flexo v/s gravure - tappi
TRANSCRIPT
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FLEXO v/s GRAVURE
Aleix MasComexi , Spain
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Contents
• A brief history in the Indian context.• Basics.• Advantage gravure.• Why flexo.• Advantage flexo.• Trends• Typical costings.• Conclusion
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History
• India typically a roto gravure market, with almost all jobs in the wide web done on roto.
• Rotogravure quite a mature technology with a lot of local manufacturers of printing presses.
• Cylinder making technology widely available
• Huge support from local ink suppliers.
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Rotogravure- direct printing
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Flexo – Indirect printing
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Advantage gravure.• Direct printing process gave the best print
quality.• Sturdy robust machines with excellent web path
and drying giving a very stable and consistent print.
• Good manufacturing facilities for precision manufacturing, advanced electronics and controls for extremely good registration control.
• Fast changeover possibilites.• Capability to handle a huge range of substrates.• Easy availability of experienced manpower
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Why Flexo
• Substrates elastic in nature especially PE.• Short runs (?)• Pressure to reduce packaging costs.• Reduced wastages.• Great advancements in flexo technology
leading to “Comparable Printing Quality” at economical cost of printing/ kg!
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Comparable quality – how?
• High precison construction of the press.• Monoblock frames with thicknesses upto
120 mm – solid and robust.• High precision central impression drum :
max TIR +/- 4 microns.• Direct Direct drives. • Automatic registration control and
pressure settings.• A/C or servo drives
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Comparable quality – how?
• Dynamically balanced rollers.• Very efficient drying.• Availability of good plate technology.• Availability of anniloxes.• Double guided decks for stability and
rigidity.
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So lets see how the two technologies are comparable……………….
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Typical roto machine
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Typical flexo machine
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Heavy duty constructionHeavy duty construction-- RotoRoto
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Heavy duty construction Heavy duty construction -- flexoflexo
MonoblockMonoblock framesframes
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Robustness - flexo
Upper and lower guidesUpper and lower guides
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Precision/Stability
• TIR +/- 4 microns• Direct direct drive.
• No coupling between the motor and the drum – no play, no tolerances
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Carbon fibre technology
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Individual drives - roto
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Individual drives - Roto
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Individual drives - flexo
• Photo of flexo deck
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Drying chambers - roto
• Individual dryers per station with possibilites of extended dryers and double hood driers.
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Drying chambers - Flexo• Interdeck drying chambers + tunnel after the
last station.
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Drying chambers - flexo
• Advantage – heat consumption is lower in flexo
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Job Changeovers - roto
•Make ready trolleys
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Changeovers - flexo
• Make ready sleeves mounted with printing plates
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Changeovers - flexo
• Online cleaning of stations – advantage flexo – fully or semiautomatic.
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Changeovers - flexo
• Magnetic doctor blades – advantage flexo
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Developments
• Registration and pressure settings from within the job itself.
• Demonstration of very high speeds of printing without loss of register.
• Demonstrations during the Drupa of getting the job in register right from the word “go”.
• Growing awareness of Opaltone.• Flexo contribution to green printing - Ebeam
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Cost variables
• Application oriented - thinner and thinner gauges of elastic materials.
• Capital investment.• Interest / finance costs.• Depreciation• Utilities• Manpower.• Payback.
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Cost variables
• Consummables• Ink• Solvent• Plates• Anniloxes
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Cost / kg of print - PE
• Add excel file.
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Advantage flexo• Capability to handle thinner and thinner gauges
of elastic material.• Comparable print quality.• Lesser ink consumption.• Lesser power consumption.• Lesser manpower requirement ( as in the
following example )• Faster changeovers.• Next job preparation while the first job is
running!
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World wide trends ……
• Increasing presence of flexo machines.• Global trends indicate a y-o-y growth of
8%. • Business getting more localised and
therefore resulting in smaller and smaller runs.
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Conclusion
• Flexo is here to stay, and inevitably will be a strong contender against the rotogravure technology as more and more concerns for thinner materials, print costs / kg as well as environmental concerns push the manufacturers to roll out more machines and also reduce costs by economies of scale.
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THANKYOU