Stay Ahead. With Agfa.

Stay Ahead. With Agfa.

Offset Printing
Offset Printing
Training on offset printing and Training on offset printing and
pressroom applications pressroom applications
GS/Global Services GS/Global Services
T. De Jaeger 7420 T. De Jaeger 7420
tony.dejaeger@agfa.com tony.dejaeger@agfa.com
Part 3
Part 3
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1: Inks and
1: Inks and
fountains
fountains
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Ingredients of a sheetfed offset ink
Pigment 10 - 20 %
Resins 25 - 35 %
Alkyd resins 5 - 15 %
Mineral oils 0 - 30 %
Natural oils 30 - 0 %
Additives 8 12 %
Drying agents
( Cobalt, Manganese) 1 5 %
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3
Inks

Ingredients of offset ink
Ingredients of offset ink
- - Basic components: pigments (10 to 20 %) and resin vehicles (bin Basic components: pigments (10 to 20 %) and resin vehicles (binding ding
medium) (up to 75 %). medium) (up to 75 %).
Offset inks: the resin vehicle is a colloidal solution of resins Offset inks: the resin vehicle is a colloidal solution of resins and drying and drying
oils in a mineral oil. oils in a mineral oil.
- - Drying agents (1 to 5 %) to accelerate drying Drying agents (1 to 5 %) to accelerate drying
- - Colour is determined by the pigment Colour is determined by the pigment
- - The resin vehicles transport and fix the colour pigments to the The resin vehicles transport and fix the colour pigments to the paper or paper or
substrate to print on. substrate to print on.

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Ink manufacture
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5
Inks
Inks

Ink properties
Ink properties
- - Inking rollers come in contact with water: the ink takes up up Inking rollers come in contact with water: the ink takes up up to 30 % to 30 %
of water: emulsification of water: emulsification
- - Too much water: over emulsification with loss of density and b Too much water: over emulsification with loss of density and bad ad
drying as a consequence. drying as a consequence.
- - Offset ink has to be water resistant: pigments should not separ Offset ink has to be water resistant: pigments should not separate from ate from
the vehicle or wash out. Washing out of pigments causes tinting, the vehicle or wash out. Washing out of pigments causes tinting,
scumming scumming, ,
- - Also the resin vehicle has to be water resistant: has to provid Also the resin vehicle has to be water resistant: has to provide adhesion e adhesion
and solidification on the paper. and solidification on the paper.
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Inks
Inks

Ink properties
Ink properties
- - Printing ink must neither be too fluid or too viscous. Printing ink must neither be too fluid or too viscous.
- - Ink consistency: viscosity or degree of liquidity Ink consistency: viscosity or degree of liquidity
thixotropy thixotropy or transformation from viscous at rest to or transformation from viscous at rest to
fluid when moving (ink rollers) fluid when moving (ink rollers)
flowability flowability: different flow properties in ink fountain : different flow properties in ink fountain
tackiness: stickiness or resistance tackiness: stickiness or resistance to split to split
- - Press speed and type and quality of paper must be taken into Press speed and type and quality of paper must be taken into
consideration with respect to tack and viscosity: the higher the consideration with respect to tack and viscosity: the higher the tack the tack the
more picking (depends on stability of the paper too); the higher more picking (depends on stability of the paper too); the higher the the
speed the higher the tendency to picking. speed the higher the tendency to picking.
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Inks
Inks

Ink layer thickness
Ink layer thickness
- - Ink layer thickness in offset printing: max 3.5 on the paper. Ink layer thickness in offset printing: max 3.5 on the paper. Because Because
the ink is split between plate/blanket and blanket/paper the lay the ink is split between plate/blanket and blanket/paper the layer on the er on the
paper is thinner than on the plate paper is thinner than on the plate
- - To achieve desired density: thicker ink layer is possible. This To achieve desired density: thicker ink layer is possible. This is OK to is OK to
print solids but creates excessive dot gain when printing halft print solids but creates excessive dot gain when printing halftones. ones.
Increased amount of pigments (up to a maximum level) increases d Increased amount of pigments (up to a maximum level) increases density ensity
and brilliancy and brilliancy
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Inks
Inks

