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Issue 1/2008

PROCESSES | PRACTICES | PERSPECTIVES

Process technologies, consumables and applications for sheetfed offset printing on plastic substrates

Printing on plastics and composites

Whether in advertising or magazine printing, in the display sector or packaging, end customers and agencies alike are constantly in search of that special extra which will enable their product to stand out above the crowds. In response, more and more printers are looking beyond traditional papers and board stocks and are discovering the possibilities for printing on plastic films and synthetic papers, or composites of paper, plastic film and aluminium coating. Once domains of screen printers and narrow web presses, these markets are today interesting prospects for sheetfed offset, with its weighty arguments of optimum quality and cost-effectiveness. Koenig & Bauer and KBA-Metronic are long-standing pioneers in the fields of UV and waterless offset print, and are now able to play out their great knowhow lead to promote printing on non-absorbent substrates such as plastic film and aluminium. In cooperation with selected, and in some cases exclusive partners, innovative solutions have been developed for this booming market segment. The plastics equipment package for KBA Rapida presses comprises special components to ensure smooth sheet travel, and can be complemented with unique options such as a corona tower (as to be seen below on a Rapida 105) or substrate-friendly inert UV interdeck dryers. Several Metronic solutions, furthermore, permit direct printing on products such as plastic cards, CDs, DVDs and Blu-ray Discs, even in non-standard shapes and formats. KBA offers by far the broadest range of presses and machines for offset printing on film substrates and data storage media. The term plastics covers a whole group of individual materials with the most varied printability and process properties. Only certain polymers are properly suitable for any given application, for example banners, signs, logos, lenticular images, cards, in-mould labels or folding boxes and displays. Against this background, this brochure is intended as both inspiration and a decision aid for users considering an investment in this exciting branch of the print industry. The authors include KBA partners with special expertise in the fields of polymer films, UV inks and coatings, in-mould labels, antistatic systems and surface treatment. We have dispensed with detailed articles on the more general aspects of waterless offset, UV curing or photoinitiators, as they were already topics in previous issues of KBA Process. These earlier issues are unfortunately out of print, but can be downloaded in five languages from the KBA web site under News & Press\Press Service\KBA Process. As in all previous publications, KBA has done its best to present an objective overview of the processes, their potential, quality demands and possible applications.

Contents
KBA Editorial 2

Plastics Modern substrates with great potential: PVC, PE, PP, PET 3 The making of plastic webs: Rigid PVC and its properties 5 Versatile polyester 8 In-mould labels based on PP film 10 Printability Simple determination of surface tension on plastic films 12 Raising surface tension with a corona tower 14 Sheet travel Antistatic systems on sheetfed offset presses

16

Inks and coatings Oil-based and UV-cured inks for printing on plastics 18 Finishing of plastic films with UV-cured coating systems in sheetfed offset 21 Applications KBA users hold the key to new fields of business: Examples 23 Lenticular film: Special effects for future-oriented niche markets 27 Glossary Resources and partners Contacts 29 30 31

Editorial

Dear customers and friends of KBA,

The issues of KBA Process to date have documented Koenig & Bauers pioneering work in the most varied fields of offset printing: Direct sheetfed offset on corrugated board, ecological waterless and keyless offset print, product refinement with hybrid finishing and economical inline coating. This latest issue of KBA Process is now to take a look at a rather less widespread sheetfed offset application for which KBA again has plenty to offer in the way of technology and experience: Printing on non-absorbent substrates. This is as always a topic with potential for the future. After all, the extraordinary look, feel and utility value of plastics, composites and synthetic papers expand the repertoire of innovative, open-minded print businesses and represent an outstanding opportunity to break out from the often purely price-driven standard market. Plastics printing offers interesting possibilities to establish a regular base of discerning customers. And it is no secret: If you can build up a reputation for high-quality speciality products in a small, future-oriented market segment, then it is much easier to generate comfortable margins. A well-prepared entry into the world of film and plastics printing, whether with an individually tailored press configuration or a dedicated system for direct printing on CDs, DVDs and plastic cards, is an investment with a promising future. KBA can point to numerous installations and excellent references for plastics printing in all format classes. And we confidently bring the full weight of our expertise to bear in championing the high productivity, quality and format flexibility of sheetfed offset compared to conventional processes for printing on plastics. No other press manufacturer is able to present such a broad product range with so many innovations for this fast-growing segment. It is already several years ago that KBA adapted two previous narrow-web solutions for sheetfed applications, namely inline corona treatment and inert UV interdeck drying. In both cases, our design engineers in Radebeul mastered the challenge of achieving the desired effects despite the presence of gripper systems. Such brilliant coups are of course only possible when working hand in hand with exceptional partners. Many of these partners have contributed to this issue of KBA Process, and all have earned our boundless gratitude for their long-standing cooperation. Once more with the proven support of trade journalist Dieter Kleeberg, the authors have, I believe, succeeded admirably in identifying the application diversity of plastics printing, while at the same time presenting the unfamiliar material properties and processes in a manner immediately understandable

Ralf Sammeck, Executive Vice-President Sheetfed Sales, Koenig & Bauer AG

also to those readers with no previous experience in this field. We would be delighted if KBA Process No. 5 is able to provide a valuable tip here and there, whether for your first steps in plastics printing or the further expansion of existing activities; and when all's said and done, that is actually the whole idea behind this series of publications from KBA. Hoping that we can in this way contribute to your business success, we will continue to do all we can to pinpoint attractive business ideas and to open up new avenues for you, our customer. Because in the end, we all benefit together from the strengthening of print in its countless facets.

Yours,

Ralf Sammeck Executive Vice-President Sheetfed Sales

2 Process 5 | 2008

Plastics | Substrates

Modern medium with great potential

Plastics in modern common usage, that is the general term for a wide range of so-called polymers, i.e. organic macromolecules composed from simpler hydrocarbon molecules (monomers). The chaining, branching or cross-linking of these monomers determines the individual structure of the molecule group. Polymers are today used in many ways as packaging and print substrates.
advance before. The spiral of innovation is turning ever faster. New plastics have inspired new ideas for potential uses, new printing inks, new processing machines and techniques, and new demands to be satisfied by the material. And this in turn triggers desires for new possibilities and thus new materials Whereas the packaging sector has paid most attention to transparency and stability, the print industry was naturally forced to consider above all printability issues. It is not long ago that flaming was the only possibility to enable printing on polypropylene. To activate the surface and to improve ink adhesion, the sheet was heated momentarily with a gas flame, but without allowing the plastic to melt. Not surprisingly, many companies shied this complicated and expensive process. Even so, polypropylene continued to stimulate the imagination of designers; after all, practically no other synthetic material is as versatile and despite being a plastic as environment-friendly as polypropylene. Consequently, some manufacturers began to treat the surface in a special factory process to facilitate later

Slipcase printed with a floral design in sheetfed offset on PriPlak, a corona-treated polypropylene film produced by ArjoWiggins and distributed by Papier Union

It is by no means the case that polymers are always modern synthetic products. In fact we have already been using naturally occurring biopolymers, such as asphalt or tree resins, for many thousands of years. When we speak of plastics, however, we usually mean the range of synthetic polymers encountered in practically every sphere of daily life, e.g. PVC, polypropylene, polyethylene or polyester (see box).

Changed demands on the print and packaging industry

New colourings, surfaces and processing options have made plastics an increasingly popular medium for designers, and thus also a relevant concern for the print industry. Experts estimate that the use of synthetic materials rose by 10 to 15% between 2005 and 2006. Where paper and board were once the principal vehicles for informa-

tion, further industrial developments have in the meantime led to an elementary shift in interests. Even more specific demands are being raised regarding the packaging, protection, transport and presentation of goods. Consequently, the demands to be met by the print substrate have also gained in complexity: Labels are to be tear- and waterproof, but nevertheless simple to print or write on. Reference works are to be more durable and must not tear even when subjected to heavy use. Transparent packaging is viewed as necessary to enhance the presentation of goods. Presentation possibilities at the point of sale are to be improved. In such a situation, conventional papers and boards soon reach the limits of their performance capabilities but the chemicals industry is on hand to save the day.

Plastics change the world

The discovery and further development of the most varied plastics has changed the world like practically no other technical

Synthetic polymers in daily life

Polyvinyl chloride (PVC) is the most widely used chlororganic plastic. According to Federal Environment Office figures, approx. 1.5 million tonnes of PVC were being produced and processed in Germany at the end of the 1990s. Some 10 to 20% of the PVC is used for packaging, and a further 20 to 30% for a diversity of articles for daily use. Polypropylene (PP) is the overall designation for a series of weldable thermoplastic polymers which stand out by way of their great hardness, rigidity and heat resistance. PP is processed, for example, in sheets, buckets and bottles, and its pollutant-free incineration permits ecologically compatible disposal. According to Wikipedia, 30 million tonnes of PP were produced worldwide in 2001. Polyethylene (PE) is easily recognised by way of its soft, wax-like surface with pronounced non-stick properties. It displays a low density, but at the same time high strength, hardness and resistance to chemicals. PE is used, for example, for environment-friendly self-adhesive foils and extremely tear-resistant sheet and roll materials, such as the fabric-like DuPont Tyvek. Polyethylene terephthalate (PET) is a thermoplastic polymer of the polyester family. Its high tear strength makes PET an ideal material for film sheets of all thicknesses, from an ultrathin 1 m up to 500 m. Applications range from aroma-tight food packaging to coloured sun-protection films and test strips for the pharmaceuticals industry. It is today almost impossible to imagine the soft drinks industry without PET bottles. Further uses are to be found in textile fibres, e.g. for sportswear, and in many other spheres of daily life.

Process 5 | 2008 3

Plastics | Substrates

printing. In conjunction with special inks and the corresponding technology, this so-called corona treatment today permits relatively trouble-free printing of this once difficult material. At the same time, other synthetic print substrates such as polystyrene, rigid PVC and self-adhesive foils were developed further and are in the meantime in daily use in many print companies.

New materials, techniques and markets

While plastics remained rigid materials, they were a safe domain for screen printers. Only their machines were able to handle such unwieldy media. But then films and other flexible synthetics came onto the market. And more and more companies began to address a completely new challenge: Offset printing on flexible plastics. Plastics up to a thickness of 1 mm are already no longer a problem for specialised offset printers, and the combination with UV-cured inks lifts all previous restrictions on creativity. Waterless offset and the hybrid technology each also thanks to the pioneering work of KBA have similarly played an important role in promoting the use of plastic substrates. A relatively new product class on the market is that of digital flat-bed printing systems operating with solventbased or UV inks. With these systems, the printing of synthetics can be handled cost-effectively also for very short runs. The most interesting market segment for plastics printing and currently the fastest-growing is advertising. There is no overlooking the colourful packaging, signs, posters and displays wherever we go. But plastics are also finding their way increasingly into the office sector. So-called permanent paper can first be printed in a classic offset process, and subsequently sent through the office laser printer preprinting for synthetics.

PowerJet Texpo banner of polyester fabric Trevira CS B1, printed in a digital inkjet process

Conference clipboard printed onto Lucprint rigid PVC

Prospects
In future, too, there will still be countless fields of application for classic board materials, especially where it can be further refined by way of coating, embossing and lamination, etc. But the use of plastics for the

most varied products will continue to increase. Wholesalers such as Papier Union have already reacted to this trend by establishing independent sales departments with specifically trained specialists for the new synthetic materials. It remains to be seen whether the users of synthetic substrates will in future have to or choose to rely further on the tried and trusted materials of the past. Heated discussions are almost certain. Most likely, however, is that new developments will emerge, with plastics on the basis of renewable raw materials rather than the limited resource mineral oil. This development will require new printing inks, presses and techniques. And it will trigger new desires. Service providers hoping to gain a share of this interesting market are advised not to wait too long before jumping on the bandwagon because it is already moving faster and faster. Klaus Fischer (Papier Union GmbH), Cornelia Lillelund

Food-safe Lucprint PVC films are used, among other things, for exclusive packaging

4 Process 5 | 2008

Plastics | Manufacturing process

The making of plastic webs

Plastic films are produced by completely different technologies to papers and boards. The example of unplasticised or rigid PVC production at Klckner Pentaplast illustrates how the later film properties are set on the high-temperature calender machines.
3,000 mm. The advantages of the HT process are to be seen in the broader options for modification of the film properties and the greater production output on significantly wider machines. The materials used are mainly S-PVC and M-PVC with K values (degree of polymerisation) around 58 to 63, which produce films with high transparency, good deep-drawing properties and appreciably greater thickness.

Schematic representation of a calender machine

The production of film materials is an established field of polymer processing, as such films can be used in an endless diversity of applications. Whether as semi-finished or end products, their broad range of modification possibilities helps meet the prerequisites of the most varied branches of industry. Several differing process technologies have been developed for the production of plastic webs, and together permit suitable films to be made available economically for a comprehensive spectrum of uses. These technologies are extrusion with slot-die or blow

forming, spreading, casting and calendering.

