plate
material during exposure.
Analog Method
Analog Method

26. . . .. . . SAKATA INXSAKATA INX
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Plate Image Making : Analog and Digital (CTP)
Ultra-violet (UV) light is then flooded over
the negative which allows only plate
exposure in the open image areas of the
film negative.
The area which comes direct in contact with
exposure becomes hard and rest area
remains soft.
A second exposure is completed.
The plate is then chemically processed to
remove polymer in non-image areas.
The resulting plate has a raised image area
and a recessed “floor” for the non- printing
areas.

27. . . .. . . SAKATA INXSAKATA INX
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Plate Image Making : Digital (CTP)
In the digital imaging process a black carbon
masking material is used on the
photopolymer plate material instead of
negatives,
Laser ray removes (ablates)the carbon
masking material from the plate in image
areas After the mask has been imaged by
the laser,
The plate is exposed to UV light without
being placed in a vacuum frame that
removes all air. Since the mask is integral to
the plate, there is no need for vacuum to
hold them together. Digital Method

28. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Plate Image Making : Digital (CTP)
Once the digital plate has received the same two
exposures as the conventional plate, it is processed with
chemical to remove polymer in non-image areas.
 This creates the raised image area that is characteristic
of flexographic printing plates .

29. . . .. . . SAKATA INXSAKATA INX
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Flexo Plate : Processing

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Plate Making Process: Conventional and CTP

31. . . .. . . SAKATA INXSAKATA INX
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Post Exposure
and Light
Finishing
Solvent Processing Drying
Back Exposure Digital Imaging Main Exposure
Laser
CTP Plate Making Process
UVA
UVA
UVAUVC

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Dot Structure Comparison
Conventional Process Direct-to-Plate Process

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Conventional Analog vs Digital Dot vs Hybrid Top Dot
Analog Dot
§


Digital Dot Digital Hybrid Dot
Cover Sheet
Film
Nitrogen
Flexo require Pre-press work to optimise for print result

34. . . .. . . SAKATA INXSAKATA INX
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High Resolution and Standard Printing

35. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Flexo Anilox Volume : Print Quality
The amount of ink that is transferred from a cell depends
upon the carrying capacity of the cell, or the cell’s
volume. Volume must be accurately measured and
maintained and is THE Primary Controlling Factor In
Flexo Printing.
In Flexo, we print with a
wet and fluid film of ink and
it is beneficial to print with
the thinnest ink film
possible. Therefore, we
need to make sure of
anilox volume, or cell
carrying capacity, suits the
specific printing needs of
operation.

36. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Flexo Anilox Volume : Print Quality
Thinner films of wet ink are easier to control, reduce dot
gain, and increase graphic capability. If you are trying to
print with excess volumes, you will have a hard time
reaching the optimum flexographic process in your
facility.
Why are thinner ink films important? Because dot gain is
decreased with thinner ink films, simply because there is
less ink to transfer from the printing plate dot.
As shown in the photographs below, lower anilox
volumes provide cleaner, sharper graphics, as opposed
to the heavy print produced by the higher anilox volume
below.

37. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Flexo Anilox Volume : Print Quality
Thinner Ink Films
Effect:
Dot Gain/Tonal
Range
Contrast/Fidelity
Trap and Press
Speed
Ink Mileage
Thinner Ink Films Yield:
Predictable Dot Gain
Clean Printing
Smaller Dots
Open Reverses
Clean Type
Sharp Edges

38. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Flexo Anilox Volume : Print Quality
However, you still need to achieve acceptable densities
from your inks.
Therefore, you must evaluate the ink you are using. If you
are not getting adequate color strength, you may need to
re-think your current ink choice or talk to your ink supplier
to see if they have a solution.
Ink manufacturers have responded to the demand for
higher pigmented inks. They may cost a bit more in the
beginning, but improved graphics will more than offset
this cost. Also, because you are transferring less ink,
handling less ink, and wasting less ink, you will be buying
less ink.

39. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Flexo Printing – Inks
•Flexo inks are highly pigmented to achieve the desired colour
density at low BCM aniloxes.
•Also, the grinding is ensured at minimum possible level by
introducing latest technologies.
•A typical colour density with 800 anilox for process colours
follows as:
Cyan – 1.35 – 1.4
Magenta – 1.3 – 1.35
Yellow – 0.95 – 1.05
Black – 1.45 – 1.4
For consistent and good print result, the anilox selection against a
particular Ink is important.

40. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Flexo Printing – Cell Volume (BCM Value)
ØA cell with too shallow depth will not transfer enough ink and also too
deep cell will transfer excessive ink, therefore optimization of depth to
opening ratio (D/O Ratio) is important.
ØFor print dot 2% on plate, the suggested LPI ratio plate to Anilox is
1:6.

41. . . .. . . SAKATA INXSAKATA INX
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Flexo Printing - Anilox Selection
Ø Depth to opening ratio –
§Ensures Better ink release from cell
§Better results observed with 60° Hex Cell and lower volume anilox.
§As a good rule of thumb, 23% to 33% D/O ratio gives good result.
§60° Hex Cell with 23% to 33% D/O ratio is known as BOWL shaped Cell.
§Best result is attained at 23 – 33%.

42. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Flexo Anilox Volume : BCMs
Anilox volumes are measured in BCMs
(Billions of Cubic Microns). Keep in mind
that we are dealing with very small
measurements and that every micron is
critical. How big is a micron? A human
hair is approximately 70 microns in
diameter.
Echotopography is used to measure
anilox cell volume. This measurement
system uses reflected light to gather
height information of microscopic surface
patterns with accuracy as fine as 10
nanometers.
Measuring Anilox Volumes

43. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Anilox Cell Volume
Cell volume is the capacity of the engraved surface in a
square inch, expressed in Billion Cubic Microns (BCM).
Anilox cell volumes are typically measured in units of
BCM (Billion Cubic Microns per square inch)
= volume of a single cell X screen count in line per inch
squared
A more sensible unit is microns (µ
3
/µ
2
). As a unit of
length it gives a measure of the linear size of the cells.
The conversion is
Cell volume/Area(µ) = 1.55BCM .

44. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Anilox Cell Volume : BCM
BCM Defined
Cell volume is the capacity of the engraved surface of Anilox roller in a square inch,
expressed in Billion Cubic Microns (BCM).
So, BCM = Cell Volume in cubic micron / Cell Area (sq inch)
1 mm = 1000 µm (micron)
1 BCM Volume = Billion Cubic Micron
Length = 1000 µm, Width = 1000 µm and height = 1000 µm
1 BCM Volume = 1000000000 µm³
1000µm
1
0
0
0
µ
m

1
0
0
0
µ
m

45. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Anilox Cell Volume : BCM
One Sq inch
Area =25400 µm*25400 µm
= 645160000 µm²
So, Cell Volume per Sq inch in micron (BCM) =
(1000000000 µm³ / 645160000 µm²) BCM
BCM = 1.55 µm
It means 1.55 µm is wet ink thickness in one sq inch
However, Anilox to Plate transfer is only about 50% and
also from plate to Substrate ink transfer is only about 50%
So Total, wet ink transfer on Substrate from 1.55 µm= 1.55/4 =0.3875 µm
1 inch = 2.54 cm =25.4 mm = 25400
µm
1

in
c
h

=

2
.
5
4

c
m

=

2
5
.
4

m
m

=

2
5
4
0
0

µ
m

46. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Flexo Ink GSM
Printing Length = 10 km PET of 1000 mm width Anilox = 4 BCM That is 4 BCM / Sq inch
So, Sq mtr = 10000mtr*1mtr Transfer from Anilox to Plate =2 BCM That it 2 BCM / Sq inkch
= 10,000 Sq mtr Transfer from Plate to Substrate=1 BCM That is 1 BCM / Sq inch
1Sq mtr=1550 Sq inch
So, 10,000 Sq mtr = 10,000*1550 Sqinch
=15,500,000 Sq inch
So Total ink Volume =15,500,000 BCM
Now, 1 kg ink @1 density = 1000 CC =10cmm*10cm*10cm = 100mm*100mm*100mm =1000,000 mm³ = 1000,000 BCM
So, Total Kg of wet ink Required =15,500,000/1000,000 = 15.5 Kg
Dry ink required @35% solid = 15.5*0.35 =5.425 kg
Hence, Ink GSM = 5425gm/10000sqmtr =0.5425

47. . . .. . . SAKATA INXSAKATA INX
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Anilox Cell Volume
Conversions of Metric to BCM
cm3/m2 BCM
79 51.00064558
  
cm3/m2 BCM
30.980 20
Hence, CCM = 1.55 BCM
While US market uses Anilox Volume as BCM,
European Market uses as cm³/m² also known as
CCM

48. . . .. . . SAKATA INXSAKATA INX
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Anilox Selection

49. . . .. . . SAKATA INXSAKATA INX
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Anilox selection

50. . . .. . . SAKATA INXSAKATA INX
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Anilox selection

51. . . .. . . SAKATA INXSAKATA INX
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Anilox selection:

52. . . .. . . SAKATA INXSAKATA INX
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Ink Transfer from Plate to Substrate:

53. . . .. . . SAKATA INXSAKATA INX
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Gravure and Flexo
Flexography has become very attractive alternative to
rotogravure printing, because the low associated costs
and increased “flexibility” with flexo.
•Short run very easy
•Printing plate cheap.
•Better registration
•Various films can be easily printed.