Ink properties
Ink properties
- - Viscosity and tack can be modified by adding thinners (printing Viscosity and tack can be modified by adding thinners (printing oil), oil),
pastes or varnish pastes or varnish
- - Additives change the concentrate of the pigment: reduce tinting Additives change the concentrate of the pigment: reduce tinting
strength and drying capability: strength and drying capability:
- - when ordering ink, specify the application when ordering ink, specify the application
- - if additives do become necessary, only use the recommended if additives do become necessary, only use the recommended
types types
- - use additives in the right (lowest possible) concentration use additives in the right (lowest possible) concentration
- - if necessary, add drying agents. if necessary, add drying agents.
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Inks
Inks

Ink properties
Ink properties
- - Printing oil makes ink more fluid and short: too much will caus Printing oil makes ink more fluid and short: too much will cause e
bleeding in the dampening system, drying problems and plate bleeding in the dampening system, drying problems and plate scumming scumming. .
- - Printing paste makes ink short but not fluid: prevents picking Printing paste makes ink short but not fluid: prevents picking
- - Varnish (available in different viscosities) modifies ink from Varnish (available in different viscosities) modifies ink from fluid to stiff. fluid to stiff.
Never makes a printing ink shorter. Never makes a printing ink shorter.
- - Mixing inks always results in inferior printing properties comp Mixing inks always results in inferior printing properties compared to ared to
the unmixed inks the unmixed inks
- - Brightening with transparent white reduces the fastness to ligh Brightening with transparent white reduces the fastness to light. t.
- - Maximum 5 % opaque (zinc) white can be added because of tone Maximum 5 % opaque (zinc) white can be added because of tone
changes and bleeding. changes and bleeding.
- - Drying agents up to recommended limit: too much makes ink dry i Drying agents up to recommended limit: too much makes ink dry in the n the
fountain and tends to reduce drying capability. fountain and tends to reduce drying capability.
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Inks
Inks

Drying
Drying
- - The liquid binding media attach the well dispersed pigment to th The liquid binding media attach the well dispersed pigment to the e
substrate and protect it from chemical influences substrate and protect it from chemical influences
- - Two types of binding media: Two types of binding media:
- - physically drying media primarily used for physically drying media primarily used for flexographic flexographic inks, gravure inks, gravure
inks and inks for letterpress newsprint; drying by evaporation a inks and inks for letterpress newsprint; drying by evaporation and setting nd setting
- - chemically drying media drying by oxidation primarily used for chemically drying media drying by oxidation primarily used for
letterpress and offset inks letterpress and offset inks
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Inks
Inks

Drying
Drying
- - The liquid binding media attach the well dispersed pigment to th The liquid binding media attach the well dispersed pigment to the e
substrate and protect it from chemical influences substrate and protect it from chemical influences
- - Two types of binding media: Two types of binding media:
- - physically drying media primarily used for physically drying media primarily used for flexographic flexographic inks, gravure inks, gravure
inks and inks for letterpress newsprint; drying by evaporat inks and inks for letterpress newsprint; drying by evaporation and ion and
setting setting
- - chemically drying media drying by oxidation primarily used for chemically drying media drying by oxidation primarily used for
letterpress and offset inks letterpress and offset inks
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Inks
Inks

Drying
Drying
- - Physical drying: Physical drying:
- - Vehicles are natural of artificial resins in solvents Vehicles are natural of artificial resins in solvents
- - vehicles adjusted to the stock vehicles adjusted to the stock
- - drying by withdrawal of the solvent (e.g. by volatilization in drying by withdrawal of the solvent (e.g. by volatilization in case of case of
heatset heatset, , flexo flexo or gravure) or gravure)
- - drying by setting in case of inks for newspaper (web presses) drying by setting in case of inks for newspaper (web presses)
- - drying by combination of the two processes. drying by combination of the two processes.
- - the resin remaining on the surface of the stock after removal o the resin remaining on the surface of the stock after removal of the f the
solvents anchors the pigment on the printing base. solvents anchors the pigment on the printing base.
- - Inks which dry Inks which dry physcially physcially do not react to the addition of drying agents. do not react to the addition of drying agents.
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Inks
Inks