Calendering of unplasticised PVC films

Calendering is the process by which high-viscosity polymer formulations are moulded into an endless web under pressure and at a defined processing temperature in the gap between two or more rolls. The set width of the gap determines the thickness of the resulting film. The arising gap pressure is derived from the gap geometry and the rheological properties of the mass to be calen-

Fields of application for PVC

An analysis of product quantities and costs over the past few years illustrates how the market development for PVC has been influenced by four principal factors: Economic recessions, the introduction of restrictive packaging legislation, several anti-PVC campaigns and improved substitute films (polypropylene, polyester or polystyrene). Contrary to the forecasts of wide-scale replacement by the above-mentioned substitutes, PVC has actually maintained a relatively constant market share, especially in the market segments packaging and technical products. Reasons can be seen in the inexpensive production and modification of PVC and in the generally good processability of the semi-finished and end products.
20 % 15 10 5 0
19.6 15.0

900 000 t
9.3 4.7 2.8 2.8

8.4 3.7

8.4 3.7

8.4

8.4 4.7

10

11

12

13

The West European market for rigid PVC films accounts for a consumption of 900,000 tonnes. Of this, 60% is used for packaging (1 Foods, 2 Non-foods, 3 PVC composites, 4 Box lids, 5 Pharmaceuticals, 6 Oriented films, 7 Others) and 40% in technical applications (8 Adhesive tapes, 9 Office films, 10 Furniture and frames, 11 Offset/screen/digital printing, 12 Construction, 13 Others).

dered. A calender is thus to be treated as a processing machine purely for forming purposes. The first calender-like machines were already designed before 1800 for the smoothing of textile surfaces. In 1836, the first patents were granted for calender machines for rubberising and for the application of rubber to textiles. Demands for higher production speeds and closer tolerances promoted further development of the calender and expansion of its range of applications to include the processing of polyvinyl chloride (plasticised and unplasticised PVC) in addition to rubber. The first calender for unplasticised PVC, introduced in 1937, was designed to be heated to 220C. Once highly active stabilisers became available from around 1960, it was possible to supplement the previously used low-temperature process (LT) with a high-temperature process (HT) based on modified recipes and higher temperatures within the calender. The technical configurations and implementations have remained practically unchanged over the past decades. The only real variation has been to widen the calender rolls to increase output or to facilitate avenues of specialisation in film production. The established technology for the production of unplasticised PVC films is based on the HT process and four- or five-roll calenders in widths between 1,800 and

Unplasticised PVC
In terms of production capacity and consumption, PVC occupies third place in the list of most commonly used standard polymers with 28.6 million tonnes per year, after polyethylene (57 million tonnes) and polypropylene (35 million tonnes). The constantly increasing consumption over the past 60 years or so, from initially around 10,000 tonnes to now almost 30 million tonnes per year, is indicative of the continued industrial significance of PVC. Thanks to its compatibility with a whole range of auxiliaries and media, PVC has built up and maintained a very broad range of applications, from window frames and films to pastes and coatings. In Germany and the rest of Europe, the processing volume of unplasticised PVC is around double that of plasticised PVC. Unplasticised PVC films account for an approx. 15% share of the total consumption of PVC. Packaging films make up some 60% of the total film production. Further important applications are technical films and films for printing. 20% of the unplasticised PVC is calendered, with the most important market segments being packaging and technical applications. Vinyl chloride was first produced by Henri Victor Regnault in 1835. The first industrial-scale production began at IG Farben in Germany in 1938, and at almost the same time at Union Carbide

Process 5 | 2008 5

Plastics | Manufacturing process

and DuPont in the USA. Nowadays, it is produced by way of a single- or two-stage reaction involving chlorine and ethylene. PVC, with a chlorine content of 57%, requires less mineral oil than any other polymer and is produced industrially by one of three methods: Emulsion polymerisation (EPVC) for pastes and film applications; Suspension polymerisation (SPVC) the main process, for all applications; Mass polymerisation (M-PVC) primarily for rigid PVC applications. The choice of a particular PVC type is governed by the demands of further processing and the purchasing price. S-PVC and MPVC are ver y versatile and mutually exchangeable. M-PVC, due to its purity, is preferred for transparent products.

2 Comparison of material properties of four different polymers: GB = Gas barrier, WB = Water vapour barrier, Mi = Migration, Mo = Modification, Tr = Transparency, EM = Elastic modulus, HR = Heat resistance, SpW = Specific weight

3 Comparison of processing properties of four different polymers: Pr = Printability, Th = Thermoforming, Fo = Folding, Se = Sealing, AS = Antistatic properties, En = Process energy, Gl = Gluing, Sc = Scratch resistance

elevations influences the optical quality of the film. Flow lines are caused by inhomogeneities in the kneaded polymer melts fed to the rolls, the reasons for which, in turn, may lie in throughput fluctuations or temperature differences. The current limit values for thickness fluctuation for different applications lie between 3 and 10% for rigid PVC films (see table). Own research has demonstrated that thickness deviations are rarely recipe-dependent.

Surface properties for the printing process

displays the following selected properties: High mechanical strength, rigidity and hardness, Impact-sensitive at low temperature in unmodified form, Varying degrees of transparency, Good electrical properties in the low-voltage and low-frequency ranges, High resistance to chemical attack, Self-extinguishing upon removal of the ignition source. These properties are only to a small degree attributable to the production process. A greater role is played by the additives introduced during further processing, such as stabilisers, slip agents, pigments, fillers and static eliminators (Fig. 4). Rigid PVC films are produced with a choice of glossy, matt and embossed surfaces. The individual film surface is achieved by way of a corresponding matt or glossy roll surface, or else with a separate stamping module, dulling agents in the recipe or temperature control at the final calender rolls and delivery. For printing films, in particular, the homogeneity of the surface is a decisive factor, as the surface is required to display specific properties appropriate to the subsequent print process. Glossy, matt and embossed films are all suitable for screen-printing and UV offset. For conventional offset, matt films are the most commonly used substrates, while glossy films are preferred for gravure applications.

Film thickness and thickness fluctuation

The film thickness is set by way of the calender roll adjustment. For packaging films, the thickness normally lies within the range from 100 to 800 m. It is measured radiometrically during the production process, but checked mechanically in the laboratory between two gauge surfaces subjected to a specified pressure. Thickness deviations can occur in both the lengthwise and crosswise directions, as well as diagonally. Fluctuations in the crosswise directions are essentially overcome by the compensation systems of the calender. The thickness profile can be improved by measures such as crowning, bending or skewing of the rolls, with blower systems providing for zonal thickness corrections. Lengthwise deviations are generally the result of excessive play in the bearings of the calender rolls, out-of-true running or speed fluctuations after the final calender roll. Fluctuating loads in the roll gap are similarly a possible cause. Another source of annoyance is the formation of so-called flow lines oblique to the running direction. The varying light refraction resulting from the approx. 10 m

Film properties
PVC can be distinguished not only by its production process, but also by its material and processing properties (Figs. 2 and 3). The standard international designations are PVC-U (for unplasticised or rigid PVC) and PVC-P (for plasticised PVC). Rigid PVC, as the variant suitable for printable films,

Processing improvement
Thermo-stabilisers Internally and externally effective slip agents Calendering aids

Film recipe
PVC S, M, E

Application improvement
UV stabilisers Impact strength enhancers Pigments Static eliminators Anti-blocking, dulling, flameproofing agents High-temperature modifiers SAN and ABS

Film shrinkage
Shrinkage refers to the changes in length and width of a film when exposed to heat. Shrinkage can be influenced by the temperature and speed control after the calender, additives influencing the glass transition temperature, additives influencing stretching, design measures to reduce relaxation. The cause for this shrinkage lies in the expansion of the film above the so-called glass transition temperature, which marks the relatively narrow transition range between hardness and elasticity.

Composition of a PVC-U recipe

Limit values for thickness deviation

Film thickness Below 100 m Below 200 m Below 400 m Below 400 m Maximum thickness fluctuation for packaging films films for customer and credit cards 10% 7% 10% 5% 7% 3% 5% 3%

6 Process 5 | 2008

Plastics | Manufacturing process

100 % 75 50 25 0

160 C 120 80 40 0

1 2 3 4 5 6

7 8

1 2 3 4 5 6

7 8

5 Transparency (%) of different plastic films, relative to PMMA (100%): 1 PP random copolymer, 2 High-impact modified PVC, 3 PETG, 4 Rigid PVC, 5 PC, 6 PS (Styrolux), 7 High-impact modified PMMA, 8 PMMA

6 Temperature stability of different polymers on the basis of their Vicat softening temperature (C): 1 PP, 2 APET, 3 PETG, 4 High-impact modified PVC, 5 Rigid PVC, 6 PS, 7 PMMA, 8 PC

Oxygen and water vapour barrier properties of different plastics, relative to rigid PVC = 1

The expansion leads to orientation of the molecule chains, which are then frozen in their new state upon subsequent cooling. Later reheating to a temperature above the glass transition temperature releases the frozen stresses and the molecules return to their original configuration. The arising restoration forces reverse the original deformation and produce the shrinkage.

Transparency
One important optical property of a film is its transparency (Fig. 5), i.e. the extent to which contours behind the film, e.g. packaged goods or lettering, remain visible and accurately recognisable. The transparency is influenced by the recipe, the surfaces of the last calender roll and the first delivery roll, and the temperature control at these two rolls. Film defects affecting transparency include, among others, the abovedescribed flow lines, whose thickness fluctuations lead to optical distortions.

flatness defects, with the result that sheets refuse to lie flat and reels deviate from their true running direction when unwound. Such temperature differences may also be the cause of expansion over the film width, in exactly the same way as various expansion problems arising from out-ofparallel roll settings or truerunning errors. Such defects are noticeable above all at the edges of the film web, and in extreme cases may mean that these edges are no longer suitable for further processing. Excessive dwell times due to unfavourable flow processes in the plasticiser or the first roll gap also lead to variations in the thermal loads acting on the film and consequently to varying thermal degradation. The resultant inhomogeneities in the molecular structure are manifested as strength fluctuations when the film is stretched or flexed. This may lead, for example, to tears or holes in the film during crosswise stretching.

8 Permeation coefficients of polymers for oxygen permeation [cm3 m m2 d1 bar 1] and water vapour permeation [g m m2 d1]

Film homogeneity and flatness

Film homogeneity can be understood as the regularity of certain optical and mechanical film properties which are of particular importance for downstream processes such as stretching, printing or deep-drawing. Temperature differences, whether over the roll width or around the roll circumference, cause thickness deviations in the form of

Impact strength and rigidity

Films are often exposed to mechanical impact stresses during further processing or later use. Their ability to withstand such stresses is known as impact strength, and is classified on a scale from brittle to high impact strength. The impact strength can be varied by way of suitable modifiers such as MBS, CPE, ABS or

acrylate. Their effect is greater, the higher the K value of the PVC concerned. Optimum setting of the plasticising and calendering processes in respect of homogeneity and temperature control is similarly significant for attainment of a particular impact strength. The rigidity of a film is dependent on its modulus of elasticity and its thickness. For example, a PP film would have to be 1.3 times the thickness of a PVC film to obtain the same flexural rigidity.

various polymers. Polycarbonates are excellently suited where such demand profiles apply.

Barrier properties
The higher the barrier effect of a film (Fig. 7), the lower its permeability for certain media. The barrier properties are quantified by the extent of permeation (Fig. 8) of a volume or amount of gas (gas permeation) or vapour (e.g. water vapour permeation) through one square metre of a film of a specified thickness at a defined gas or vapour pressure difference over the period of one day. Frank Wamann (Klckner Pentaplast GmbH, Montabaur)

Temperature stability (Vicat)

Where films are intended for further processing or use in the food and pharmaceuticals industries, one critical property is temperature stability, e.g. to permit heating in a microwave oven or sterilisation process. Figure 6 shows the so-called Vicat softening temperatures of

Process 5 | 2008 7

Plastics | Versatility

Polyester The epitome of versatility

The polyester family of plastics has gained a foothold in many areas of packaging, advertising and CD/DVD printing in recent years. Contrary to the most frequently used PVC and polypropylene substrates, polyester attracts attention through the possibilities for modification and a very broad suitability for different print and packaging applications and even as a substrate for electrically conducting inks.

The term ester derives from the German Essig-ther (literally: vinegar ether), which is an old name for ethyl acetate. Polyesters are thermoplastic polymers with the ester functional group [COO] in their main chain. Thermoplastic means that these polymers can be formed at higher temperatures and then maintain their new form after cooling. Polyesters are produced by various polycondensation processes, depending on their chemical composition.

Polyethylene terephthalate (PET, PETB)

The best-known and most versatile polyester is PET, which is obtained through the reaction of the monomers terephthalic acid and ethylene glycol. Semicrystalline PET molecules (CPET) are linear chains without lateral branches ideal for crease-, tearand weather-resistant fabrics such

as Trevira or fleece, or equally for tennis racquet strings. Colourlesstransparent amorphous PET (APET) is processed into films in thicknesses from 1 m up to that of cinematic film stock; PET is no longer interesting as a material for magnetic tapes. APET can also be used to form injection- or stretchblown bottles, e.g. disposable bottles for soft drinks, but is in this field gradually being replaced by polyethylene naphthalate (PEN). The high tensile strength, athermanous properties, and gas and water impermeability of even thin films serve to identify APET as an ideal barrier in composite films for aroma-sealed food packaging, which can then be printed quite easily in a flexo process. Biaxially oriented APET films (boPET, DuPont Mylar) are even used as insulation for space suits.

