Flexo and Gravure inks

The latest evolutions in the formulation of Flexo / Gravure inks mainly concern water-based
inks. New emulsions (resin / water suspensions) enable new water based inks to be
formulated, providing alternative solutions to solvent based inks and thereby limiting
problems linked to the environment (emissions of VOCs) and the safety of users (toxicity,
flammability,etc).

However, in certain sectors, the printing constraints imposed mean solvent-based inks still
have to be used. In this article, we will briefly cover the following points:
 Formulation
 Drying
 Preparation
 Troubleshooting
Formulation
Flexo and Gravure inks are formulated from the following components:

Components Content Principal functions

Solvents 50 – 75% Volatile organic products used to

solubilise the polymers. Principal
families: alcohols, esters, ketones,
glycols and water.

Cellulosic, vinyl, 15 – 30% Constituents of the binder (solvent +

acrylic and polyamide polymer) that largely determines the
polymers adhesion on substrates, the gloss
and the mechanical, physical and
chemical properties of the ink.

Organic or mineral 8 – 20% Pigments chosen as a function of the

pigments binder and the fastnesses required
by the application. Constituents that
Organic colorants enable intense and very transparent
inks to be obtained.

Additives 3 – 5% Products that confer specific

properties to the ink such as
 
rheology, adhesion, rub and scratch
  resistance, anti-foaming effect, etc.
Typical Flexo – Gravure ink formulation
Principal polymers

In water based inks, two types of acrylic polymers are used:

• Polymers in emulsion or dispersion, which improve the drying, gloss, adhesion and
water resistance of inks.
• Polymers in solution, which improve pigment wetting and make re-solubilizing
and cleaning easier.

In solvent-based inks, the various families of polymers cited above are used singly
or as mixtures, depending on the application and the final properties required of the
print.

Principal solvents
Names Evaporation Flash point Risks
index (°C)
Petroleum spirit C 2 - 20 F

Ethanol 95 8.3 13 F

Ethanol 99 8.3 13 F

Isopropanol 10 12 F

n-Propanol 11 14 F

Secondary butanol 33 24 F, X Harmful

Ethyl acetate 2.9 -4 F

Isopropyl acetate 4.2 7 F

Methoxy propanol 43
54 F
acetate

Ethoxy propanol 33 42 F

Methyl ethyl ketone 3.3

-4 F, X Irritant
(MEK)

Methyl isobutyl ketone 2

14 F, X Harmful
(MIBK)

Cyclohexanone 40 43 F, X Harmful

Monopropylene glycol - 107

The solvent is chosen as a function of the application, the desired drying speed and the type
of polymers used. The lower the evaporation index (ether = 1), the more volatile the solvent
and the faster the drying speed.
The flash point is the minimum temperature at which the solvent can ignite in the presence
of a heat source (spark, naked flame, etc.).

Drying
Solvent based inks

Drying occurs through:

• Forced evaporation of the solvent
The print is passed through a hot air drying chamber that extracts the emitted vapour. In
certain cases, extraction can be used on its own if the substrate is likely to be deformed by
high temperatures.

• Through penetration into the substrate

uniquely in the case of absorbent substrates (paper, cardboard, etc.), part of the solvent
penetrates into the substrate.

The elimination of solvent leads to an increase in the viscosity of the ink and then gives a dry
ink film that adheres well to the substrate.
Both methods of drying may be combined.

Water based inks

Drying and film formation in water based inks are complex phenomena.
Drying takes place through:
• Coalescence
The emulsion or dispersion, which acts as binder for the ink, contains small spherical
particles held in suspension. The evaporation of the aqueous phase enables these particles
to come into contact with each other and form a continuous film.
• Through penetration into the substrate
uniquely in the case of absorbent substrates (paper, cardboard, etc.), part of the solvent
penetrates into the substrate.

The elimination of solvent leads to an increase in the viscosity of the ink and then gives a dry
ink film that adheres well to the substrate.
Both methods of drying may be combined.

Preparation
Due to the diverse nature of the printing equipment used (inking units, anilox screen rulings,
doctor blades, etc.), print jobs carried out, Flexo, and Gravure inks are delivered in
concentrated form.
The printer therefore has to prepare the ink before each print run in order to optimize the
quality of the print, by adjusting:

• The viscosity
• The intensity
• The drying speed

The viscosity

The viscosity of a Flexo / Gravure ink is measured by the time it takes, in seconds, for a
precise volume of ink to run through an orifice of a given diameter. The higher the viscosity,
the slower the run off.
Several parameters are involved in the adjustment of the viscosity:

• The inking unit

Certain former generation “rising” inking units require high viscosity inks (above 60 seconds)
to ensure the ink is properly transferred from the roller to the plate.