Drying
Drying
Chemical drying: Chemical drying:
- - Vehicles drying chemically are produced by boiling down artific Vehicles drying chemically are produced by boiling down artificial ial
resins with oils that dry by oxidation (e.g. linseed oil, resins with oils that dry by oxidation (e.g. linseed oil, soya soya oil, wood oil) oil, wood oil)
- - Chemical drying by oxidation or by Chemical drying by oxidation or by polymerisation polymerisation of the individual of the individual
molecules to a firm film of ink. molecules to a firm film of ink.
- - Polymerisation Polymerisation in presence of drying agents and under access of in presence of drying agents and under access of
oxygen. oxygen.
- - Drying velocity controlled by the usage of catalysts such as co Drying velocity controlled by the usage of catalysts such as cobalt, lead balt, lead
and manganese salts. To be adjusted in such a way that the ink d and manganese salts. To be adjusted in such a way that the ink dries as ries as
rapidly as possible on the stock, but on the other hand drying o rapidly as possible on the stock, but on the other hand drying on the n the
rollers has to be avoided. rollers has to be avoided.
- - In In sheetfed sheetfed- -offset a combination of binders that dry by oxidation and by offset a combination of binders that dry by oxidation and by
setting. On closed surfaces (bags, metal, ) exclusively drying setting. On closed surfaces (bags, metal, ) exclusively drying by by
oxidation. oxidation.
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Inks
Inks

Printing conditions
Printing conditions
- - Printing conditions (also external influences) should be consta Printing conditions (also external influences) should be constant to get nt to get
constant print quality. constant print quality.
- - Temperature has an important influence on the consistency of th Temperature has an important influence on the consistency of the ink e ink
(viscosity, tack). Increased tack on a cold press means higher f (viscosity, tack). Increased tack on a cold press means higher forces to orces to
separate the sheet from the blanket which can lead to elongation separate the sheet from the blanket which can lead to elongations and s and
distortions. distortions.
- - Too high temperatures can lead to excessive dot gain and to dis Too high temperatures can lead to excessive dot gain and to disturbed turbed
ink ink- -water balance which can lead to over water balance which can lead to over- -emulsification. emulsification.
- - The ink The ink- -acceptance properties and setting properties of the ink also var acceptance properties and setting properties of the ink also vary y
with the temperature. with the temperature.
- - The viscosity of the ink is also influenced by temperature. In The viscosity of the ink is also influenced by temperature. In the roller the roller
nips the printing ink is heated up to about 50 C by friction, s nips the printing ink is heated up to about 50 C by friction, splitting and plitting and
transport. transport.
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Inks
Inks

Fastness to light
Fastness to light
- - Fastness to light is important for printed matter exposed to da Fastness to light is important for printed matter exposed to daylight. ylight.
- - The energy of the daylight gradually transforms and destroys th The energy of the daylight gradually transforms and destroys the e colour colour
pigment. pigment.
- - The process is accelerated by heat and other factors. The process is accelerated by heat and other factors.
- - Fastness to light drops when mixing with transparent white. Fastness to light drops when mixing with transparent white.
- - Defined in standard DIN 16525 according to the Defined in standard DIN 16525 according to the Woll Woll scale (values scale (values
between 8 and 1) between 8 and 1)

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Fountains
Fountains

Basic composition:
Basic composition:
- - Acids: to clean and enhance Acids: to clean and enhance desensitisation desensitisation
- - Buffering agents: to Buffering agents: to stabilise stabilise the pH the pH
- - Plate protecting agents Plate protecting agents
- - Desensitising Desensitising agents: to avoid background toning due to oxidation agents: to avoid background toning due to oxidation
- - Sequestering agents/ Sequestering agents/complexing complexing agents: to avoid blinding (Calcium agents: to avoid blinding (Calcium
salts) salts)
- - Wetting agents: surface active agents to improve wetting capab Wetting agents: surface active agents to improve wetting capabilities ilities
by by optimisation optimisation of the surface tension and interfacial tension; also to of the surface tension and interfacial tension; also to
control the emulsification. control the emulsification.
- - Corrosion inhibitors: to protect plates and machine parts from Corrosion inhibitors: to protect plates and machine parts from oxidation. oxidation.
- - Biocides: to avoid slime build Biocides: to avoid slime build- -up, smell up, smell
- - Alcohol substitutes Alcohol substitutes
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Fountains
Fountains