A selection of polycarbonate CDs and DVDs, printed in six-colour waterless UV offset on a KBA-Metronic CD-Print

APET film sheets, in some cases with different levels of glossiness for the top and reverse surfaces, are well suited for laser and digital inkjet printing, e.g. for projection foils and pointof-sale advertising. They are also in increasing use in UV offset (wet and waterless). APET, or better still glycol-modified PET (PETG), is furthermore the basis for lenticular substrates. In this case, the top side is formed with the narrow lens stripes, while the reverse accommodates high-precision printing Mini-movie on PET lenticular film, printed in waterless in sheetfed offset with sheetfed offset on a 74 Karat press from KBA waterless, UV or waterless UV inks. The ability to print on both smooth PET and lenticular Metronic Genius 52UV presses films has enabled users of the to capture considerable market KBA Rapida 74 UV and 105 UV, shares. For the booming producRapida 74 G, 74 Karat and KBA- tion of bank and customer loyalty cards a domain of the KBASoft drinks bottles and their labels are today Metronic presses APET is used often made from PET or PEN for the lamination.

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Plastics | Versatility

Polybutylene terephthalate (PBT)

PBT is used for injection-moulded parts requiring high dimensional stability and minimal abrasion wear, e.g. operating elements for vehicle interiors or electrical components. Its heat-shock resistance renders PBT a material of choice for coffee machines and steam irons. In fibre form, we come across PBT as the bristles of toothbrushes or sheathing for fibre-optic cables and thus also in cables for networking on printing presses and in coextrusion with CPET as stretch cord for trousers. More recently, PBT has been used as a nano-filler. In transparent films which are to be stretched to become opaque, the nanoparticles support the process of cavitation. They fill the forming voids and prevent these voids leading to a loss of material strength. Many an opaque film for UV offset, therefore, contains PBT. In injection-moulded parts, the PBT nano-particles act as flow enhancers for heated thermoplastics, enabling more intricate and pliable parts to be processed.

AttoP-Check is a prefabricated PET tag which is applied to transparent packaging films. The nano-ink reacts with distinct discoloration as soon as the underlying package contents become even slightly discoloured. Paper supplier Mondi produces and uses such tags calibrated for the correct paper moisture level to monitor larger batches. (photos: Attophotonics.com)

The fastest decoration method for these discs is waterless UV offset, which at the same time achieves a photo-realistic image quality. With its keyless machines CD-Print (6,000 six-colour discs per hour) and Premius (7,200 four-colour discs per hour), KBA-Metronic offers two optimum solutions for this market. It is true that photorealistic results could also be achieved by thermal retransfer printing, but this process is too slow. The screen and inkjet processes, on the other hand, lag behind waterless UV offset in terms of both speed and quality. Polycarbonate is well known in prepress departments from the transparent and coloured housings of Apple computers. On account of its perfect transparency, PC has replaced the polymer polymethyl methacrylate (PMMA, Plexiglas) in many applications.

An HDTV flat-panel display from Samsung, using not liquid crystal polymers but instead active-matrix OLEDs on PET carriers a future prospect for sheetfed offset? (photo: Aving.net)

Printing with electrically conducting polymers

Depending on the intended purpose, polyesters namely flexible PET and PEN and rigid PA are alongside paper the preferred substrates for another fast-emerging technology: Industrial printing with electrically conducting inks. These printing inks are themselves actually special polymers, whose partially ionised structures provide for the electron transport hence the usual terms ionomers or organic electronics. One such highly promising copolymer is PEDOT:PSS, which comprises the two ionomers polyethylene dioxythiophene and polystyrene sulfonate. PEDOT:PSS currently appears to be the most suitable choice for printing in sheetfed or narrow web offset, as it can be applied reliably and correctly reproduces even fine structures, despite the lower tack than a pasty offset ink. Successful tests have already been completed with PEDOT:PSS added to the dampening solution and the inking units left unused. Here, the aluminium oxide non-image

Another field of application for PETG is shrink labels. Oriented PETG permits the full enveloping of containers of any given form, e.g. wine bottle necks or preserve jars, with film labels printed on the reverse in flexo (full body sleeves, wrap-around labels, shrink sleeves). Like PVC and polypropylene, APET or an APET composite with polyethylene can also be used for deep-drawn packaging components. The coextrusion sequence PETGAPETPETG produces GAG-PET, which forms the blister cavities for press-out packaging, e.g. for tablets or for appropriately small products. The lidding then comprises a 4/1printed Chromolux card finished with a heat-sealing blister coating on the front. The coextrusion of APET with a PET modified with isophthalic acid (PETIP) achieves sealable films which are then usually bonded into metallised composites, e.g. for aroma-safe coffee packaging.

Polycarbonate (PC)
PC is the most expensive polyester. It is produced from toxic carbonyl chloride (phosgene) and a glycol. All CDs, DVDs and Blu-ray discs are made from PC, because this polyester is highly transparent and also permits error-free writing of the data layer through the polymer.

areas of the printing plate suddenly become the image areas, whereafter the PEDOT:PSS is transferred fully to the substrate via a special blanket. The general goal of printed electronics is a drastic cost reduction compared to silicon wafers and liquid crystal polymers. To date, for example, it has been above all the costs for production and application which have prevented the wide-scale introduction of RFID tags (Radio Frequency IDentification). It is still the case that only the trivial RFID components electrodes and bipolar antenna are printed. More complicated electronic components, such as transistors, diodes, capacitors, oscillators, integrated circuits, power sources and light-emitting (OLED: Organic Light-Emitting Diodes, e.g. for logos, lettering or displays) or light-absorbing structures (OPV: Organic PhotoVoltaics, i.e. photocells) need to be built up in several layers when printed. Dieter Kleeberg

It is not yet possible to print all components of an RFID transponder (photo: Infineon)

Process 5 | 2008 9

Plastics | Substrates

Polypropylene in-mould labels in sheetfed offset

In-mould labels (IML) represent a cost-effective alternative for the decoration of packaging containers and lids. Unlike self-adhesive labels, they are integrated inseparably into the surface of the product. In most cases, in-mould labels are printed in sheetfed offset, ensuring maximum print quality also for this segment of the labels market. The production process and selection criteria for IML films are here explained by supplier Treofan GmbH.
temperature and stretched in its lengthwise direction. The stretching is accomplished by rollers rotating with different surface speeds. The normal procedure is to stretch the film by a factor of four to five. The film thickness is reduced correspondingly. After lengthwise stretching, the film is also stretched in its crosswise direction. To this end, the film is inserted into a so-called stenter, where it is held along its two edges by a chain of clips. The film is now heated once more, and stretched crosswise by a factor of eight to ten once the defined constant temperature is reached. At Treofan, IML films are usually produced in widths up to seven metres. After stretching, the film is stabilised to eliminate any stresses in the material, and cooled, as it then immediately comes into contact with rollers. To guarantee printability, the film surface is treated with a corona discharge to raise the surface tension to approx. 40 mN/m. To complete

Most injection-moulded packaging for ice cream and salads is decorated with the IML film Treofan Decor EUH. The five-layer film with a density of a mere 0.55 g/cm3 is corona-treated on both sides and displays very good antistatic properties. Its behaviour in connection with injection moulding varies. The cellular core is embedded in two white OPP intermediate layers.

In-mould labelling is generally understood as a process by which an injection-moulded, blow-moulded or thermoformed product is already provided with its label in its final mould. The special surface properties of the IML film cause it to bond permanently with the product. It is thus normally no longer removable.

Gravure is preferred for high-volume production, e.g. labels for margarine tubs. Medium runs are often entrusted to web offset printers. Die-cutting is performed either inline or offline, depending on the print process.

Film manufacturing
The use of polypropylene films or to be more precise: OPP (oriented, i.e. stretched PP) and CPP (cast PP) films for the decoration of injection-moulded packaging has seen enormous growth over the past 15 years. The substrates used are mostly OPP films, in some cases also for particularly large labels, e.g. for paint buckets. To manufacture a CPP film, a singleor multilayer PP film is extruded through a slit die. The film is then trimmed and usually also pretreated with a corona discharge ready for printing. Finally, the film is wound

Label printing
In-mould labels can be printed in various processes: Sheetfed offset with oxidatively drying or UV-cured inks, Gravure, Narrow web offset with UV inks, Flexo with UV inks, Letterpress with photopolymer plates and oxidatively drying or UVcured inks. The order of the list above corresponds more or less to the popularity of the individual processes. Sheetfed offset is a frequent choice on account of the possibilities to combine various images on a single sheet, as well as the excellent detail reproduction in its photorealistic printed images. Given the favourable price of reel supplies, it is also useful to configure a sheeter unit ahead of the press feeder when planning to work with IML films.

onto a reel and later cut to the width requested by the customer. Typical film thicknesses lie between 80 and 100 m. The manufacturing of an OPP film is much more complex. First of all, in the same way as for a CPP film, a multilayer PP film is extruded. For IML films, it is usual to coextrude three to five layers. The different melt flows are already combined in the die and are deposited together onto the chilling roller. After this socalled pre-film has cooled and set, it is heated once more to a defined

Typical products sold in IML-decorated packaging

Forming method Injection moulding Food products Margarine, butter, cheese, yoghurt, ice cream, salads, desserts, dried soups Non-food products Paints, detergents, garden products Fabric softeners, cosmetics, car care products

Blow-moulding Thermoforming

Yoghurt, cheese (under development)

Relevance of interactions of IML films and inks

Between film and forming Product application Form Cooling Between film and printing Register Flatness Temperature Chemical compatibility Between printing and forming Sheet/label separation Electrostatic charging Heat resistance Design

10 Process 5 | 2008

Plastics | Substrates

Treofan Decor IML film range for PP and PE injection-moulded packaging

Product OPP films EUH* EWR ETR CPP films CWD CTD Appearance opaque/white, glossy/matt white, glossy/matt glossy, translucent white transparent Film thickness 50 m to 90 m 57 m 57 m 80 m and 100 m 82 m Weight 27.5 to 49.5 g/m2 54.7 g/m2 54.7 g/m2 74.2 and 92.8 g/m2 72.2 g/m2

These injection-moulded containers and lids for ice cream were decorated with the IML film Treofan Decor ETR. The three-layer film with a density of 0.91 g/cm3 is corona-treated on both sides and possesses a transparent OPP core.

the process, the film is wound onto a machine reel and passed on for cutting down to the widths required for printing or sheeting.

Properties of films for IML applications

OPP films for IML applications place particular demands on the material properties. Unlike the OPP films used as packaging materials, IML films are often required in trimmed form (sheets) or even as single labels. Consequently, IML films are usually thicker than typical OPP packaging films (57 to 90 m). It is furthermore important that the IML sheets and labels can be separated easily. This is normally achieved by designing the IML film with a glossy surface on one side and a matt surface on the other. The matt surface enables air to penetrate better between the sheets and facilitates

removal from the pile. In combination with special additives, the matt layer is also able to reduce the electrostatic charging arising from separation of the two surfaces. The demand for labels which lie as flat as possible, i.e. with only minimal tendency to curl, calls for careful selection of the raw materials for the various layers, as well as precise matching of the individual layer thicknesses. In this connection, it is also necessary to ensure that the print process and ink systems used similarly exclude unwanted curling.

Choice of IML film

The selection of a suitable IML film is to a large extent dependent on the process used for moulding of the final product. In the case of injection-moulded products, the essential influencing factors are the required appearance

Composition of a five-layer IML film: The top surface (1) is responsible for the glossiness, the antistatic properties and following corona discharge treatment for the bonding of the inks and a possible metallising coating. The two intermediate layers (2, 4), together with the core (3), determine the whiteness, opacity and density, and thus also the strength and flexural rigidity of the film. The bottom layer (5) provides for bonding to the moulded product.

of the label surface (glossy or matt) and the product form. Products with high-gloss labels can only be produced with a heavy OPP film (e.g. EWR, ETR) or a CPP film (CWD, CTD). One undesirable side-effect manifested with OPP films, in particular, is a strong tendency to distortion after injection moulding when applied to thin-walled, non-symmetrical products. This could be avoided by choosing a film with a cellular structure (EUH). The trade-off here, however, is that it is not possible to create high-gloss labels. For the marketing specialists, on the other hand, it is a simple matter to turn the necessity of a matt surface into a virtue and to sell the orange-peel effect as a soft-touch finish. Cast PP films display practically no influence with regard to distortion of an injection-moulded product. Due to their greater thickness and thus greater weight, however, they are more likely to be used for very large items, such as 5 or 25-litre paint buckets, than for food packages. As the pressures involved are lower when forming blow-moulded products, such as HDPE or PP bottles, the materials used are mostly films with a specific sealing coating. This sealing coating is furthermore applied with a certain pattern to promote the escaping of the air between the product and the label. Tests aiming to achieve this same effect with an OPP or CPP film designed for injection moulding have not yet produced reliable solutions. With the film type UND, however, Treofan GmbH is developing an alternative which permits the air to escape through a permeable film. At the same time, this film requires no coating. Thermoformed products are subject to similar problems to those faced

when blow-moulding. In the past, it proved very difficult to displace the air from between the moulded product and the label surface. Earlier tests sought a solution by perforating the labels. This approach, however, demanded an additional process step, and also brought the disadvantage that the perforation remained visible later. Since 2006, new progress has been made in this field. Through optimisation of the deep-drawing process, use of a foil with a cellular structure and modification of the sealing, it has become possible to produce bubble-free IML labels. The label surface, on the other hand, is once more a matt orange-peel finish. If a breathable film such as Treofan UND is used, however, it is also feasible to produce a gloss label in conjunction with suitable coatings. Wilfrid Tews (Treofan GmbH, Neunkirchen and Raunheim)

Process 5 | 2008 11

Plastics | Surface tension

Simple determination of surface tension on plastic films

The printability of a plastic film is essentially dependent on its surface tension. To enable the ink to adhere, the surface tension of the film must be higher than that of the ink. Simple methods permit fast checking of whether or not the surface tension of a plastic substrate is sufficiently high.
remains adhered to the body. The tensile force is gradually increased until the film of liquid tears. The surface tension can then be calculated from the maximum tensile force, the dimensions of the immersed body and the density of the liquid.