• The type of work

Fine screen-printing (four-color process) requires quite a low viscosity (20 to 25 seconds) to
optimize dot sharpness and limit dot gain.
In the case of solid prints, a higher viscosity (above 40 seconds) will result in smoother
prints.

• The nature of the substrate

A relatively high viscosity is recommended on very absorbent substrates (vellum, kraft
paper, etc.) to avoid the phenomenon of ink “burying” itself by penetrating too quickly into
the substrate.

These various parameters should be kept in mind when determining the most suitable
viscosity to ensure optimal print quality.

Viscosity adjustment should always be carried out on inks at room temperature just before
they are used on the press.

• Solvent based inks

Viscosity adjustment must be carried out with the recommended thinning solvents.
Normally, the amount of thinner added varies between 20 and 30 %. The thinner(s) should
be added slowly, while agitating the ink. It is preferable to adjust the ink to a higher viscosity
than the planned viscosity in order to be able to fine tune this viscosity at the start of the
print run.
Once the inks have been correctly adjusted, the viscosity should be checked during the print
run. The viscosity has a tendency to increase in proportion in ambient temperature, and
when there is low consumption of ink. It then needs to be re-adjusted as explained
previously.

• Water based inks

In normal conditions of use, viscosity adjustment is carried out using tap water. Since the
viscosity drops very rapidly, the ink should be diluted in small dosages of 2 to 5 %.
Alternatively, viscosity reducer (5 to 10 %) should be used instead of water.
One of the principal characteristics of water based inks is that they have good stability on
the press. However, when the temperature is high or the ink consumption is low, it is
nevertheless necessary to incorporate a small amount of regenerator (1 to 2 %) every hour
in order to maintain the viscosity and the pH at their initial levels.
The intensity

The intensity of the print is influenced by the speed of the press. Only carry out intensity
adjustments at the true printing speed.
Optimum intensity is obtained with inks that are correctly adjusted in terms of viscosity and
evaporation speed.
To reduce the intensity:
• Reduce the amount of ink deposited by making the appropriate adjustments to the press
or by using a lower capacity cylinder screen.
• Add the recommended decolorant to the ink, adjusted beforehand to the same viscosity
as the ink. Decolorant may be added in any proportion and does not alter the physical and
chemical characteristics of the ink, with the exception of the light fastness .

The drying speed

• Solvent based inks
Three types of thinning solvents are used:

 Normal solvent
This does not modify the initial drying speed of the ink. It should be used in most cases for
viscosity reduction.

 Retarding solvent,
This improves the stability of the ink on the press. It should be used for printing texts and,
more generally, for print runs with low ink consumption. Normally, the amount that should
be added is between 10 and 25 %.

 Accelerating solvent,
This is used for cases where drying is difficult (solid prints) or for increasing printing speed. It
can be used in place of the normal solvent.

• Water based inks

The drying speed of water based inks is only slightly influenced by the incorporation of
solvents. The addition of a retarding solvent can improve stability.

Troubleshooting
Incidents
 

1. Mottled print
The print has a mottled or flecked appearance, with colored or black circles usually
appearing in light colors.
 

2. Drying too rapid

The ink dries on the inking system (plate and cylinder) and hampers ink transfer.
3. Drying too slow
Lifting of the ink, or marking of the feed rods. Blocking in the spool. Ink sticky.
 
 4. Poor adhesion of the ink to the substrate
Poor mechanical resistance (poor rub, adhesive tape, scratch resistance, etc.).
 
5. Print not intense enough
6. Print too intense
 
7. Poor ink transfer
The plate does not deposit enough ink onto the substrate.
 

8. Viscosity increases in the ink duct

 
9. Ink not homogeneous
Particles in suspension.
 
10. Moiré effect
Blurred four color prints.

11. Blocking in the reel

Spools stick together, making the prints unusable.
Print leaves marks on the underside of the substrate.
 
12. Prints clogged up or slurred
Excess ink around halftone dots and small text and poor character definition
 
13. Streaking
Wide streaks across the print.

Probable causes and remedies 

 

 1. Mottled print

The print has a mottled or flecked appearance, with colored or black circles usually
appearing in light colors.

Cause Viscosity too low.

Remedie Add non-diluted ink and adjust the viscosity.
Change the plate.
 Cause Surface of plate in poor condition.
Remedie Add thickener.

Cause Pollution (anti-foam, silicone, etc.) of the plate.

Remedie Carefully clean the plates. Do not use materials likely to leave
lint on the plate.

Cause Fount roller or anilox in poor condition.

Remedie Check the condition of the roller, the wear on the anilox cylinder
 
and check that the ink cells are not blocked.

Cause Unequal absorption of the ink into the substrate.

Remedie Use softer plates or opaque inks.  

 
2. Drying too rapid
The ink dries on the inking system (plate and cylinder) and hampers ink transfer.
(back to incidents)

Cause Solvent based inks:

The thinning solvent evaporates too quickly.
Remedie Use a solvent with a slower evaporation rate.

