Apex International, a provider of anilox metering solutions, has refined its patented GTT 2.0 open slalom channel anilox engraving to help printers master quality and consistency for profitable operations. According to the company, the GTT 2.0 anilox engraving can help box makers master higher-value product lines in box print designs while saving on money, downtime, and waste.
With a rise in demand for elaborate box designs and luxury micro-flutes, corrugated print quality is being given a second look. Printing the traditional ‘this side up’ block letter jobs will not be enough to thrive in the future of corrugated packaging. Box makers must learn to master the art of corrugated print to remain competitive and diversify their product portfolio for the sustainable success of the company.
According to Apex International, the anilox roll is among the big factors in mastering quality print production. Choosing the right anilox will bring one a step closer to achieving the required corrugated print.
Mastering corrugated inks
Most corrugated printers use water-based inks in production. The laydown consistency of water-based inks can positively or negatively impact dry time, press speed, print quality, and cleaning/maintenance downtime. If too much ink is applied to the board, it will lead to smearing, blurry graphics, and other print defects from the ink not drying properly at full speed. If too little ink is applied, the graphics may appear spotted and granular from low dot gain and cause absorption into the paper.
According to Apex, the shallow open slalom channel geometry of the GTT 2.0 allows a uniform layer of ink onto the anilox roll and easy transfer to the printing plate. The other long cell or HEX cell geometries are generally engraved too deep, knowing that cell-based engravings always leave a small amount of ink in each cell, clogging the anilox and reducing the color strength on the corrugated sheet.
This can result in graphics appearing dull and a subsequent increase in ink consumption to produce a vibrant graphic. The secret to the GTT 2.0 innovation is the 50% reduction in cell wall surface area across the anilox, as well as the decrease in the required channel depth by an average of 25%. Choosing the patented GTT 2.0 design will ensure optimal ink transfer and uniform laydown across the print plate, Apex said.
Water-based inks can also struggle with foaming issues due to aeration from cell-based engraved anilox roll or aeration from the ink pump or ink system. When ink is pressurized between the cells and the doctor blade, air can be forced into the cells, causing micro-foaming. This foaming can result in a splotchy look in print and will render a portion of ink unusable. Considering that water-based ink is one of the more expensive types, it is important to utilize every dollar of ink to maximize profit margin.
The GTT 2.0 anilox cell geometry is said to reduce liquid turbulence within the anilox, significantly reducing foaming, without needing the combination of a de-foaming agent and transfer agent in inks. In a recently published study, a 60-degree HEX engraved anilox and a GTT 2.0 open-channel anilox were compared within a production environment. The GTT 2.0 anilox roll showed significantly less foaming, if any, over the hex engraved roll. Time is money and with GTT 2.0 one can master consistent ink laydown, extend ink mileage, and decrease foaming for a profitable print operation, according to the company.
Master print quality
The increasing demand for micro-flutes and luxury corrugated suggests that box makers need to achieve smaller print types, vibrant flood coat colors, and soft blends and gradients. This is no easy feat for a box maker accustomed to standard block letter print. However, eCommerce box designs, DTC packaging, and POP displays are becoming a more common ask from brand customers and there is no sign of slowing down. To take advantage of these full graphic design jobs, box makers must control their print processes, including the anilox roll and ink system.
The GTT 2.0 anilox roll has a reduced channel depth and open channel geometry to allow inks to easily flow through all channels in the anilox, then to the print plate. Manufactured with T.I.R. and O.D. tolerances, GTT 2.0 is engineered to OEM specifications and measured for quality control throughout the manufacturing process.
With little or no need for de-foaming and transfer additives, one can decrease print defects such as trapping issues, mottling and pin holing in flood coats, blurred or faded typeface, and more.
Master productivity
To master corrugated print, it is important to master production efficiency and performance. Constantly stopping production for print defects, troubleshooting, and maintenance, will affect the profitability of operations and lead to a loss of competitive advantage.
The company says, “With GTT 2.0 anilox rolls, one can steer clear of the downtime required to troubleshoot for the common corrugated print defects and keep production running with stable, predictable, and repeatable print results. The open slalom channel geometry of the GTT 2.0 has been enhanced over the last several years to improve its cleanability and extend roll life. Manufactured with a super-hard hybrid ceramic coating and engraved in a wave-like pattern, the GTT 2.0 is extremely durable in production, reducing bounce and downtime for anilox changes. The GTT is also known to maintain print quality consistently throughout the life of the roll.”
“Anilox cleaning and maintenance is a large part of production downtime and GTT 2.0 has been engineered for easier cleaning and less required cleaning to ensure maximum uptime of the press. In a recent Apex study, the GTT C14 engraving was compared to a 130L/cm long cell volume of 13.7 over 8 months. The results below demonstrate that the new GTT 2.0 required only one deep clean after about 8 months, whereas the long cell required a deep clean about every three months. These cleaning requirements not only result in downtime for roll cleaning but also impact print quality as the roll gets further away from the manufactured volume,” the release said.