Measuring methods for solids

The cohesive forces between the molecules establish a state of energy equilibrium in the bulk of a liquid, but not at the surface (illustration: Schmid Rhyner) Youngs equation permits the surface tension of a solid to be calculated from the cosine of the contact angle

Surface tension characterises the behaviour of an interface between a liquid (e.g. water) or solid (e.g. film) and a gas (e.g. air), and is thus also referred to as interfacial tension. This phenomenon is manifested, for example, in the way a liquid naturally seeks to minimise its surface area. Consequently, a droplet of liquid which is not subject to external forces in free fall, for instance will always assume a near-spherical shape.

Molecular interactions
Neighbouring molecules are subject to attractive and repulsive forces, so-called cohesive forces. In the bulk of a liquid, these forces are able to interact equally in all directions. This is not true for the molecules at the surface, however, as they possess fewer neighbours than the interior molecules. Within the liquid, the motions of the individual molecules exist in state of energy equilibrium, whereas motion at the surface requires energy to be expended to break molecular bonds. If the surface of a liquid is to be increased, therefore, a certain

quantity of work must be done. The work required to enlarge the surface is dependent on the surface tension of the liquid. The ratio between the work done and the resultant surface enlargement is the surface tension (represented by the symbol sigma) = W / A which is usually expressed in the unit mN/m (millinewtons per metre), corresponding to the SI units 0.001 kg m/s2 or mJ/m2 (millijoules per square metre). Water at 20C displays a surface tension of 72.8 mN/m, compared to 484 mN/m for mercury or 21.7 mN/m for isopropanol. Surface tension is temperaturedependent and generally decreases as the temperature rises. Surfactant substances, such as the tensides in dampening solution additives, reduce the surface tension of the liquid to improve the wetting of an offset printing plate.

work done to achieve this. Examples are the ring method developed by Pierre Lecomte du Noy, the Wilhelmy plate method and the frame method after Philipp Lenard. In all three methods, a solid body (ring, plate or frame) is immersed in the liquid, and then drawn back out such that a film of liquid

The surface tension of solids can similarly only be measured indirectly. When using the contact angle method, a solid is wetted with two different liquids with a known surface tension. The chosen liquids are frequently water and diiodomethane. In Youngs equation, to be seen alongside, the indices S and L stand for Solid and Liquid; the symbols S and L describe the surface tension components of the two phases; YSL represents the interfacial tension between the two phases, and stands for the contact angle, cor-

Measuring methods for liquids

In most cases, the surface tension of a liquid is measured by increasing the surface area of the liquid in a defined manner and then determining the quantity of
For an unformed liquid L to be able to spread and wet the formed surface of a solid S, the surface tension of the solid must be greater than that of the liquid (bottom example), otherwise it will be repelled in beads (top example) (illustration: Weilburger Graphics)

12 Process 5 | 2008

Plastics | Surface tension

One commercially available camera contact angle measuring device is the pocket goniometer PG-2 from Swedish manufacturer Fibro Systems Test inks in use: On the left, the ink has spread, i.e. this full wetting shows that the surface tension of the film is at least as high as the known surface tension of the test ink. On the right, there is no wetting, i.e. the surface tension of the film is lower than the known surface tension of the test ink

responding to the angle between the vectors L and YSL. To determine the surface energy, various initial equations for YSL are combined with Youngs equation, with cos representing a function of the phase surface tensions. With this system of equations, it is possible to calculate the surface tension of the solid. The market offers a range of instruments for the fast and simple determination of contact angles. Such goniometers comprise a system to inject a test liquid and a camera to measure the bead cross-section. This measurement is then used to calculate the corresponding contact angle values. A contact angle of 0 results if the liquid spreads, i.e. if the solid is completely wetted. A contact angle between 0 and 90 is considered to represent good wetting, while a contact angle between 90 and 180 is treated

as poor wetting. A contact angle of 180 means that the liquid is repelled in the form of spherical beads. This phenomenon is commonly referred to as the lotus effect, after the corresponding properties exhibited by leaves of the lotus plant. Another typical method to determine the surface tension of solids is to use test inks. An ink with a known surface tension is applied to the material to be tested with a brush. If the test ink wets the surface, then the surface tension of the material is equal to or higher than that of the ink. On the other hand, if the test ink retracts into a bead within 3 seconds, then the surface tension of the solid is lower than that of the test ink.

With a set of test inks, the surface tension of a film substrate can be determined iteratively

Test inks ideal for plastics

The test ink method is based on the knowledge that liquids achieve good wetting of a solid if their

surface tension is lower than that of the solid in question. This is also why it is problematical to print on substrates with a low surface tension. To guarantee sufficient wetting of the substrate by

the printing inks, it is necessary to ensure that its surface tension is higher than that of the inks, either through appropriate selection or pretreatment, etc. A set of test inks is thus a very convenient means to check the properties of a particular plastic substrate. Beatrix Genest (SID Schsisches Institut fr die Druckindustrie GmbH, Leipzig)

Surface tension of different plastic substrates

Material PTFE (polytetrafluoroethylene, Teflon PE (polyethylene) PE (polyethylene) after corona treatment PVC (polyvinyl chloride) PS (polystyrene) PET (polyethylene terephthalate, polyester)
PC monitor image from the camera of a goniometer. The contact angle is clearly greater than 90, indicating that the wetting of the surface is poor

Source: Fraunhofer IGB Surface tension 22.5 mN/m 36.1 mN/m 38 44 mN/m 38.4 mN/m 43.5 mN/m 47.0 mN/m 49.0 mN/m 46.7 mN/m

PMMA (polymethyl methacrylate) PC (polycarbonate)

Process 5 | 2008 13

Printability | Corona treatment

Raising surface tension with a corona tower

Corona treatment is an effective method to raise the surface tension not only of plastic films and metallised substrates, but also of non-absorbent paper and board surfaces. It is only above approx. 38 mN/m that the surface tension is sufficient to enable an ink to bond. Since the corona effect on factory-treated films diminishes over the course of storage, many plastics printers use inline corona systems. KBAs partner in this field is Ahlbrandt System GmbH. Adaptation for sheetfed offset printing
KBA offers a corona option for Rapida presses from a format width of 74 cm. Its partner for such installations is Ahlbrandt System GmbH, based in Lauterbach/ Hessen, which supplies corona systems specially adapted for sheetfed offset printing exclusively to KBA. The AS Corona Star series was originally developed for use on flexo and narrow web presses and for film manufacturers. In these applications, the film passes the quartz electrode at a clearance of only 2 mm. On a sheetfed press, however, it is impossible to work with such a small clearance because of the grippers. The alternative of shifting the corona discharge to the feed table is similarly impracticable due to the overlapping sheet stream and the sheet deceleration. Consequently, only one possibility remains: The corona system must be accommodated in a separate tower ahead of the first printing

The keyless and waterless KBA Rapida 74 G in the customer demonstration centre at KBA in Radebeul incorporates a corona tower ahead of the first printing unit (right-hand arrow) and direct ozone extraction (left-hand arrow). In this particular configuration, it is already able to print selected film types. The Rapida 74 G can also be supplied with UV equipment, in which case it is able to process all types of plastic substrate.

How corona treatment functions

Corona treatment is the most frequently used method to improve the printability of film surfaces. Raising the surface tension provides for better bonding not only for UV inks and coatings or waterless offset inks, but also for adhesives. The Latin word corona refers to a crown or garland. If high voltage is applied to an electrode, uncontrolled discharge produces a bluish, luminous corona around that electrode the surrounding air is ionised. More properly speaking, the high-frequency current is breaking down the oxygen and nitrogen molecules in

the air to form radicals. In the corona treatment system, these

radicals are channelled from a quartz electrode to a ceramiccoated back roller or in the case of the KBA Rapida to the chromeplated impression cylinder. In the process, they are accelerated along the field lines and penetrate up to 0.1 nanometres into the film surface, hurling hydrogen atoms out of the polymer chains as they do so. Atoms are also released in similar fashion from the surface of a metallised substrate. Within just a few milliseconds, gaps are left in the surface cross-linking structure; this effect is also referred to as roughening. The cylinder here functions as the counter-electrode, i.e. it dissipates the charge, and at the same time provides for the correct clearance between film and corona electrode.

View into the corona tower of a KBA Rapida 74: The blue shine around the activated quartz electrode can be seen behind the white sheet guide rollers. The chrome-plated back cylinder in the foreground is effectively a double-size impression cylinder.

14 Process 5 | 2008

Printability | Corona treatment

unit. In such a corona tower, it is necessary to increase the clearance between electrode and film sheet to approx. 5 mm and with it also the discharge power. Depending on the format width, and thus the available space in the corona tower, up to three 15 kV electrodes are installed, each with a power rating of 3 kW or more. At full discharge power, the surface tension is raised to the desired degree even at maximum production speed. One important factor contributing to uniform surface roughening is the full-area contact between the film sheet and the back cylinder, which thus takes the form and dimensions of an impression cylinder. There is no need to adjust the electrode length for different film widths. The ozone arising in the dielectric is extracted directly.

Corona tower liberates the printer from restrictions

The principal advantage of an inline corona system is that printers are no longer compelled to use up pretreated substrates before the expiry date of the corona effect. In fact, they can simply purchase untreated materials as and when needed, and these materials are naturally less expensive than pretreated film. Or else they could build up a stock of different substrates, so as to be able to react flexibly to customer wishes, but without having to worry about a loss of printability over time. Another point is that the corona effect on factory-treated sheets may be quite literally rubbed away during separation from the pile and transport of the sheet stream on the feed table. Even if a surface tension measurement (with test inks) indicates that sufficient effect remains, this does not necessarily mean that this surface tension will actually survive through to the printing units. Printers working on a press with corona tower must still always test the surface tension of the untreated substrates. After all, they need to know which discharge power is required to work at the maximum possible production speed. And furthermore, it is beneficial for both profits and the environment not to discharge energy unnecessarily and to keep the amount of ozone produced to a minimum.

In the tower frame designed by KBA, the Ahlbrandt corona unit is mounted with optimum clearance to the back cylinder (top photo). All three electrodes of this corona unit possess individual hoses for ozone extraction (bottom photo)

Alternative methods
Factory-treated substrates have not always been processed in a corona discharge system. But there are no cost advantages to be derived from alternative treatment methods. Film manufacturer Klckner Pentaplast, for example, has developed the so-called Dynox process, which is used at least for rigid PVC

films. This treatment raises the surface tension to over 45 mN/m. In contrast to corona treatment, the surface effect lasts for more than a year, and is also not destroyed on the feeder. Another method is plasma treatment. The desired effect is here achieved by bombarding the surface with ions. And once again, the effect remains stable for longer than with corona discharge.

A third alternative is for the film manufacturer to finish the material with a special primer, a so-called top coat which preserves the corona effect. The Ciba Prime IT technology is a similar method.

less expensive untreated materials. And if they do so, they can at the same time be sure that the printability of the chosen sheets is absolutely reproducible. Dieter Kleeberg Matthias Lange (KBA Radebeul)

Summary
Printers working with plastic substrates on a regular basis can easily calculate whether it makes sense to purchase an inline corona unit and to use

Process 5 | 2008 15

Sheet travel | Static elimination

Antistatic systems on sheetfed offset presses

The prevention of electrostatic charging is already of great general significance for smooth sheet travel through a sheetfed offset press. But because the electrostatic tendency of plastic films is so incomparably greater than that of paper sheets, it is here absolutely imperative to provide antistatic systems at the feeder and infeed.

Principle of electrostatic charging through electron transfer Principle of electrostatic charging (voltage U > 0) at sheet separation

What is static electricity?

All matter comprises individual atoms. These atoms, in turn, each comprise a positively charged nucleus and orbiting negative electrons. Any single nucleus possesses exactly as many negative electrons as the number of positive charges (protons) expressed by its atomic number. Overall, therefore, the charges cancel each other, and all matter is thus in its original natural state electrically neutral we can speak of uncharged matter. This natural equilibrium of positive and negative charges, however, can be disturbed if objects are brought into contact, pressed together or rubbed against each other and then separated once more. Negative particles (electrons) are effectively torn out mechanically from the surface of one object and passed by this friction to that of the other object. In the resulting charge imbalance, one object now possesses too few electrons to compensate all the positive charges of its protons, and is thus positively charged. The other object, at the same time, now possesses too many electrons, and is consequently negatively charged. Objects with like charges irrespec-

tive of whether positive or negative repel each other, whereas differently charged objects are attracted to each other.

which is responsible for the charging of plastic films.

Factory-installed antistatic systems

To combat the problems of electrostatic charging, KBA sheetfed offset presses can already be fitted with various configurations of antistatic equipment from KERSTEN Elektrostatik GmbH, Freiburg im Breisgau, before they leave the factory. The essential requirements for thin or coated papers and boards are handled by a relatively simple basic package. Corresponding upgrade levels expand the range of potential applications and cover also the significantly higher demands of plastic substrates. The fully plastics-capable equipment package on the Rapida 106 press installed in the KBA test print centre enables us to identify the individual components and to briefly describe their purpose.