54. . . .. . . SAKATA INXSAKATA INX
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Gravure and Flexo
•Wider substrates – so three – four jobs in one run.
•Ink GSM is lower so is adhesive requirement.
•Low energy requirement for the drier.
•Graphic reproduction is poor in comparison to Gravure.
•Both side print not possible in flexo.

55. . . .. . . SAKATA INXSAKATA INX
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Gravure and Flexo
•In Gravure one cylinder can have half tone and line
images which is not possible in Flexo.
•The ink for Flexo has to have very high resolubility (ink is
exposed for longer time in flexo than gravure) for better
image transfer but it creates trapping problem on the other
side.
•Shade control in gravure is much better through Ink route.

56. . . .. . . SAKATA INXSAKATA INX
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Gravure and Flexo
•Ink cleaning from gravure is easier than cleaning of plate.
•Ink build up on plate and anilox plugging to be handled
frequently and effectively in flexo.
•Photo polymeric plate making is much easier and
variables to control consistency are lower than gravure
cylinder and so is the consistency for laser engraved
aniloxes.

57. . . .. . . SAKATA INXSAKATA INX
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Gravure and Flexo
•In the past, the knock on flexo was the poor print quality
when compared to gravure. But as flexo technology
evolves, the print quality gap narrows and flexo continues
to strengthen its case as the printing process of choice for
flexible packaging.

58. . . .. . . SAKATA INXSAKATA INX
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Advantage Flexo
Flexo is the Solution to the Converters:
• Fast Changeover, Less set up time.
• High Speed Presses- 400 to 600 mtr/ min- High Output.
• Plate making is fast, Cost Advantages
• Inks are toluene free, Ink consumption is less.
• Can handle thin films better- PE/ BOPA etc.
• Less Solvent/ VOCs Emission.
• Lower Power Consumption- Dryer length is shorter.

59. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Advantage Flexo
What this means to Converters?
• Frequent design changes,
• Smaller printing runs.
• New product design cycle times continue to shrink.
• Costs need to come down.
• They have to handle thinner films for printing.
• Environmentally friendlier solutions.

60. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Cost of Laminates in Flexible Packaging
Thickness SubstrateSubstrate Substrate
SubstrateSp. Gr.(micron) GSM Sq mtr / KgSq mtr/ 100 Kg
PET 1.4 10 14 71.4286 7142.8571
PET 1.4 12 16.8 59.5238 5952.3810
BOPP 0.9 18 16.2 61.7284 6172.8395
BOPP 0.9 15 13.5 74.0741 7407.4074
Prl BOPP 0.7 35 24.5 40.8163 4081.6327
PE 0.92 45 41.4 24.1546 2415.4589
Al-foil 2.7 9 24.3 41.1523 4115.2263
We can have a formula here as:
Sq. Mtr. of a Substrate = Gram of Subatrate / GSM of Substrate.

61. . . .. . . SAKATA INXSAKATA INX
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Print Cost Calculator
SubstrateDensity
Thickness

(Micron)
Substrate
GSM
Print
Quantit
y (Kg)
Substrate
Sq mtr
Ink GSM
Total Dry Ink
required
(KG)
Colour
Colour
Ratio %
Dry ink
Consum
ption
Ink Solid
%
Fresh Ink
Required
Kg
Fresh ink
Cost
Rs. /Kg
Colourwise
Cost
PET 1.4 12 16.8 50029761.92 59.52Whiite 50 29.7639.0076.3123117628.21
  Yellow 12 7.1419.0037.59224.78447.37
  Magenta 7 4.1719.5021.37235.25025.64
  Cyan 5 2.9820.9014.24233.13319.38
  Black 3 1.7922.008.12204.751661.93
 
Consideration:
Toluene base Vinyl Ink System
Red 7 4.1720.0020.83266.75556.25
  Green 3 1.7921.008.50270.92303.57
  Medium 13 7.7414.0055.27180.69982.14
  Total
Cost
  59.52   242.24   53924.49
 
