MDC Max Daetwyler AG

ERA Packaging Conference, Kiev
Welcome
Efficient Solutions for the
Preparation of Gravure Cylinders
Robert Albrecht
MDC Max Daetwyler AG
ERA Packaging Conference, 14 - 15 November 2005
Kiev, Ukraine
© 2005 MDC Max Daetwyler AG. All rights reserved. Subject to changes without prior notice.
ERA Packaging Conference, Kiev
Gravure has woken up against Flexo
Why and what are the reasons
Flexo-Gravure
ERA Packaging Conference, Kiev
Reasons
Lower image transfer tolerances = Higher production stability
Expansion of technical possibilities = Cost reduction in form preparation
Cylinder life time and repeat orders = Plus in respect of cost effectiveness
and technical aspects
ERA Packaging Conference, Kiev
Criteria
Criteria for Economy and Quality in Cylinder Production
1. Total Investment
2. Throughput / Capacity
( Process Times )
3. Ink Consumption
( Cell Character )
4. Quality
* CT – Ink lay, Vignettes, Details
( Cell Character )
* LW – Resolution
* Repeatability of Cylinders
( Process Type )
ERA Packaging Conference, Kiev
Electormechanical Engraving
1. Vision 3 Engraving Head (8 kHz)
Multi frequency Feature
Transcribe Option
2. Complete Gravostar Line
Gravostar 1315/ 2215/ 3615/ 5215
Gravostar 1212 (Economy)
3. Soon: Vision 4 Engraving Head (12 kHz)
ERA Packaging Conference, Kiev
Direct Laser System
Advantages for cylinder
makers in the
Packaging Gravure industry:
• Higher productivity – Speeds of up to 70’000 cells / sec.
• Flexibility of screen patterns and creation of composite cells
• Finer resolutions without compromise on cell volume
• Do away with the need to correct cylinders
• Superior balance between line work and continuos tone
ERA Packaging Conference, Kiev
Laser Master
Screen
conventional
Laser Master
Screen
halfautotypical
Master Screen
Electro
mechechanical
Laser Engraving
Resolution 100 l/cm
Screen 70/4
Resolution 400 l/cm
effective screen 110
Magnified sample of Kanji in Master Screen
conventional printed on aluminium substrate
Original size
ERA Packaging Conference, Kiev
Laser applications in Rotogravure – today:
Laser applications
Spotsize Laserbeam:
1. Direct Structure in Zinc (DLS) Daetwyler Laserstar
conv.
2. Indirect Imaging in Copper
halbautotyp.
min. 30 µm
(Cu-Etching with Fe- or Cu-Chloride or electrolytical de-coppering)
a) Direct Ablation of the Etching Mask Schepers Digilas
15 µm
b) Photoresist (Expose, Develop and Strip)
10 µm
Think Laboratories Laserstream
Creo/Acigraf
Exactus
ERA Packaging Conference, Kiev
Cylinder making work flows
Stylus Engraving
DLS
DIGILAS
(9 Steps)
(8 Steps)
(12 Steps)
(13 Steps)
DECHROME
DEPLATE
Cr & Zn
DECHROME
DECHROME
CUT OFF
CELLS
CUT OFF
CELLS
DEGREASE
DEGREASE
COPPER
PLATE
COPPER
POLISH
COPPER
PLATE
COPPER
POLISH
CUT OFF
CELLS
I.
DEGREASE
COPPER
PLATE
COPPER
POLISH
DEGREASE
ZINK PLATE
ZINC
POLISH
COAT/ DRY
II.
STYLUS
ENGRAVE
LASER
ENGRAVE
ABLATE
ETCH
STRIP
III.
Exactus/ Laserstream
COAT/ DRY
EXPOSE
DEVELOPE
ETCH
STRIP
DEGREASE
CLEAN
DEGREASE
DEGREASE
DEGREASE
CHROME
PLATE
CHROME
PLATE
CHROME
PLATE
CHROME
PLATE
Cr POLISH
Cr POLISH
Cr POLISH
Cr POLISH
ERA Packaging Conference, Kiev
Daetwyler GRAVOSTAR 3615
Automatic engraving line
ERA Packaging Conference, Kiev
Automatic Laserstar line
ERA Packaging Conference, Kiev
Automatic plating and finishing line
ERA Packaging Conference, Kiev
Geometry
An precise Cylinder Geometry - The Basis for a Optimal Surface Finish
Unnecessary Polishing Passes = Affects Geometry, Additional Cost
Taper + Radius
ard
d
n
a
t
S
y
r
t
s
u
Ind
Clean Face
Precise Diameter
ERA Packaging Conference, Kiev
Polishing Follows Geometry
Desired Polishing Structure
Surface finish
ERA Packaging Conference, Kiev
Cutting & surface finish
Duostar – All In One and Fully Automated:
• Cutting to Predefined Diameter
• Taper and Radius
• Polishing with Optimum Pressure
• Polish Cylinder Ends Multiple Times
• Squeegees the Cylinder Dry
ERA Packaging Conference, Kiev
Polishing
Finishstar - Automatic Polishing Using Correct Sequence of:
• Polishing Steps
• Polishing Passes
• Optimum Pressure
• Polish Cylinder Ends Multiple Times
• Squeegees the Cylinder Dry
ERA Packaging Conference, Kiev
Starbase light weight cylinder
Technical Highlights:
• Substantial savings for manufacturing
costs compared to steel cylinder bases
• Reduced shipping cost compared
to steel cylinder bases
• Easier handling (a 1 meter cylinder
weights
ERA Packaging Conference, Kiev
Doctor Blades
Blade Types
Straight Steel
Radius Edge
Bevel Edge
MDC - Lamella Tip
ERA Packaging Conference, Kiev
Thank you for your attention
End