Static electricity on sheetfed presses

This phenomenon also affects a printing press in various ways. The attraction forces between appropriately charged sheets can even bring the whole production process to a halt. At the feeder, for example, this may be manifested in blocking of the pile, poor separation, double sheets and waviness on the feed table, and crooked arrival at the front lays. In the delivery, the sheets are not straightened up properly when dropped from the gripper carriages and thus form a disorderly pile. That, in turn, restricts further processing of the printed sheets. In the case of very sensitive materials, the ink application may also be impaired. The tendency of a material to build up electrostatic charges is dependent not just on its physical properties, but also on its handling and the ambient conditions in the press room. While paper is subject to charging at low humidities, it is above all friction during transport

feeder. The two central components are DK 106 antistatic heads, which are mounted on the KBA separating air nozzles (1.1) and thus use the air of the separation burst for static elimination. Alongside, four DD 406 antistatic nozzles are used to blow a variable volume of antistatic air into the top of the pile as loosening air (1.2 and 1.3). Two further static eliminators are mounted at the pile side edges. Here, too, the antistatic heads are fitted to the KBA air nozzles. On the feed table, a DE 206 electrode (4) is used to treat the top surface of the sheet, a DR 106-8 electrode array (5) takes care of the underside, and a DR 206-6 array (7) helps to lift the first sheet.

Antistatic systems in the delivery

The antistatic systems for the delivery are exclusively DE 206 electrodes, which eliminate the electrostatic charges over the full format width. The underside of the sheet is treated at the decurler (8.2) and after the sheet brake (8.1), the top surface at the powder sprayer (9.1) and with three electrodes above the pile (50.1 to 50.3). The objective of these systems is to enable smooth

Antistatic systems on the feeder

All the antistatic systems at the pile edges serve to support separation of the sheets and are thus essential for trouble-free functioning of the feeder. Six antistatic heads are installed across the rear width of the

16 Process 5 | 2008

Sheet travel | Static elimination

The KERSTEN antistatic systems (depicted in yellow) on the feeder of the KBA Rapida 106 in the test print centre: Two DK 106 antistatic heads (photo top left, component 1.1, on the separating air nozzles), one of four DD 406 antistatic nozzles (top right, components 1.2 and 1.3, as loosening blowers), and for the feed table a DE 206 antistatic electrode (bottom left, component 4, for the top sheet surface) and a DR 206-6 array (top centre, component 7, to lift the first sheet). As can be recognised from the schematic drawing, the DR 106-8 array (component 5, for the underside of the sheet) is not visible.

sheet transport, an even powder application and precise pile formation.

Function principle
As already explained above, electrostatic charging is the expression of an imbalance in the charges at atomic or molecular level. To elimi-

nate the disturbing effect, this imbalance must be neutralised, i.e. the positive charges must be compensated with an appropriate number of negative inputs, and vice versa. The result is then once more a neutral charge distribution. Antistatic systems draw the necessary compensating charges from the

molecules of the surrounding air. To this end, a voltage of at least 2,500 V is applied to needle-point electrodes, producing charged particles (ions) in the immediate vicinity of the needle points. These ions can carry either a positive or negative charge, depending on the polarity of the applied voltage.

50.13

9.1

8.1 8.2
The KERSTEN DE 206 antistatic electrodes in the delivery of the KBA Rapida 106 in the test print centre: Static elimination for the underside at the sheet decurler (component 8.2) and after the sheet brake (component 8.1), and for the top surface of the sheet at the powder sprayer (component 9.1) and above the pile (components 50.1 to 50.3).

An antistatic system for a printing press provides for a constant adequate supply of both negative and positive ions. With the neXt systems from KERSTEN, this is ensured by using a stabilised bipolar DC voltage. Both polarities are present at the electrodes at the same time. Consequently, a maximum availability of both positive and negative charge carriers can be maintained constantly. This technology also produces significantly more ions than the previously used AC systems. An electrical field provides for homogeneous distribution of the ions over a wide surrounding area. The relevant law of physics states that opposite charges are always attracted to each other. The charged sheet thus soaks up precisely those ions which are required to neutralise its surface. If sufficient ions are made available, the electrostatic charging of the sheet will be eliminated completely. Any excess ions are taken back by the antistatic system itself.

Process 5 | 2008 17

Inks and coatings | Offset inks

Results and benefits for the user

With such antistatic systems, it is possible to handle even difficult print substrates without problems, as the neutralisation is performed at precisely those points on the press where electrostatic charging is relevant. Given the high purchase prices for plastic substrates, the investment in antistatic equipment is usually already returned after only a few weeks.

The most important and above all tangible effects for the user at a glance: Improved sheet separation at the feeder; Fewer double sheets and press stoppages; Reduced non-productive times; More exact alignment at the front lays; Enhanced productivity through higher production speeds;

Handling of substrates for which static elimination is imperative (plastic films); Neutral delivery piles with tidy pile edges; Better and faster further processing of the printed sheets; Fast return of investment; Greater operator satisfaction.

Operation and maintenance

Antistatic systems are easy to care for and practically maintenancefree. From the electrical side, the system is fully self-regulated, i.e. it requires no special user settings. The needle points of the electrodes are the parts responsible for the production of the compensating ions. To ensure the full static elimination performance, therefore, they must be cleaned at regular intervals as demanded by the level of contamination (usually once a week). A certain amount of experience is also necessary for correct positioning and setting of the antistatic air nozzles, particularly in respect of the air blown into the feeder pile. Wolfgang Zierhut (KERSTEN Elektrostatik GmbH)

Function principle of the KERSTEN antistatic systems: An electrical field provides for homogeneous distribution of the ions and full charge compensation (electrical charge Q = 0).

Oil-based and UV-curing Inks for film and foil printing

In the past, offset printing on plastic film mainly used inks with mineral-oil based binding vehicles. With printers, converters and end customers having been demanding better performance systems over the past few years, the conclusion has been reached that UV technology is the best alternative to oilbased inks. This article is to present in more detail the status and innovations of the two ink systemsfrom the perspective of ink manufacturer Siegwerk.

Special requirements for printing on film and foils

Synthetic substrates such as plastic film and other nonabsorbent printing substrates are becoming more and more frequent in the printing sector, and particularly in offset printing.

The challenge to find a suitable offset ink system for these applications include good printability, improved running characteristics on increasingly faster presses,

1 The torque (y axis) of a rotation viscosimeter mapped against the water content (x axis) of the ink permits conclusions on how the ink-water balance influences the printability of inks. The more water an ink can absorb, the greater the margin for problem-free printing of films and foils. Here a higher torque denotes a lower influence of the dampening ratio. Older types of UV inks (1 and 2) did not absorb enough water. Latest-generation UV inks (3) exhibit an equally suitable behaviour as oil-based inks (4)

18 Process 5 | 2008

Inks and coatings | Offset inks

Table 1: Criteria in film printing with oil-based inks

Criterion Fount solution Parameter pH value IPA content Water feed Pile height Pile temperature Powder quantity Period between printing and post-press Level >5* 3 12% ** As low as possible restricted *** < 40 C *** specified < 48 h

Piling Powder Waiting time ****

*) Higher fount solution acidity slows drying down; **) Up to 12% recommended for printing with smallest possible amount of fount solution; ***) To prevent blocking and set-off; ****) Do not over-ink, coating if scratch resistance is too low

solution exhibit a much greater margin between over and underdamping. For some years now, alcohol-free printing has been on the increase. Especially in film and foil printing, however, the use of isopropanol has proved to be the better choice, with reduced surface tension of the fount solution for optimal printing and a good ink-water balance. Instead of IPA, alcohol substitutes might be used depending on press configuration, plates etc.

especially of the UV coating, the more volume is there to shrink. One result is reduced adhesion. Especially in the crosscut test, the adhesive force of the adhesive tape can exceed the bonding force between the ink/coating and the printing substrate, causing the inkcoating layer to lift off from the substrate. Adhesion quality also depends strongly on the use of highly flexible ink/coating/binding vehicle systems that reduce shrinking.

Adhesion of UV inks
In the past, UV inks showed restricted adhesion on foils and films, but these issues have been overcome by newly developed special ingredients and optimized ink formulas. An essential condition is, however, that the substrate such as PVC does not contain any plasticizers, static inhibitors and other substances that might diminish adhesion. The recommended surface tension for PVC is 35 mN/m. For substrates made of ABS, PP, PET, PE and PS, a surface tension of over 40 mN/m is essential. These substrates should also be free of problematic additives like static inhibitors, which might impede uniform ink adhesion due to their separating effects. The correct surface tension in a synthetic substrate lies in the material formulation and thus with the manufacturer of the substrate. Manufacturers also sometimes use so-called corona discharge technology to electrically treat the surface of films. The surface tension might fall during longer storage of the substrate, and the corona pretreatment must be repeated directly in the web or sheet-fed press. This option is also advisable if non pre-treated substrates are used for economical reasons. Moreover, the molecular structure of the cured ink layer widely influences adhesive characteristics, flexibility and scratch resistance.

Curing of UV inks
Differing curing characteristics can also influence the adhesion of the ink/coating layer. If the ink does not cure completely, adhesion might be diminished by insufficient cross-linking of the ink/ coating layer. In rare cases, an over-cured ink/coating layer might shrink strongly and become brittle, which results in lower flexibility and adhesion.

secure adhesion and scratch resistance on non-absorbent substrates. In contrast to most paper and carton substrates, the surface structure of typical plastic film does not allow the ink to set. Drying and adhesion support by filtration into the substrate is not possible. Additionally, the presence of fount solution in oil-based ink offset generally impairs the drying process. Therefore, a good ink-water balance is a key factor in influencing the drying process. Special oil-based inks have been developed for synthetic substrates to accommodate special technical requirements concerning the quality of the printed product. However, a good compromise between fast drying, safe piling, adhesion and abrasion resistance remains a difficult thing to achieve with oil-based inks (see Table 1).

Here the advantages of UV curing technology should be used, including immediate hardening of the ink layer, low influence of the amount of fount solution, and fast readiness for further processing.

Development of modified radiation-curing printing inks

When UV ink systems were first introduced in the printing industry, they were criticised for their problematic printing behaviour in offset presses and for adhesion problems. These problematic characteristics have been successfully overcome by new raw materials and innovative ink formulations.

Versatility of UV inks
In the early days of UV technology, it was rarely possible to use inks specially formulated for film and foil printing also for printing on paper and carton due to the high tackiness of the oligomers, which ensure adhesion. Today, optimized qualities allow the use of UV film printing inks on paper-based substrates in many cases.

Printability of UV inks

Requirements on UV systems in film printing

The filming quality of UV inks can be markedly improved by the use of doped lamps or in a nitrogen atmosphere (inert UV). So-called cold UV systems reduce the emitted heat and the pile temperature, preventing dimensional changes in the films and foils; however, it also slows down the polymerization of the UV inks and coatings. If the molecular cross-linking process takes place in the presence of nitrogen, polymerization is faster, permitting higher printing speeds. It is essential to test the adhesion of inks and coatings on the substrate in all jobs. Unlike scratch resistance, generally adhesion

In non-absorbent substrates such as plastic film, the fount solution cannot filter into the surface. The first generation of UV inks tended to build up on rollers, plates and/or blankets due to excessive fount solution absorption and the resulting loss of tack. Here, an 2 Ink-water balance profile in the production run. The wet optimized ink-water tack of the ink changes over time because of alternating balance improved downtimes (make-ready, pile change, intermediate washing) and optimum production speed. Recent UV inks (green) printability. New ink retain the set ink-water balance while former-generation UV generations with inks get increasingly out of control optimized absorption and release of fount

Flexibility of UV-cured layers

UV inks and coatings generally tend to shrink during curing. The thicker the layer of the ink, and

Process 5 | 2008 19

Farben und Lacke | Offset inks

3 Characteristics of the UV offset ink series developed by Siegwerk for printing on plastics: Pr = printability, Mi = low migration, Ad = adhesion, Ve = versatility, Od = low odour

initiator systems, the use of ultrapure monomers and oligomers of high molecular weights and adapted formulations result in very low migration and thus help to meet new demands. With all the high purity of materials and sophisticated manufacturing technology, users still should check and coordinate the qualities recommended by the ink supplier with the technical environment in the printing shop (press, UV system, printing speed, etc.) according to the legal regulations. Apart from ink and coating, organoleptic and

inherent odour after UV radiation. Careful handling and storage of the printed run is another important factor. For questions or special jobs, especially in the sensitive area of food packaging, it is always advisable to contact the local representative of the ink and coating manufacturer in order to receive the best possible technical support and advice.

Resume
Printing on increasingly demanding substrates with impenetrable surfaces from plastic films to metalized substrates or even sheet metal requires ink manufacturers to constantly develop their products. Increasing press speeds and the resulting shorter drying times present a particular challenge. Due to their absence of shrinking, oil-based systems continue to be used for special applications. However, UV technology will continue to occupy an ever increasing place in the graphic industr y, with constantly improving ink formulations and manufacture (in particular with regard to organoleptic qualities), tonal value control in pre-press and physical properties of radiation equipment. Peter Psotta and Walter J. Bolliger (Siegwerk Backnang GmbH), Marc Larvor and Olivier Deage (Siegwerk France S.A.)

does not improve any further after 12 hours from printing.