Cause Water based inks: incorrect pH.

Remedie Add 2-3 % of retarding solvent. Add regenerator (1 to 2 % every
3/4 hour).

 
3. Drying too slow
Lifting of the ink, or marking of the feed rods. Blocking in the spool. Ink sticky.
(back to incidents)

Cause Solvent based inks:

Viscosity of the ink too high.
The thinning solvent evaporates too slowly.
Remedie Reduce the viscosity with the recommended solvent.
Use a solvent with a faster evaporation rate.

Cause Water based inks:

Viscosity too high.
 Remedie Dilute with water or viscosity reducer (2 to 5 %).
Incorporate regenerator (1 to 2 %).

Cause Problem with drying tunnel.

Remedie Check the temperature and the extraction system.

 
4. Poor adhesion of the ink to the substrate
Poor mechanical resistance (poor rub, adhesive tape, scratch resistance, etc.)
(back to incidents)

Cause Ink not adapted to the substrate.

Remedie Use a suitable ink or consult the supplier.

Cause Substrate incorrectly treated or treatment has passed its expiry

date.
Remedie Check the surface tension of the substrate or consult the
supplier to check the expiry date of the treatment.
Check the possibility of applying a pre-lacquer varnish or primer
varnish or use CORONA treatment.

Cause Insufficient drying.

Remedie Increase the drying temperature and, if possible, the air flow.

 
5. Print not intense enough (back to incidents)
 

Cause Viscosity too low.

Remedie Add non-diluted ink or a concentrate.

Cause Anilox screen too fine.

Remedie Use an anilox with a coarser screen size.

Cause Anilox screen worn or blocked up.

Remedie Change or clean the anilox.

 
6. Print too intense (back to incidents)
 
 Cause Viscosity too high.
Remedie Reduce the viscosity with an appropriate thinner.

Cause Anilox screen too coarse.

Remedie Anilox screen too coarse.

Cause Doctor blade incorrectly adjusted.

Remedie Adjust the doctor blade so that it correctly wipes the cylinder.

Cause Colour strength too high.

Remedie Reduce the intensity with an appropriate decolorant.

7. Poor ink transfer

The plate does not deposit enough ink onto the substrate. (back to incidents)

Cause Viscosity too low.

Drying on the plate.

Remedie Add non-diluted ink.

Adjust the drying of the ink.

Cause Surface tension of the substrate too low or surface tension of the
plate too high.

Remedie Check the treatment of the substrate and the surface energy of
the plate.

Cause Pressure between the plate and the anilox incorrectly adjusted.

Remedie Adjust the pressure settings.

Cause Anilox screen worn or blocked up.

Remedie Change or clean the anilox.

Cause Anilox screen too fine.

Remedie Use a coarser screen.

8. Viscosity increases in the ink duct (back to incidents)

Cause Solvent based inks:

Unsuitable solvent or imbalance due to evaporation.

Remedie Add a more suitable solvent.

 Cause Water based inks:
Reduced pH.

Remedie Add regenerator (1 to 2 %).

9. Ink not homogeneous

Particles in suspension. (back to incidents)
 

Cause Wrong additive incorporated, causing precipitation.

Remedie Filter the ink in the ink duct.
Check that the product used is compatible with the ink.
Add the additives slowly, while agitating.

10. Moiré effect

Blurred four colour prints. (back to incidents)
 

Cause Incorrect ratio between the screen ruling of the plate and that
of the anilox.
Remedie Use an anilox roller adapted to the print run.
In Flexo printing, the ratio of the plate screen to that of the
anilox must be 1 to 3.5 or even 4.

Cause Plate screens not at right angle.

Remedie The colour separation films should be corrected.

11. Blocking in the reel

Spools stick together, making the prints unusable.
Print leaves marks on the underside of the substrate. (back to incidents)

Cause Ink not drying correctly.

Remedie Reduce the viscosity of the ink.
Change the thinning solvent to accelerate drying.
Change the balance of thinners.
Increase the drying capacity and/or the volume of air.

Cause Substrate temperature too high before spooling.

Remedie Install a cooling system before the re-spooling.
 Cause Spooling pressure too tight.
Remedie Reduce the spooling tension.

 
12. Prints clogged up or slurred
Excess ink around halftone dots and small text and poor character definition.
(back to incidents)

Cause Pressure between plate and anilox too high.

Remedie Adjust the pressure correctly.

Cause Ink dries too rapidly.

Remedie Adjust the drying of the ink.

Cause Ink viscosity too high.

Remedie Dilute the ink.

13. Streaking
Wide streaks across the print. (back to incidents)
 

Cause Worn gears.

Remedie Replace the worn gears.

Cause Excessive tightening of the inking cylinder.

Remedie Check the thickness of the plate (using a too thinplate
compensated by excess tightening).