pH
pH

Buffer capacity
Buffer capacity

Conductivity
Conductivity

-
-
What is this?
What is this?
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Fountains
Fountains

Recommended water quality
Recommended water quality

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pH: 7
pH: 7
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-
8
8

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Total Hardness: 8
Total Hardness: 8
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12 dH
12 dH

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Hydrogen carbonate: 150
Hydrogen carbonate: 150
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200 mg/l
200 mg/l

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Chlorides: <= 25 mg/l
Chlorides: <= 25 mg/l

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Nitrates: < 20 mg/l
Nitrates: < 20 mg/l

-
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Sulfates: < 50 mg/l
Sulfates: < 50 mg/l
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Fountains
Fountains

Water treatment
Water treatment

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Tap water
Tap water

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Deionized water (zero hardness)
Deionized water (zero hardness)

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Reverse osmoses (controlled hardness)
Reverse osmoses (controlled hardness)

-
-
additives
additives
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Fountains
Fountains

Tools to measure and control
Tools to measure and control

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pH
pH
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and conductivity meter
and conductivity meter

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Thermometer
Thermometer

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Water analysis kit (Merck)
Water analysis kit (Merck)

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Alcohol meter (densimeter)
Alcohol meter (densimeter)

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Lab analysis (IR, Gasschromatography)
Lab analysis (IR, Gasschromatography)
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Fountains
Fountains

Measurement of fountain solutions:
Measurement of fountain solutions:
- - pH: mild acidic in the range 4.3 pH: mild acidic in the range 4.3 - - 5.5 5.5
highly acidic fountains no longer needed on highly acidic fountains no longer needed on
modern substrates modern substrates
- - Conductivity: depending on the type of fountain solution; each Conductivity: depending on the type of fountain solution; each fountain fountain
has its own working range; best way to control the working has its own working range; best way to control the working
concentration. concentration.
- - Water hardness: Ca Water hardness: Ca- - and Mg and Mg- -Carbonates cause many problems like Carbonates cause many problems like
blinding of the rollers, plate blinding, build blinding of the rollers, plate blinding, build- -up on blankets. The up on blankets. The
hydrophilic salts penetrate in the pores of rollers, on the subs hydrophilic salts penetrate in the pores of rollers, on the substrate and on trate and on
the blankets. the blankets.
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Fountains
Fountains

Water analysis: an example
Water analysis: an example
249 S/cm
249 S/cm
Conductivity
Conductivity
5.56
5.56
pH
pH
87 mg/l
87 mg/l
Hydrogen
Hydrogen
carbonate
carbonate
7 dH
7 dH
Total hardness
Total hardness
RO + additive
RO + additive
Type of water
Type of water
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Fountains
Fountains

Water hardness:
Water hardness:
Very hard
Very hard
> 30 dH
> 30 dH
Hard
Hard
18
18

30 dH
30 dH
Middle Hard
Middle Hard
8
8

18 dH
18 dH
Soft
Soft
4
4

8 dH
8 dH
Very soft
Very soft
0
0

4 dH
4 dH
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Fountains
Fountains

Dosage:
Dosage:
2730
2730
4.52
4.52
4.0
4.0
2460
2460
4.52
4.52
3.5
3.5
2190
2190
4.52
4.52
3.0
3.0
1890
1890
4.52
4.52
2.5
2.5
1590
1590
4.56
4.56
2.0
2.0
980
980
4.68
4.68
1.0
1.0
249 S/cm
249 S/cm
5.56
5.56
0.0 %
0.0 %
Conductivity
Conductivity
pH
pH
Dosage
Dosage