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Gravure printing shifts from oil-based ink to water-based ink

Date: Oct 24 2024  From: Star Color   

Gravure printing, as an important printing method, has a wide range of applications in packaging printing, book illustrations, valuable securities, and other fields. Traditionally, gravure printing mostly uses oil-based inks. However, in recent years, with the enhancement of environmental awareness and continuous technological advancements, gravure printing is gradually transitioning from oil-based inks to water-based inks. This transition not only benefits environmental protection but also improves the quality and efficiency of printed products. However, this transition is not achieved overnight and requires a series of adjustments and improvements.

I. Adjustment in Ink Selection

There are significant differences in composition and performance between oil-based and water-based inks. Oil-based inks mainly consist of pigments, resins, and solvents, while water-based inks are made by adding pigments, water-based resins, and additives to water. Therefore, when transitioning to water-based inks, it is first necessary to select appropriate water-based inks.

1. Pigment Selection: Water-based inks typically use nanoscale organic or inorganic pigments, which have good dispersion and stability in water.
2. Resin Selection: Water-based resin is an important component of water-based inks, determining the drying speed, adhesion, and water resistance of the ink. Currently, acrylic resins and polyurethane resins are commonly used, and the choice of resin system depends on the printing substrate.
3. Additive Addition: To improve the printing performance and stability of water-based inks, surfactants, defoamers, leveling agents, and other additives are usually added.

II. Adjustment of Printing Equipment

Gravure printing equipment needs to adapt to the printing requirements of water-based inks. Due to the differences in viscosity and drying speed between water-based and oil-based inks, corresponding adjustments to the printing equipment are necessary.

1. Ink Circuit Adjustment: Water-based inks have lower viscosity and better fluidity, so the pressure and flow rate of the ink circuit system need to be adjusted to ensure that the ink can be evenly and stably delivered to the printing plate.
2. Drying Device Improvement: Water-based inks have a relatively slower drying speed, so the drying device of the printing press needs to be improved. The drying capacity can be enhanced by increasing the drying temperature, increasing the exhaust air volume, or changing the air volume and wind speed of the drying device.
3. Printing Plate Adjustment: The drying of water-based inks is irreversible, so laser-engraved gravure plates with square-shaped cells are used to avoid clogging caused by ink drying at the bottom of the cells. At the same time, operators need to clean the gravure plates timely and thoroughly to prevent the drying and scrapping of the plate rollers.

III. Adjustment of Plate-making Parameters

The plate-making parameters in gravure printing have a significant impact on the printing effect. When transitioning to water-based inks, corresponding adjustments to the plate-making parameters are required.

1. Cell Depth Adjustment: Water-based inks have higher boiling points, so electronic engraved or laser-engraved gravure plates with shallower cell depths are used.
2. Engraving Angle Adjustment: The engraving angle affects the ink transfer volume and the consistency of the printed color phase. When transitioning to water-based inks, the engraving angle needs to be adjusted to meet the printing requirements of water-based inks.

IV. Adjustment of Operating Norms

When transitioning to water-based inks, operators need to master new operating norms to ensure printing quality and efficiency.

1. Ink Mixing: Mixing water-based inks requires certain skills and experience. Operators need to mix the ink according to printing requirements and ink properties to ensure that the viscosity, drying speed, and other performance indicators meet the requirements.
2. Printing Speed Adjustment: The printing speed of water-based inks needs to adapt to the drying speed of the ink and the performance of the printing press. Operators need to adjust the printing speed based on actual conditions to ensure the quality and efficiency of the printed products.

The transition from oil-based to water-based inks in gravure printing is a significant advancement in the printing industry. This transition not only contributes to environmental protection and sustainable development but also improves the quality and efficiency of printed products.

In the future, with continuous technological advancements and the active efforts of printing enterprises, the application of water-based inks in gravure printing will become more widespread and in-depth.

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