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Printing plates after exposure are unstable and the effect in print is unpredictable

Instability of matrices after exposure is a common cause of errors, such as fit variation, blurred details and quality control difficulties. At Print Systems , we help eliminate these problems by implementing Toyobo water-based matrices and state-of-the-art UV LED expositors that ensure consistent quality and full image repeatability. This avoids production losses, complaints and gives you a predictable print result on every job.

  • What do we hear at the printing plant?
  • Our approach
  • How do we operate?
  • What do we use?
  • What does the printer gain?
Flexographic plates
1

What do we hear from printers?

  • The quality of the dies varies from order to order.
  • We have problems with the reproduction of fine elements, tonal transitions and details.
  • Traditional UV lamps wear out quickly, are unstable and require constant replacement.
  • The exposure process is unpredictable.
  • Energy and lamp operating costs are very high.
  • We would like printing plates to always come out the same - no surprises.
  • We are concerned about the transition to UV LED technology because we don't know if the team can handle it.

Do you have similar problems?

See how to solve them
2

Our approach!

Exposure without compromise - quality, economy and ecology in one process

We have designed a printing plate exposure technology that guarantees the highest quality matrices, cost savings and an eco-friendly approach. One that allows you to print without compromise regardless of whether the printer works on water or solvent plates.

What do you gain from this approach?

Find out
3

How do we operate?

  • We implement stable and energy-efficient UV LED floodlights.
  • We calibrate the device for the type of plates the printer works with.
  • We install equipment with full implementation and training.
  • We calculate the cost-effectiveness of the technology relative to classic lamps.
  • We provide service and control of UV parameters.
  • preparation of printing plates
  • QUICKER FLOW T100
  • PS-machines
4

What do we use?

QUICKER UV LED exposers

Designed for precision curing of photopolymer plates in flexographic and letterpress technology, available in three exposed plate sizes: 75cm, 100cm and 200cm.

We designed them to provide the uniform UVA and UVC exposure necessary for stable printing plates production and the precise control of light time and intensity parameters that guarantee repeatability.

QUICKER FLOW T100

It performs washing, drying and illumination in a single cycle, eliminating material waste and improving the quality of printing molds. Precise regulation of parameters such as brush speed, water pressure and UV LED intensity ensures repeatability and high quality.

5

What do printers who cooperate with us gain?

  • Take full control of the exposure process. Stable LED light source eliminates power fluctuations.
  • Significantly reduce operating costs. The UV LED lasts more than 5,000 hours - avoid frequent fluorescent lamp replacements and reduce power consumption by up to 50%.
  • Increase the precision and quality of the detail. Thanks to modern optics, you will reproduce the finest elements of your design - even with hybrid rasters.
  • They protect their process from changes in environmental regulations. UV LED irradiators do not emit harmful substances and comply with the latest ecology requirements.
  • Speed up the die preparation process . With an intuitive HMI and ready-to-use programs, you'll reduce handling time and minimize operator errors - even with employee turnover.
  • Avoid downtime with fast service support. You're guaranteed 48h parts delivery, remote diagnosis and technical support - all to ensure that your device is not a "dead end" in the process.

Do you have a problem with unstable dies?

Write to us
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Blog

Knowledge from the back of the printing plant

  • UV Led exposure device – optimization of the printing printing plate preparation process
  • QZ, next-generation photopolymer plates
  • Capacity measurement and quality control of aniloxes
  • Italian packaging printers invest in print quality measurement and control systems
  • 8 causes of flexo printing misfit
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Center knowledge

Our many years of experience and the numerous problems we have solved for our clients have enabled us to build a knowledge base in the field of printing.

Possible causes:

  • Inadequate pressure of the print roller against the material.
  • Incorrect pressure ratio between the anilox roller and the printing roller.
  • There is not enough Printing inks the ink system or the ink reservoir.
  • Used, damaged printing plate.
  • For film materials—no need to prime the substrate for printing.

Possible solutions:

  • Creation of a printing taxonomy.
  • Regular inspection of all components: anilox, printing plate, cylinders.
  • Use of camera video surveillance systems.
  • Before printing, always check that the material is activated; if in doubt, activate it.

Possible causes:

  • Print cylinder misalignment.
  • Printing cylinder bearing wear.
  • Wear on the gears in the print unit.
  • Too much tension on the printed material.
  • Poor assembly of the printing plate.

Possible solutions:

  • Given that parts are subject to wear and tear, prevention and periodic technical inspections of all components are of the utmost importance.
  • It is necessary to check whether the printing machine meets boothard printing conditions (unwind tension, pull guides, etc.).

Possible causes:

  • The differences in the raster angles for individual process colors are less than 30 degrees
  • An anilox roller with a line count less than five times that of the printing plate was used

Possible solutions:

  • Adjust the screen angles used to the values recommended for this printing process
  • The ideal ratio between the anilox roller and the working line spacing is 5:1

Possible causes:

  • Contamination of the Printing plate screen on Printing plate
  • Anilox roller damage
  • If dirt or a defect appears in different places every few rotations of the roller, it may be due to contamination of the printing plate.
  • The doctor blade is allowing too much Printing inks to pass Printing inks the anilox roller.
  • The squeegee becomes damaged, and metal particles contaminate the anilox roller—they can damage the anilox roller by causing circumferential scratches.

Possible solutions:

  • Check the cleanliness of Printing plate ; use only the cleaning agents specified by the manufacturer or supplier of the plates.
  • Inspect the technical condition of the anilox roller; handle the roller’s surface with care.
  • Replace the squeegee blade each time before starting a new job.
  • Using only recommended squeegee blades, checking wear.

Possible causes:

  • Paint with a very high tack
  • Excessive ink coverage in the area where this problem occurs—over 300% for paper

Possible solutions:

  • Dilute the paint with an appropriate solvent or reduce its viscosity by adding an appropriate resin to the mixture.
  • Reduce the total tonal value to 270%–280%
All

Blog and News

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    Capacity measurement and quality control of aniloxes
  • Microscopio a scansione 3D Troika, anilox measurement
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    8 causes of flexo printing misfit
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