Sensory and migration properties

Printed films are used as wraps, shrink film, cosmetics packaging, labels and much more. Some of these applications require particular specifications in UV inks and coatings, such as low odour, no influence on the taste of the packaged goods, no migration into the packaged goods. Against the background of constantly increasing demands by consumers, legislation and better analyses, ink manufacturers must satisfy new requirements every day. Ink qualities are formulated

4 For the testing of printing inks, a liquid chromatograph/mass spectrometer (LC/MS) system may be used to measure impurities, which might migrate in very small amounts

with special materials that minimize the organoleptic effects, e.g. the excitation of sensitive receptors such as olfactory and gustatory nerves in the mucous membranes, and reduce molecular migration. Optimized photo

migration data can be influenced by many other parameters beyond the influence of the ink manufacturer. This applies in particular to suitable cleaners and dampening additives. Printing substrates also might develop an

Table 2: UV litho printing inks of Siegwerk Druckfarben AG for film printing

Substrates Printing ink series Folding boxes for primary food packagings Folding boxes for secondary food packagings Folding boxes for cosmetics, pharmaceuticals, tobacco Folding boxes for chemicals Labels & tags IML Display Brochures, leaflets Metal Dec 3P Non-absorbent X ** *** *** *** X *** *** *** X *** ** * ** * * * *** *** ** * * * *** * * * Paper/Board Sicura LM *** *** * * * *** * * X X ** *** *** *** X *** *** X Sicura Plast SP Sicura Plast LO Sicura Plast LM Sicura Litho

*) Not fit to purpose but can be used; **) Recommended; ***) Highly recommended; X) No possible use

20 Process 5 | 2008

Printability | UV coating

Finishing of plastic films with UV-cured coating systems in sheetfed offset

Apart from the fact that UV gloss coatings require a certain time to spread before the UV radiation is applied, the curing mechanisms for UV inks and UV coatings are basically identical. The point calling for attention is the different behaviour of a plastic substrate compared to paper or board stocks. This contribution from coating supplier ACTEGA Terra describes some of the special considerations.
This heat is by all means welcome to support the curing process, but can easily lead to curling of the sheets if too intense. The resultant problems are reduced register accuracy and undesirably high pile temperatures. It is thus important to use only as much UV radiation as is actually required to cure the inks and coating applied. Adaptation of the process parameters can help to eliminate unnecessary heat input. Normally, UV curing takes place under the influence of the ambient air. However, as the oxygen molecules in the air also strive to react with constituents of the ink or coating, this competitive reaction must be compensated by raising the lamp power, which naturally also places unwanted heat loads on the substrate. With the inert UV technology, a long-established technology in webfed applications, a solution is also on hand for sheetfed offset. The space between the UV lamp and the substrate is rendered inert by flushing with nitrogen to displace the parasitic oxygen. The competitive reaction with the atmospheric oxygen is prevented, with the result that the lamp power can be reduced significantly, and thus less heat is introduced into the substrate. A further advantage is that the necessary photoinitiator content of the UV inks and coatings is lower, as a prerequisite for low-odour UV systems.

UV-coated plastic labels

Photo: ACTEGA Terra

Chemical curing by way of UV radiation is one of the most innovative technologies used in the print industry for the drying of inks and coatings. With the aid of the UV technology, it is also possible to print on a diversity of nonabsorbent substrates. The first applications in the early 1970s already exploited the same process benefits as remain valid today (Table 1). In the narrow-web sector,

UV curing has in the meantime secured a share of over 90%. UV systems are also gaining in popularity among packaging printers, where sheetfed offset is increasingly the process of choice for printing and coating. Intensive research and development concerning both raw materials on the one hand, and the inks and coatings on the other, has promoted ever more widespread use of the technol-

ogy in many areas of the modern print industry also for the printing of plastic films. When compared to paper and board applications, however, there are various special points to be taken into account when applying coatings to plastic films (Table 2).

Heat sensitivity of the film

UV lamps always release also a certain amount of IR radiation, i.e. heat.

Table 1: Benefits of UV coating

Criterion VOC emissions Content of solid matter Productivity Gloss Chemical resistance Mechanical resistance Cleaning Quality None (solvent-free) 100% Immediate further processing Very high (up to 100 points) High High Simple (does not dry)

Table 2: Special considerations when coating on plastic films

Properties Heat sensitivity of the film (thermoplasticity) Polymerisation shrinking of the coating Surface tension of the film Electrostatic charging of the film Smoothness of the film or coating Consequences Shrinking, swelling or curling of the film Curling of the film Bonding of the coating to smooth, non-absorbent film surfaces Repulsion of the coating, glass plate effect Glass plate effect

Process 5 | 2008 21

Printability | UV coating

Table 3: Phases of coating on plastic films

Application phase Spreading phase Curing phase and possible results thereafter Bonding problems Curling/shrinking Optimum result

The coating is applied to the plastic film

The liquid coating spreads to form an homogeneous surface

Excessive shrinking within the coating prevents proper bonding to the substrate

The bonding is good, but the coating contracts due to polymerisation shrinking and causes the plastic film to curl

A matched coating with the correct polarity and reduced polymerisation shrinking provides for optimum bonding without curling

Bonding of the coating to the substrate

Numerous factors determine the bonding to a plastic substrate. As this bonding is actually always a process of mechanical adhesion, surface tension plays an important role. To achieve good bonding of the ink or coating, the surface tension of polyolefin substrates, e.g. polypropylene (PP) and polyethylene (PE) films, should be at least 38 mN/m, and preferably 40 mN/m. In most cases, the surface of the film is already corona-treated by the individual supplier. It is nevertheless recommended to check the surface tension before use, as the positive effects of pretreatment diminish over time and are lost after at most six months, and often significantly earlier (for details of test methods, see the article on surface tension). If the measured surface tension is too low, it can be raised once more by corona treatment immediately prior to printing. Particularly for PP and PE, this has been shown to be a very expedient provision. With PVC, PET and PS substrates, on the other hand, corona treatment is not usu-

ally necessary, but may still prove useful if adhesion problems are encountered. KBA offers corona modules for inline pre-treatment ahead of the first printing unit.

Curling of the substrate after printing and coating

The heat input is not the only factor which can lead to curling of the substrate. The same effect is produced by so-called polymerisation shrinking. The curing of the UV inks and coatings reduces their volume by 2 to 10%, depending on the quality of the individual product. This also causes the surface area of the ink or coating film to contract, resulting in curling of the plastic film. The effect can be reduced or at least influenced significantly by selecting a non-shrinking UV coating. It is similarly important to ensure that the coating application is not unnecessarily thick.

sheets, this leads to problems with separation at the press feeder and during downstream further processing. Besides installation of antistatic systems on the presses and finishing machines (see the article on antistatic systems by Kersten), correct storage is also able to reduce charging. To permit proper acclimatisation, the films should be kept at temperatures between 20 and 22C and a relative humidity of 55% for three days before printing. Especially in the case of very thin films, poor separation of the printed film is almost to be expected. For this reason, it may be useful to use a coating with a static eliminator component to avoid the so-called glass plate effect, where the mutual attraction of the sheets is further enhanced by the air being forced out from between the sheets and by the very smooth film and coating surfaces.

Electrostatic charging and glass plate effect

All plastic films irrespective of whether in web or sheet form are in general highly susceptible to electrostatic charging. In the case of

Coatings for plastic films in sheetfed offset

To obtain optimum results, the raw material formulation of UV coatings for plastic films differs from that of UV coatings for paper and board. UV

Table 4: Formulation differences between UV coatings for paper/board and for plastic films
Component Binder (high-viscosity pre-polymers) Reactive thinner, monomers/polyether (low to medium viscosity) Photoinitators Additives UV coating for paper/board Epoxyacrylates: Hard, brittle, high gloss, average bonding Di-tetrafunctional, average bonding, medium to high polymerisation shrinking Diverse Flow-control agent, foam inhibitor, stabilisers UV coating for plastic films Modified epoxyacrylates: Flexibilised, good gloss, improved bonding properties; Urethane acrylates: Flexible, good bonding Mono- to trifunctional, good bonding, low polymerisation shrinking Diverse; no significant differences Flow-control agent, foam inhibitor, stabilisers, static eliminator

film coatings thus possess very good binding properties, and the flexibility of the final coating on the sheet is enhanced. In addition to the standard highgloss and matt coating types, various gold and silver effects, pearlescent finishes and opaque white grades are similarly available for use on plastic film. UV film coatings can also be tailored to provide individual functions, such as chemical resistance to the most varied solvents, acids and alkalis. Special formulations, furthermore, are able to influence the mechanical properties of the result. High rub resistance and friction values across the whole range from antislip to instant release effect are possible. Further options are heat-resistant UV coatings for inmould labels or low-odour and lowmigration UV systems for food packaging. The printing and coating of plastic substrates places particular demands on all those contributing to the process: the press manufacturer, the film, ink and coating suppliers, and not least the printer at the end of the chain. It is thus indispensable for the user to maintain intensive dialogue with all partners, as only in this way is it truly feasible to become a successful player in this interesting and innovative market segment. Mark Fregin (ACTEGA Terra GmbH, Lehrte)

22 Process 5 | 2008

Applications | Examples

KBA users hold the key to new fields of business

No other manufacturer is able to match KBAs comprehensive portfolio of press configurations for plastics printing, waterless and UV equipment, and special machines for printing on films, cards and data storage media. KBA users can be sure of a tailored solution as the key to new fields of business. That also becomes clearly evident from the following cross-section of recent application examples.

Film and plastics printing package for KBA sheetfed offset presses
Applications: Non-absorbent surfaces (glossy coated board, films/composites with board-like flexural rigidity) Infeed/feeder*: Antistatic systems, coatings (e.g. chrome), timed guide shaft with rollers, rollers above front lays, timed sheet guide with rollers, blower air support Printing units/coating units*: Sheet guiding with mechanical board guides and blower air support, sheet travel sensors, modified grippers, antistatic systems, preparations for UV (ink agitators, rollers, washing systems, UV interdeck drying, coating supply) Delivery*: Sheet guide plates with controlled air, switching between suction and blowing, sheet brake, antistatic systems, extraction system, extended delivery with UV final dryers *) The available features vary according to press type and format, and are matched to individual customer requirements.

KBA-Metronic: Direct printing on cards and data storage media

KBA-Metronic AG has already been highly successful on these two specialist markets for many years. In the data media segment, the Blu-ray Disc is set to ensure order continuity when CDs and DVDs approach the ends of their product life cycles.

KBA-Metronic OC200 for direct printing on ISO-format plastic cards

The discs can be printed in optimum waterless offset quality with the machines CD-Print and Premius. The latter also handles mini-discs and digital business cards of deviating sizes and shapes. The KBA-Metronic OC200 is the worlds most widely used machine for direct printing on ISO-format plastic cards (both with and without cavities to accommodate a chip). A turning facility at the end of the print section permits immediate printing of the card reverse. Subsequently, it is possible to personalise the cards in an inkjet process on the KBA-Metronic universys, or to add scratch-off patches or labels. As an alternative minimalist solution, the scratch-off module UDA150-S can be combined

with up to two alphaJET C inkjet printing heads.

KBA Rapida 74 and 74G: Strong with plastics

The Rapida 74 has built up a significant share of the market for the printing of plastics. Rudolf Berle, the owner of berle:druck in KaarstBttgen, invested in a five-colour coater press with UV equipment in 2004. He prints above all lenticular film, the same specialisation as family printers Staffner in St. Johann in

The waterless Rapida 74 at Roldn Grficas prints PVC, PETG and PS cards

Personalisation, labelling and scratch-off patches for plastic cards on the KBA-Metronic universys

Standard discs, mini-discs and digital business cards printed on the KBA-Metronic Premius

Process 5 | 2008 23

Applications | Examples All KBA presses and machines on which films and plastic substrates can be printed (subject to further changes)
Model
KBA-Metronic CD-Print KBA-Metronic Premius KBA-Metronic OC100/200 KBA-Metronic universys

Max. format
CD, DVD, Blu-ray CD, DVD, Blu-ray 8.6 x 5.4 cm x2 8.6 x 5.4 cm

Possibilities for plastics printing

Special machine for rigid data storage media Special machine for rigid data storage media

Inks
Waterless UV Waterless UV

Finishing options
UV screen-printing or flexo primer UV screen-printing primer, UV coating UV primer, UV coating Scratch-off hot-foil stamping, labelling Scratch-off hot-foil stamping, labelling UV coating UV coating UV coating Dispersion coating (Tippl Tipadur P-1203 B3) UV coating UV coating UV coating UV coating UV coating UV coating UV coating UV coating UV coating UV coating UV coating UV coating

Corona option
no no no no no no no realised realised possible possible realised realised possible upon request upon request upon request upon request upon request upon request upon request

KBA-Metronic UDA150-S Scratch-off 8.6 x 5.4 cm KBA-Metronic Genius 52UV KBA Performa 74 UV KBA Rapida 74 UV KBA Rapida 74G KBA Rapida 74G UV NEW: KBA Rapida 75 UV KBA Rapida 105 NEW: KBA Rapida105 (previously universal) NEW: KBA Rapida106 KBA Rapida 130 KBA Rapida 130a KBA Rapida 142 KBA Rapida 162 KBA Rapida 162a KBA Rapida 185 KBA Rapida 205 36 x 52 cm 52 x 74 cm 52 x 74 cm 52 x 74 cm 52 x 74 cm 52/60.5 x 75 cm 74 x 105 cm 74 x 105 cm 74 x 106 cm 91 x 130 cm 96.5 x 130 cm 102 x 142 cm 112 x 162 cm 120 x 162 cm 130 x 185 cm 151 x 205 cm

