How to convert from offset to flexo

Editor's note: This is a case of lithographic offset printers in South America who turned to flexographic printing. How did they develop from ignorance to rapid entry into the role of the well-developed America? Thanks to the perfect product supply chain, professionalism Their support and their own understanding of competitiveness, and more importantly, they learn and understand this technology that is different from offset printing from a completely open perspective, establish a standard set of standard management processes, and benefit from it...

JACKROM is a professional label and carton printer, headquartered in Caracas, Venezuela, and managed by President Saragossa. This company based in Central America employs 70 professional talents and was founded in 1972. Lithographic offset printing has so far been used.

JACKROM decided to take an important step in the competition strategy, becoming a flexographic printer, and recently purchased a Mac Andy 2200 flexo press. This machine is equipped with a full UV printing unit, hot stamping and embossing functions, and a crosscutting unit. Although JACKROM is now fully UV-printed, the machine is also equipped with hot-air drying to allow printing with ink and ink. JACKROM went to Flexo after a year of consulting and training of employees. Here is the story of their progress and challenges.

Large customer base

JACKROM has a very large customer base, many of which can easily be transferred to new flexo presses. The company's customers include food, pharmaceuticals, beer/wine, tobacco and other industries. In the future, many of the company's existing businesses can be moved to the flexo. The company's business has a lot of need for hot stamping and embossing, which is what makes the company's president, Saragsa, realize that the future of JACKROM is a flexographic version. At present, JACKROM's many bronzing and embossing operations are still performed offline. Once employees have fully mastered the printability of flexographic printing, the company will obtain considerable value from the complete in-line flexographic printing, bronzing, embossing, and die-cutting processes. benefit.

The proper training method

Correct flexographic knowledge training for employees is critical to the development of the company's flexo. Training starts at the management level. First, it lets employees know how to place tools in the right place. The purpose of this training is not only to make workers become a flexographic operator, but also to let them know how to set up and manage the next steps. Prepress preparation area, printing area, operation area. The goal of training is to achieve standardization and repeatability in every step of the entire production process. Finally, it is necessary to reach each employee to master the basic knowledge of flexo printing, including classroom training and hands-on instruction for a period of time—all the relevant contents from printing preparation to the final product, the use of anilox rollers, stickers, and ink. Use and so on.

Since this is JACKROM's first contact with flexo, it is very important for employees to spend time preparing for the next thing. The company established an inventory system of anilox rollers, knives and plate cylinders, used production planning forms and other documents to track the data of anilox and plate cylinders, and consulting company experts helped set up an inventory of anilox rolls and knives. Management procedures.

Machine printability test

Experts at the consulting company discussed the details of the tests with the expert Gray of the platemaking company before going to JACKROM to prepare the test machine for printability. The plate-making company prepared a professional test version. As for the parameters of the anilox roller, it was determined when ordering the machine. Gray said: "JACKROM has made all preparations before moving the machines and tools to the workshop." In the beginning of e-mail and telephone communication, Susan, who is responsible for design and prepress production, stated, “There is no doubt that the company has worked hard to achieve the best results that the flexo can perform from the very beginning.” This goal will use digital laser platemaking and incorporate FM technology into the screening process.

At the beginning of the training, they performed the first print test of the machine and used a spectrodensitometer to collect and measure the data in order to provide the basic information of the machine to the plate making company.

It is very important to test and proof the machine early, so that there is enough time to analyze the printed information to obtain feedback. The personnel of the plate-making company need to obtain the curve on the JACKROM company's printing press, and they can apply this information in the subsequent plate-making process. Achieve the best results. The plate-making company has also prepared a "improve trapping" of print and printing to help adapt and run the registering agency. All of these tasks are for obtaining data, finding methods and improving the application level of JACKROM as fast as possible. They also carried out proofing of a four-color CMYK file, using a 1000-line 1.6 BCM anilox roller. During the proofing process, they had the opportunity to observe the register conditions of the machine, check the drying system and tension control. The sampling test of the machine is an excellent opportunity to train operators to master the operating guidelines in the Flexographic Image Reproduction Specification & Tolerances (FISRT) of the American Flexographic Association. Of course, for some experienced offset printing operators, the language of consultants has to be “translated” and Susan takes on these tasks.

All test prints were run at a speed of 120 m/min and were extremely stable. In the process of 80 m/min to 150 m/min, the test results of the prints showed that the dots did not change, indicating the pressure of the machine. The control was very good and did not fluctuate with the increase of speed. The printing machine's sampling process was very successful. Gray of the plate-making company said: “The results are very good, especially the performance and registration of hybrid screening, pressure, color tone, and high-gloss small outlets are beyond my expectations. This is the best 'newbie' I have experienced over the years. On the road'."

Stickers

After finishing the printability test of the machine, the training part of the sticker needs to be carried out by hand. Employees must understand what kind of double-sided adhesives are needed for printed films, aluminized materials, and paper, and what their density is. The machine has been optimized at the last test, and the machine will print a variety of materials in the future, so it is important for the operator to understand how to select the double-sided adhesive according to the printed material.

It is also important to learn how to set up a print preparation area so that you can get the most convenient materials and tools. The consultants specifically directed the two operators, Rio Maier and Edison, in order to enable them to be organized and maintain a neat working environment, more efficient, and Riomayer and Edison quickly Understand the method of pasting, and through several techniques to improve the quality of the stickers, continuous practice, to a very high level. The instructors were also pleased to see that they soon adapted to this new training.

Printer Operation Guide

The training of the printing press begins with the unwinding unit and then enters tension control. Tension control is important for effective register adjustment. Since the operator's experience comes from a sheet-fed offset press, tension is a problem that has never been considered before. This part of the training goes smoothly. The next step is to set the impression cylinder, pressure and plate cylinder. . And how to use the correct flip stand to achieve double-sided printing.

JACKROM hopes to use inline blanching as much as possible, and trainers will provide specific instructions for the Ikela blanching unit, including the preparation process and the correct operation method. JACKROM also often uses inline embossing, including the use of anilox rollers and rotary film cutting props, all of which have undergone the necessary training.

Process parameters tracking

Recording and tracking each of the history parameters of India and India is critical to improving the efficiency and standardization of operators. The trainers helped them set up a file system at the beginning to ensure that the operator can easily repeat the first operation in the future. This repeatability does not refer to the repetition of simple printing processes. Narrow label printers are usually faced with a variety of different applications. Some are special materials, and some are special die-cutting, embossing, bronzing, or other applications.

If you build a database, the operation will be very easy. It is not merely for convenience to record these data. More importantly, other operators can also refer to it. All businesses must consider the situation when people change, and how to continue to maintain effective production. Future cross-training in the production process should also be considered by the company.

Change the inherent offset printing concept

JACKROM has been offset printing since the establishment of the company. The requirements of many businesses are very high. Especially when new customers are developed, they suddenly jump into the field of flexo printing, showing the company's determination and determination. Employees need to understand from the flexo point of view that their work is very different from offset printing: plate separation, trapping, and achieving high-quality image requirements are not the same. How to deal with the image and color separation correctly and achieve the right accuracy is JACKROM takes time to learn.

JACKROM will experience some growing pains in some places, and more often, they have achieved success. Saragsa is a very visionary and pioneering entrepreneur. We have already seen JACLROM's flexo printing business... Rapid growth.