Add
Solvent (Tol:Ethyl Ac 1:1) (Ink:
Sovent
:: 1:1.2) Cost+
290.6984 24417.79
  Ink
Cost Rs./Kg of Substrate
    107.85
  Solvent
Cost Rs./Kg of Substrate
    48.84
  Printing
Cost Rs./Kg of Substrate
    156.68
  Ink
Cost Paise/Sq mtr of Substrate
    181.19
  Solvent
Cost Paise/Sq mtr of Substrate
    82.04
               
Printing
Cost Paise/Sq mtr of
Substrate
    263.23

62. . . .. . . SAKATA INXSAKATA INX
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SubstrateDensity
Thickness

(Micron)
Substrate
GSM
Print
Quantit
y (Kg)
Substrate
Sq mtr
Ink GSM
Total Dry Ink
required
(KG)
Colour
Colour
Ratio %
Dry ink
Consum
ption
Ink Solid
%
Fresh Ink
Required
Kg
Fresh ink
Cost
Rs. /Kg
Colourwise
Cost
PET 1.4 12 16.8 50029761.92 59.52Whiite 50 29.7645.9064.8430619841.27
  Yellow 12 7.1421.8032.77288 9436.44
  Magenta 7 4.1720.8020.03279 5588.94
  Cyan 5 2.9821.2014.04278 3902.74
  Black 3 1.7924.807.20 282 2030.53
 
Consideration:
Migration Cost to Toluene Free PU ink system with same
Cyl
Red 7 4.1722.2018.77297 5574.32
  (XGL-415
SR)
Green 3 1.7922.807.83 294 2302.63
  Medium 13 7.7418.1042.7523410003.95
  Total
Cost
  59.52   208.23   58680.82
 
Add
Solvent (Ethyl Ac :IPA=80:20)
(Ink:
Sovent :: 1:1.2) Cost+
249.8887 21739.22
  Ink
Cost Rs./Kg of Substrate
    117.36
  Solvent
Cost Rs./Kg of Substrate
    43.48
  Printing
Cost Rs./Kg of Substrate
    160.84
  Ink
Cost Paise/Sq mtr of Substrate
    197.17
 
Solvent
Cost Paise/Sq mtr of
Substrate
    73.04
               
Printing
Cost Paise/Sq mtr of
Substrate
    270.21
Migration Cost from Toluene base to Non Toluene Ink System

63. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
SubstrateDensity
Thickness

(Micron)
Substrate
GSM
Print
Quantit
y (Kg)
Substrate
Sq mtr
Ink GSM
Total Dry Ink
required
(KG)
Colour
Colour
Ratio %
Dry ink
Consum
ption
Ink Solid
%
Fresh Ink
Required
Kg
Fresh ink
Cost
Rs. /Kg
Colourwise
Cost
PET 1.4 12 16.8 50029761.91.8 53.57Whiite 50 26.7945.1059.3930618173.90
  Yellow 12 6.4321.5029.90318 9508.31
  Magenta 7 3.7521.1017.77314 5580.57
  Cyan 5 2.6825.1010.67374 3991.18
  Black 3 1.6123.906.72 298 2003.89
 
Consideration:
Migration Cost to Toluene Free PU ink system with PU
base
Cylinder Bellecolor
Red 7 3.7521.8017.20360 6192.66
  Green 3 1.6122.407.17 370 2654.66
  Medium 13 6.9616.0043.5326811665.18
  Total
Cost
  53.57   192.36   59770.33
 
Add
Solvent (Ethyl Ac :NPAc:IPA=
50:30:20)
(Ink: Sovent :: 1:1.2) Cost+
230.8411025392.06
  Ink
Cost Rs./Kg of Substrate
    119.54
  Solvent
Cost Rs./Kg of Substrate
    50.78
  Printing
Cost Rs./Kg of Substrate
    170.32
  Ink
Cost Paise/Sq mtr of Substrate
    200.83
 
Solvent
Cost Paise/Sq mtr of
Substrate
    85.32
               
Printing
Cost Paise/Sq mtr of
Substrate
    286.15
Migration Cost from Toluene base to Non Toluene Ink System

64. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
@ Rs. 400.00/kg Liquid Ink cost,
at 30% solids,
Solid ink-cost = Rs. 1333.30/kg
Rs. 280.00/kg Liquid Ink cost,
at 20% solids,
Solid ink-cost = Rs. 1400.00/kg
typical Ink pick-up of 1.20 GSM,
Net ink-cost per sqm = Rs. 1.6
@ typical Ink pick-up of 1. 70 GSM,
Net ink-cost per sqm = Rs. 2.38
@ Rs. 1.70 per sqcm,
for area of 1000mm x 500mm,
Flexo plate-cost = Rs. 8500.00
@ Rs. 2.20 per sqcm,
for area of 1000mm x 500mm,
Gravure cyl.-cost = Rs. 11000.00
@ Rs. 8.00-10.00 Crores
depending on make, features
@ Rs. 10.00-15.00 Crores
depending on make, features
INK
IMAGE CARRIER
EQUIPMENT
Flexo Vs Gravure
Flexo Printing Gravure Printing
Flexo Vs Gravure Printing Cost

65. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
HOW TO REDUCE PRINTING COST FURTHER???
 A study by GAA - keeping Ink Temperature low

66. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Ink Temperature
Total Solvent Consumption
66°F=18.9 degC 79°F=26.1degC 92°F=33.3degC

67. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Ink Consumption
Ink Temperature

68. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Print Quality — Reflection Density
Ink Temperature
66°F=18.9 degC 79°F=26.1degC 92°F=33.3degC

69. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Print Quality — Specular Gloss
Ink Temperature
66°F=18.9 degC 79°F=26.1degC 92°F=33.3degC

70. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Dot Deformation (Do-nuts)
Magenta elongated tone (25%)
79°F 92°F
Ink Temperature
79°F=26.1degC 92°F=33.3degC

71. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Dot Deformation (Do-nuts)
Cyan compressed tone (25%)
Ink Temperature
79°F=26.1degC 92°F=33.3degC

72. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Magenta solid — 150 lines per inch
79°F=26.1degC 92°F=33.3degC

73. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Potential Cost Saving : A study by GAA
Parameters General Scenario
(Ink temp=33
degree cel)
Changed Scenario
(Ink temp =26
degree cel)
Savings % saving
Solvent emissions
(Kg/month)
56700 (Ink :
Solvent= 1:1.166)
43200 (Ink :
Solvent= 1:1)
13500 31.25
Ink consumption
(Kg/month)
48600 43200 5400 12.5
Annual Solvent
Costs (Rs 100/Kg)
5670000 4320000 1350000 
Annual Ink Costs (Rs
290/kg)
14094000 12528000 1566000 
Printing Cost (Rs)19764000 16848000 2916000 17.3

74. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Low Viscosity PU base Ink System Advantage
There is no advantage if the ink viscosity is
reduced just by adding solvent.
Viscosity of the ink should be lower due to low
viscosity of resin itself.

75. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Low viscosity ink system : Advantage
New approach to reduce ink consumption and
solvent consumption
By using new technology in the ink and its
application
Solvent reduction of 30% is achievable.
Ink consumption of 10% is achievable.

76. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
76
High Solid Ink & Shallow CylinderHigh Solid Ink & Shallow Cylinder
20-30% of VOC
emissions
reduction is
possible.
R
a
w

I
n
k
R
a
w

I
n
k
Average Solid Ink
175l/inch (70l/cm)
High Solid Ink
200l/inch (80l/cm)
Conventional Ink 　　
Ink : Solvent = 1.0 : 0.6　
High Solid Ink
Ink : Solvent = 1.0 : 0.3
Cylinder Engraving
Conventional ink : 175l/inch(70l/cm)
High Solid Ink: 200l/inch (80l/cm)

77. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Printing Example (1)Printing Example (1)
77
High Solid Ink make
Higher Density
High Solid Ink with
Shallow Cell make
Same Density
<Conditions>
Cylinder :
Helio :
Stylus 130°
Ink Viscosity :
15sec (Rigoh
Zhan#3)
Printing
Speed :
30m/min
by small
press
Standard
Ink175
LPI
HS Ink
175 LPI
Standard
Ink175
LPI
HS Ink
200 LPI

78. . . .. . . SAKATA INXSAKATA INX
Visual Communication TechnologyPrinting Example (2)Printing Example (2)
78
High Solid Ink make
Higher Density
High Solid Ink with
Shallow Cell make
Same DensityWhite ink is used most for the solid back up.
High Solid Ink make
Higher Density
High Solid Ink with
Shallow Cell make
Same Density
Standard
Ink175
LPI
HS Ink
175 LPI
Standard
Ink175
LPI
HS Ink
200 LPI

79. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
Use “Shallow Cylinder” to Reduce VOC EmissionUse “Shallow Cylinder” to Reduce VOC Emission
175 l/inch = 70l/cm (General Cylinder)
200 l/inch = 80l/cm (Shallow Cylinder)
130°
120°
1/175 inch
1/200 inch
Stylus
Angle
Cell
Volume:
100%
Cell
Volume
: 70%
In case of mechanical engraving such like Helio.

80. . . .. . . SAKATA INXSAKATA INX
Visual Communication Technology
THANK YOU