ABS, PC, PET, PS, PVC cards up to 1.2 mm, Waterless UV with cavity Personalisation of ABS, PC, PET, PS, Inkjet inks PVC cards up to 0.8 mm Personalisation of ABS, PC, PET, PS, Inkjet inks PVC cards up to 0.8 mm Approx. 0.1 to 0.8 mm, depending on polymer Waterless UV Films from 0.05 to 0.6 mm UV Option for films up to 1.0 mm UV, waterless UV Option for ABS, PC, PET, PS, PVC films Waterless (Zeller+ up to 1.0 mm Gmelin Toracard TF) Option for films up to 1.0 mm Waterless UV Option for films up to 1.0 mm UV, waterless UV Option for films up to 1.2 mm UV, waterless UV Option for films up to 1.2 mm UV, waterless UV Option for films up to 1.2 mm UV, waterless UV Option for films up to 1.2 mm UV, waterless UV Option for films up to 1.2 mm UV, waterless UV Option for films up to 1.2 mm UV, waterless UV Option for films up to 1.2 mm UV, waterless UV Option for films up to 1.2 mm UV, waterless UV Option for films up to 1.2 mm UV, waterless UV Option for films up to 1.2 mm UV, waterless UV

Tirol (Austria), whose five-colour Rapida 74 with coater, extended delivery, hybrid and UV equipment and plastics package was started up at the beginning of 2008. The first waterless Rapida 74 in Spain was delivered to Roldn Grficas, a member of the European Waterless Printing Association based in Terrasa near Barcelona, in 2007. It is equipped with four UV interdeck modules and UV final drying, and handles above all PVC, PETG

and PS cards. At Gse Verlag GmbH in Karben near Frankfurt am Main, the first Rapida 74G installed in Germany has been in use since November 2005. The waterless offset press with its keyless Gravuflow inking units is configured for alternating production with oxidatively dried and UV-cured inks. Specialities of the company are plastic markers, labels and tags for plant and gardening suppliers.

At Gse in Karben near Frankfurt, the Rapida 74 G is used to print plastic markers and tags for gardening suppliers in waterless UV

Rudolf Berle, berle:druck, with a lenticular sheet from his Rapida 74 UV

Markus Staffner prints primarily lenticular substrates on this raised-pile Rapida 74

24 Process 5 | 2008

Applications | Examples

The worlds first inline corona tower for sheetfed offset at Etna in Nantua (France)

One of the two inert UV interdeck dryers on the six-colour Rapida 105 at Crea Crea Printing Industries recently received an RTE Award for Innovation in the category Printing & Packaging for a biodegradable lenticular presentation box. Further product examples from the company: 1 Advertising displays with flip-image effect; 2 Floor graphics; 3 PET presentation box for bottles; 4 Transparent inserts for books and magazines; 5 School utensils with advertising designs; 6 PET packaging for underwear; 7 Medical info posters; 8 Table-talkers; 9 Ring folders; 10 Place mats

The first sheetfed offset press with an inline corona tower went into production at Etna in Nantua (France) in April 2003. The sixcolour Rapida 74 is also able to pretreat films for later printing on other presses without corona facilities.

KBA Rapida 105: Also with Inert dryers

A corona tower also belongs to the configuration of the 15-unit Rapida 105 at Graf-Poz in Poznan (Poland) at 30 metres the longest Rapida in Europe. Already ahead of the seven printing units, the film surface is roughened with a corona discharge and primed with a metallic coating or opaque white. This primer is then dried in the two subsequent intermediate dryer towers. At the end of the press, which is also equipped with special board-handling features, a double-coating configuration allows for the application of

The first unit of the 30-metre Rapida 105 at Graf-Poz in Poznan (Poland) is a corona tower

high-gloss or effect coatings. The company Serigraph in West Bend, Illinois, is one of the largest film printing specialists in the USA. The screen printing activities which lent the company its name were already complemented with offset capabilities some years ago. Serigraph has owned a six-colour KBA Rapida 105 UV coater press since 2000. Crea Printing Industries in Roeselare near Bruges (Belgium) was in 2002 the first user in the world to install the inert UV technology in sheetfed offset. Two of the dryer modules developed by SID Leipzig in cooperation with Eltosch are provided as interdeck units on the sixcolour KBA Rapida 105 with coater. Crea is thus able to print also thin PVC films without curling, because the heat input can be significantly reduced.

Process 5 | 2008 25

Applications | Examples

Capital Print, London, uses a Rapida 205 for large-format plastic advertising materials

KBA Rapida 205: Plastics in superlarge format

Capital Print, London, installed a four-colour Rapida 205 with coater, dryer and the special equipment packages for board handling and plastics in 2005. In addition to the printing of mass articles, the intention is to produce also large-format advertising materials much more cost-effectively than in screen printing.
Product examples from Serigraph in West Bend, Illinois (USA): 1 Ceiling hanger printed on both sides; 2 Vacuum-formed company logo as badging; 3 Lenticular film as wrapping band; 4 Shelf wobbler with lenticular effects; 5 Lenticular inlay for DVD packaging; 6 Wall display; 7 Vacuum-formed wall display; 8 Place-mat for restaurant chain with Micromotion effect (Serigraph technology producing a flash effect as the viewing angle changes); 9 Micromotion adhesive label for a film packaging; 10 Floor graphics; 11+15 Vacuum-formed retail displays; 13 Treadmill control panel; 14 In-mould labels on golf clubs; 16 Vacuum-formed elements for a plastic shelf display

KBA-Metronic Genius 52UV: Versatility in B3 format

What the big Rapidas can do, that is also no problem for the small-format

waterless UV press Genius 52UV. The most prominent user is the Swedish Inplastor Group, where bank cards are printed and laminated under strict security precautions. The press installed in Strngns possesses a separate coater and an extended delivery.

Ultimate quality is also the image of Kunstdrukkerij Mercurius in Zaanstad (Netherlands), who received a five-colour Genius 52UV at the end of 2006. The press is used primarily for printing on plastics. The fifth unit is required for coatings and varnishes. A separate UV

coater with UV dryer and extended delivery is also available.

Mercurius in Zaanstad prints films in four and five colours on the Genius 52UV

The KBA-Metronic Genius 52UV at Inplastor is used to print bank cards

26 Process 5 | 2008

Applications | Lenticular images

Special effects for future-oriented niche markets

Flip images and mini-movies, 3D, zoom and morphing effects these extremely attractive eye-catchers are still far from commonplace. This profitable application for plastics printers is based on the use of lenticular film. But precise and reliable press technology is equally imperative. One of the presses of the KBA product range which offers the necessary prerequisites is the KBA-Metronic Genius 52UV.
Figure 1 The lenticular sheet comprises an array of parallel cylindrical lens and is printed on the reverse (here underneath)

Many of us remember them from our childhood days: Images of figures which appeared to wave a hand or blink an eye. It was usually just a simple image change (flip) which suggested the motion or action. In the past few years, however, the technology of lenticular printing has been revolutionised. The amazing multi-stage images can in the meantime comprise up to 16 phases. They trick the human eye perfectly and convey the impression of a film sequence or diorama. There are three factors which have made the recent progress possible and which are decisive for the quality of modern lenticular printing: The finely structured lens sheet Exact preparation of the digital image data with the aid of special software

A printing press capable of delivering a brilliant, highly precise image with perfect registration.

How lenticular printing functions

The lenticular technology makes use of the laws of optics. Lenticula is of Latin origin and means small lens. A lenticular sheet comprises a multitude of very fine cylindrical lens arranged side by side across the sheet (Figure 1) and formed such that their focal plane lies exactly at the rear surface of the film. Typical lenticular films possess between 40 and 130 lens lines per inch (15 to 50 lines per centimetre). In simplified terms, the light beams emanating from any particular point on the focal plane are refracted by the shape of the lens and formed into a more or less parallel bundle. Consequently, the observer sees only one small section of the image behind the lens for example, as shown schematically in Figure 2, only the blue stripes and thus overall only the blue image portion. If the observer changes his

viewing angle, however, the blue image disappears and is replaced by the green image, and so on. This effect can be exploited to place several different images or image versions behind the individual lenses. To achieve an image sequence with four separate elements (Figure 3, line A), for instance, each element must be divided into stripes with exactly the same width as a single lens (Figure 3, line B). It is here important that each original image is divided into as many stripes as there are lenses in the array. This newly composed striped image is naturally four times wider than the actual sheet format. Consequently, it must be compressed to a quarter of its width, so that the each set of stripes fits exactly under one and the same lens (Figure 3, line C). All in all, this is a highly complex process, whose implementation has only become properly feasible with modern software, and furthermore demands the trained eye of an experienced printer.

A case for the Genius 52UV

With the Genius 52UV, KBAMetronic supplies a flexible and efficient press to handle the special demands of printing on innovative substrates such as lenticular film. Holger Volpert, director of KBAMetronic AG, sees the press as a high-performance tool for niche markets with high development potential: The Genius 52UV is ideally matched to the demand profile of print companies wanting to handle creative short to medium-run work in brilliant quality and at favourable cost. Its efficiency and particular reliability also guarantee unrivalled competitiveness for niche applications such as lenticular film. Once the final lenticular image has been calculated, it is printed onto the reverse of the transparent film. Holger Volpert, formerly sales director for print technology, understands the user's concerns in every-

Flip images printed on a Genius 52UV in sheet format 36 x 52 cm

Figure 2 Behind each cylindrical lens of width m, n image stripes are printed at the focal plane (sheet reverse). The example here is a lenticular image comprising n = 4 phases or elements. Depending on the viewing angle, the observer sees only the light beams depicting one of the image stripe sets 1 (here red), 2 (blue), 3 (green) or 4 (yellow) demonstrated above for a switch between the blue and green phases

Process 5 | 2008 27

Applications | Lenticular images

footprint of just 12 m2, promises costeffective waterless offset printing with UV-cured inks, for outstanding print quality on the most varied nonabsorbent substrates in thicknesses from 0.1 to 0.8 mm.

Attractive new markets

Lenticular printing lends images depth and motion. In this way, printed products using lenticular film achieve something which is becoming ever more valuable nowadays: They grab the attention. Whether for advertising, fairs or merchandising the list of possible applications is sheer endless. Lenticular images are particularly effective for labels, displays, brochures, packaging, decoration and many other products, drawing positive reactions from the most varied target groups with their eye-catching special effects. But such dynamic images are more than just vehicles for decorative impressions it is also possible to fit multiple information, function descriptions, detail views, etc. into a lenticular image. Holger Volpert is convinced: Technology made in Germany has enjoyed an excellent standing over many decades, but this position must now be consolidated in a globalised market. This will only be successful if we remain permanently and closely in touch with the demands of the market, and if we employ our innovative strengths to develop sustainable potential ideas and visionary strategies are what we need. With the Genius 52UV, we open up a broad spectrum of opportunities and further strengthen the reputation of KBAMetronic as a strong and committed partner to the print industry. Birgit Grosse, Dipl.-Phys. Peter Schmidt (Innovations & Patents Dept., KBA-Metronic AG, Veitshchheim)

Figure 3 For an image sequence with four elements (line A; here, as in Figure 2, coloured red, blue, green and yellow to aid understanding), each element is divided into stripes which are exactly the width of a single lens (line B). There must be exactly the same number of stripes as there are lenses in the array. As our sequence comprises four elements, the combined image is now four times the width of the lens array. Consequently, the overall image must be compressed to a quarter of its original width (line C), so that one stripe of each image element fits under each lens. All figures KBA-Metronic AG/Peter Schmitt

day practice: For lenticular printing, absolute precision is decisive. As there are no ink keys in the inking units of the Genius 52UV, the inking is consistently stable. On top of that, the register system guaran-

tees exact automatic plate mounting. As a result, the start-up waste is minimal. And that is an important argument when using expensive materials such as lenticular film. As runs are often particularly short

in the small-format sector, low consumption and fast makeready are imperative. On the Genius 52UV, a single operator can complete a job changeover in only seven minutes. The compact Genius 52UV, with a

With its waterless and keyless offset process, the Genius 52UV from KBA-Metronic sets new standards in respect of quality and cost-effectiveness for the printing of flexible and rigid films (e.g. PVC, PET, ABS) in substrate-dependent thicknesses between 0.1 and 0.8 mm

28 Process 5 | 2008

Glossary

The most important plastics at a glance

In the plastics industry, the long names of the individual chemical compounds have thankfully been reduced to manageable proportions in the form of internationally standard abbreviations. This glossary provides an overview of the abbreviations and common names for the most important polymers, including all those compounds mentioned in the articles of this brochure.

ABS: Acrylonitrile-butadiene styrene; films suitable for printing with UV-cured and waterless offset inks Acrylic glass: see PMMA APET, A-PET, PET-A: Amorphous PET; for highly transparent, highly glossy printable PET films and thin plastic card laminations BOPET: Biaxially oriented APET film (i.e. stretched in both lengthwise and crosswise directions), e.g. DuPont Mylar BOPP: Biaxially oriented polypropylene film CA: Cellulose acetate; highly transparent, highly glossy and highly rigid natural polymer CAP: Cellulose acetopropionate COC: Cyclic olefin copolymer, Topas Coextruded film: Film composite produced by extruding melts of two identical or different polymers Composites: Print substrates and packing materials in which several identical or different material layers are bonded or welded together. CPET, C-PET: Semi-crystalline PET CPO: Cyclic polyolefins

Extruder

EVOH, EVAL: Ethylene vinyl alcohol Extrusion: Manufacturing process in which a plastic film is produced by forcing one or more polymer melts through nozzles (dies) GAG-PET: Coextruded PET composite (PETGAPETPETG); for blister and deep-drawn packaging components GPPS: General-purpose polystyrene HDPE: High-density polyethylene HIPS, PS-I: High-impact polystyrene HTR, PHEMA: Hard tissue replacement, polyhydroxylethylmethacrylate; extremely tear- and UV-resistant films for flexo and offset printing; good deep-drawing and lamination properties IML: In-mould label; usually oriented multilayer PP films, integrated into the surface of a plastic package as pre-printed labels during the moulding process LDPE: Low-density polyethylene Lenticular film: Plastic film comprising a fine array of parallel, cylindrical lenses LLDPE: Isotactically linear LDPE Monofilm: Plastic film produced from a single polymer; compare: Coextruded film. Mylar: Trademark of DuPont; synonym for oriented PET films OLED: Organic light-emitting diode; printable, electrically conducting polymer which emits light when a voltage is applied OPET-A: Oriented (i.e. stretched) PET-A film; high transparency, high glossiness, high rigidity OPP: Oriented (i.e. stretched) polypropylene OPV: Organic photovoltaic; photocell comprising a printable, electrically conducting polymer

OPVC-P: Oriented (i.e. stretched) plasticised PVC film PA: Polyamide; condensation polymer with low transparency, but good glossiness and rigidity; thermoplastic whose rigid variant is also processed into films for offset printing; often found in composites with PE for food bags; as PA 6.6 fibres for synthetic papers PAN: Polyacrylonitrile; highly transparent, highly glossy and highly rigid polymer PBN: Polybutylene naphthalate PBT: Polybutylene terephthalate; polyester for heat- and wear-resistant injection-moulded parts, sheathings and nano-fillers PC: Polycarbonate; the most expensive polyester; highly transparent, highly glossy and highly rigid condensation polymer used for CDs, DVDs, Blu-ray Discs and transparent device housings PE: Polyethylene, polythene; polyolefin polymer with average to good transparency, wax-like, low gloss, average rigidity PEDOT:PSS: Copolymer of polyethylene dioxythiophene and polystyrene sulfonate; printable, electrically conducting copolymer PEEK: Polyetheretherketone PEN: Polyethylene naphthalate; condensation polymer with good transparency and high glossiness and rigidity; replacement for PET in many applications PET, PETB: Polyethylene terephthalate; most important polyester material; highly crease-resistant condensation polymer PET-A: APET, amorphous PET PETB: PET PETG, PET-G: Glycol-modified PET; rigid film with good transparency as base carrier for lenticular films and

shrink-sleeve labels PETIP: Coextrusion of APET with a PET modified with isophthalic acid; for sealable films in metallised composites PHEMA: Polyhydroxylethylmethacrylate; see HTR PK: Polyketone PLA: Polylactic acid; degradable bio-polyester produced from renewable raw materials; can also be printed in offset as a rigid film with high gloss and high strength Plastic: Trivial designation for synthetic and semi-synthetic polymers; distinction is made between thermoplastics (can be formed when heated, e.g. PVC, PP), thermoset plastics (cannot be re-formed, e.g. PUR, hardened epoxides) and elastomers (all cold-formed rubbers); generally speaking, only films produced from thermoplastics are suitable for printing; also processed into blow-moulded packing materials. Plastic films: Polymer webs produced by way of injection moulding or extrusion, processed into substrates and composites with thicknesses between 20 and 150 m (typically 50 to 100 m) and sold in sheet or reel form; available in cleartransparent to opaque white and coloured grades, with glossy, semimatt and matt surfaces, or alternatively structured with patterns or as lenticular film; effectively any plastic film can be printed using UV-cured inks; conventional and waterless inks can also be used in sheetfed offset, or solvent- and water-based inks in flexo and gravure applications; processed for use as folding boxes, flexible packaging, cards and advertising materials Plexiglas: PMMA PMMA: Polymethyl methacrylate,

Process 5 | 2008 29

Glossary | Resources and partners

polymethacrylate; known as Plexiglas or acrylic glass, usually only processed in screen printing Polyester: Ethyl acetate; polymers with the ester functional group, e.g. PET, PEN, PC Polymer: Organic macromolecule on the basis of simple hydrocarbon molecules (monomers), whose high strength and other properties are determined by the chaining, branching or cross-linking of these

monomers; homopolymers (comprising a single monomer type): PE, PP, PVC; copolymers (comprising different monomers): ABS POM: Polyoxymethylene, polyacetal resin, polyformaldehyde PP: Polypropylene, polypropene; average to good transparency, glossy, wax-like, rigid PS: Polystyrene; clear-transparent, rigid; can be foamed (then no longer suitable for printing)

PSU: Polysulphone PTT: Polytrimethylene naphthalate PUR: Polyurethane; basis for moulded parts and adhesives PVC: Polyvinyl chloride; average to good transparency, rigid PVC-P: Plasticised PVC PVC-U: Unplasticised PVC PVDC: Polyvinylidene chloride, a polyolefin polymer PVOH: Polyvinyl alcohol; antistatic, weldable, water-soluble, bio-degrad-

able, high-strength barrier film Tacticity: Preferred alignment of polymer molecules; isotactic polymers (i.e. polymers with identically aligned molecules, e.g. PP) are particularly easy to stretch TPE: Thermoplastic elastomers Dieter Kleeberg

Resources and partners

At this point we would like to thank all cooperation partners whose products, solutions and equipment enable our customers to print on plastic substrates on KBA sheetfed offset presses.

Dryer systems
Adphos Vertriebs GmbH, Hamburg (www.adphos.de, www.eltosch.de) Grafix GmbH Zerstubungstechnik, Stuttgart (www.grafix-online.de) Heraeus Noblelight GmbH, Hanau (www.heraeus-noblelight.com) Khnast Strahlungstechnik GmbH, Wchtersbach (www.uv-technology.de) Dr. Hnle AG UV Technology, Grfelfing (www.hoenle.de) IST Metz GmbH, Nrtingen (www.ist-uv.com) RadTech Europe, Den Haag/Netherlands (www.radtech-europe.com) Schsisches Institut fr die Druckindustrie (SID), Leipzig (www.sidleipzig.de)

Advice, certification
Berufsgenossenschaft Druck und Papierverarbeitung, Wiesbaden (www.bgdp.de) Druck & Beratung D. Braun, Mlheim/Ruhr (www.wluv.de) fogra Forschungsgesellschaft Druck e.V., Munich (www.fogra.org)

Inks, coatings, additives and cleaning solvents

ACTEGA Terra Lacke GmbH, Lehrte (www.actega.com/terra/) DS Druckerei Service, Reutlingen (www.dsgroup.de, www.fujihunt.com) Eckart GmbH & Co. KG, Frth (www.eckart.de) Epple Druckfarben AG, Neus (www.epple-druckfarben.de) Flint Group Germany GmbH, Stuttgart; Day International GmbH/Varn Products GmbH, Reutlingen (www.flintgrp.com, www.dayintl.com) Huber Group, Munich; Hostmann-Steinberg GmbH, Celle (www.mhm.de, www.hostmann-steinberg.de) Jnecke+Schneemann Druckfarben GmbH, Hannover (www.js-druckfarben.de) Merck KGaA, Darmstadt (www.merck-pigments.com) SunChemical Hartmann Druckfarben GmbH, Frankfurt am Main (www.sunchemical.com) Schmid Rhyner AG Print Finishing, Adliswil/Switzerland (www.schmid-rhyner.ch) Siegwerk Group, Siegburg, Backnang, Annemasse/France (www.siegwerk-group.com, www.sicpa.com) Dipl.Ing. Werner Tippl, Vienna/Austria (tippl@xpoint.at) VEGRA GmbH, Aschau am Inn (www.vegra.de) Weilburger Graphics GmbH, Gerhardshofen (www.weilburger-graphics.de) Zeller+Gmelin GmbH & Co. KG, Eislingen (www.zeller-gmelin.de)

Corona and antistatic systems

Ahlbrandt System GmbH, Lauterbach/Hessen (www.ahlbrandt.de) KERSTEN Elektrostatik GmbH, Freiburg im Breisgau (www.kersten.de)

Plastic films, metal foils, lenticular sheets

DPLenticular Ltd, Dublin (www.dplenticular.com, www.lenticular-folien.com) Folienwerk Wolfen GmbH, Wolfen-Thalheim (www.folienwerk-wolfen.de) Klckner Pentaplast GmbH & Co. KG, Montabaur (www.kpfilms.com) Leonhard Kurz Stiftung & CO. KG, Frth (www.kurz.de) Papier Union GmbH, Hamburg (www.papierunion.de) Priplak SAS, Neuilly-en-Thelle/France (www.priplak.com, www.arjowiggins.com) Schneidershne Unternehmensgruppe, Ettlingen (www.schneidersoehne.de) Treofan Germany GmbH & Co KG, Neunkirchen, Raunheim (www.treofan.com)

3D software
Digi-Art Neue Visuelle Medien Elmar Spreer, Apen (www.lenticularsoftware.de) HumanEyes Technologies Ltd, The Hebrew University, Jerusalem (www.humaneyes.com, www.dispro.at)

30 Process 5 | 2008

KBA Process 5

Koenig & Bauer AG Wrzburg Facility Friedrich-Koenig-Str. 4 97080 Wrzburg Germany Tel.: +49 931 909-0 Fax: +49 931 909-4101 Web: www.kba.com E-mail: kba-wuerzburg@kba.com Koenig & Bauer AG Radebeul Facility Friedrich-List-Str. 47 01445 Radebeul Germany Tel.: +49 351 833-0 Fax: +49 351 833-1001 Web: www.kba.com E-mail: kba-radebeul@kba.com KBA-Metronic AG Benzstr. 11 97209 Veitshchheim Germany Tel.: +49 931 9085-0 Fax: +49 931 9085-100 Web: www.kba-metronic.com E-mail: info@kba-metronic.com

KBA Process is a technically oriented publication created to facilitate strategic investment planning by providing detailed, practical information on the current status and future prospects of new technologies and advances. Publications to date: KBA Process No. 1 Focus: Direct Offset Printing on Corrugated Board (2002) KBA Process No. 2 Waterless and Keyless (2005) KBA Process No. 3 Quality Enhancement with Hybrid Production (2006) KBA Process No. 4 Inline Coating (2007) Publisher: Koenig & Bauer Group (www.kba.com) Editors: Jrgen Veil Klaus Schmidt Dieter Kleeberg

KBA, head of sheetfed offset marketing, responsible for the content, juergen.veil@kba.com KBA, marketing director, klaus.schmidt@kba.com Trade journalist/PR service provider to the print industry, dieter.kleeberg@t-online.de

Authors and contributors: Walter J.Bolliger Siegwerk Backnang GmbH, Backnang Martin Dhnhardt KBA Radebeul Olivier Deage Siegwerk France S.A., Annemasse Klaus Fischer Papier Union GmbH, Hamburg Mark Fregin ACTEGA Terra GmbH, Lehrte Beatrix Genest SID Schsisches Institut fr die Druckindustrie GmbH, Leipzig Anne-Kathrin Gerlach KBA Radebeul Birgit Grosse KBA-Metronic AG, Veitshchheim Dieter Kleeberg Dipl.-Ing. D. Kleeberg, Nidderau Izabella Kwiatkowska European Media Group, Poznan Matthias Lange KBA Radebeul Marc Lavor Siegwerk France S.A., Annemasse Cornelia Lillelund Freelance journalist (for Papier Union) Peter Psotta Siegwerk Backnang GmbH, Backnang Peter Schmidt KBA-Metronic AG, Veitshchheim Wilfrid Tews Treofan GmbH, Neunkirchen and Raunheim Jrgen Veil KBA Radebeul Frank Wamann Klckner Pentaplast GmbH, Montabaur Wolfgang Zierhut KERSTEN Elektrostatik GmbH, Freiburg im Breisgau Layout: Katrin Jeroch

If you wish to receive our free customer magazine KBA-Report, but are not yet a subscriber, please contact Anja Enders in our marketing department: E-mail: anja.enders@kba.com Tel.: +49 931 909-4518 Fax: +49 931 909-6015

KBA Radebeul

Product specifications and features may be changed without prior notice. No part of this publication may be reproduced in any way without the publishers permission and without source data. Although registered trademarks and copyrighted or patented products are not specified as such, this does not mean that they are or may be treated as public domain. Printed in the Federal Republic of Germany

Process 5 | 2008 31

KBA Sheetfed Offset

KBA Rapida 106 Your innovative makeready champion

Ever since Drupa 2004 our high-tech Rapida 105 has been defining the benchmarks for medium-format offset in terms of automation, performance, flexibility and innovation. At Drupa 2008 our new Rapida 106 took makeready efficiency, quality management, ease of operation, waste reduction and cost-effective printing one step further. The new-generation Rapida 106: all you'll ever need, all you've ever wanted, and all in one press. Come and see for yourself.

KBA.P.616.e

Koenig & Bauer AG, Sheetfed Offset Presses, Radebeul phone: +49 351 833-0, kba-radebeul@kba.com, www.kba.com