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AIMCAL CQ 2022 Rheonics Viscosity Article

AIMCAL’s Converting Quarterly Magazine features Rheonics Technology – “Ink viscosity optimization and automation – The key to quality, efficiency and sustainability in printing and coating”

Overview

Web processing & finishing focused magazine – Converting Quarterly (https://www.convertingquarterly.com/) publishes an in depth article about how SRV revolutionizes ink viscosity management in gravure printing and enables “getting it right the first time”. In this article, readers can understand how printers improve color quality, reduce setup time and scrap and achieve sustainability in their operations with complete automation of ink viscosity management.

Find the link to the publication.

Converting Quarterly Magazine – Q1 2022

To download the pdf copy of the article, please use the link below.

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Introduction

Ink viscosity is one of the most important factors for achieving high and consistent color quality in gravure printing. Despite the sophisticated measurement and control systems built into today’s printing machines, ink viscosity is still frequently measured with inefficient and inaccurate methods, such as efflux cups and falling ball viscometers.

The variability of these measurements makes consistent color quality difficult to maintain. They underscore the need for a viscosity measurement and control system that can help operators obtain the very best color quality over the very long print runs that are characteristic of gravure.

Viscosity plays an important role in the final quality of printed matter. Ink layer thickness and flow behavior deviate from the optimal values when the viscosity is incorrect, resulting in substandard print quality. Poorly adjusted ink viscosity can also lead to excessive ink consumption and unnecessary costs. Accurate viscosity measurement and control can substantially improve print quality, while reducing waste and improving efficiency.

Even though methods are now available for continuous inline measurement of ink viscosity, many are sensitive to contamination, installation variables, and baseline shifts, which can impair operator confidence and cast doubt as to their long-term reliability. We will show the value of stable, easily cleanable, and repeatable viscosity sensors in printing processes. We will support our conclusions with experience and data from printers who have been using our sensors and automation systems over a period of several years.

A further benefit of high-accuracy viscosity measurement and control is online, automatic, dynamic control of color accuracy within previously unattainable narrow limits, thus ensuring high and consistent print quality over even the longest runs.

Viscosity automation in gravure printing
Real-time ink control is achieved through inline ink monitoring facilitated by placement of viscosity sensors at each print deck. They connect and transmit data to central, multi-station and single-station handheld consoles.

Topics Covered in the article

  • Why is ink viscosity a crucial variable to be controlled in printing presses?
  • Technical challenges in online ink viscosity control
  • Installation on printing press
  • Gravure challenges
  • How viscosity affects the color precision and quality in printing? Benefits of tight viscosity control for print quality and ink economy
  • Challenges with traditional viscosity measurement units
  • Benefits of printing press automation (Industry 4.0) and predictive tracking control in terms of quality and efficiency improvements, VOC emissions and waste reductions

Some figures from the article (Part -1)

Figure 1. Inline viscometer, based on balanced torsional resonator principle
Figure 1. Inline viscometer, based on balanced torsional resonator principle

Figure 1. Inline viscometer, based on balanced torsional resonator principle

Figure 2. Installation of a symmetric resonator viscometer using a flow adapter in an ink delivery system

Figure 2. Installation of a symmetric resonator viscometer using a flow adapter in an ink delivery system

Figure 3. A symmetric resonator viscometer installed on a press using a flow adapter

Figure 3. A symmetric resonator viscometer installed on a press using a flow adapter

Figure 4. A symmetric resonator viscometer installed on a press using a tee adapter

Figure 4. A symmetric resonator viscometer installed on a press using a tee adapter

Figure 5. The sensor after measurement in cyan ink

Figure 5. The sensor after measurement in cyan ink

Figure 1. Inline viscometer, based on balanced torsional resonator principleFigure 2. Installation of a symmetric resonator viscometer using a flow adapter in an ink delivery systemFigure 3. A symmetric resonator viscometer installed on a press using a flow adapterFigure 4. A symmetric resonator viscometer installed on a press using a tee adapterFigure 5. The sensor after measurement in cyan ink

Unique advantages with the Rheonics SRV sensors

Rheonics sensors have built-in temperature measurement, permitting the temperature of the ink to be monitored. This permits the viscosity readings to compensated for temperature, which is essential for ensuring consistent production through typical daily and seasonal temperature variations.

There are many benefits to using an inline viscosity sensor like the SRV for printing applications. and some include:

  • Works accurately in most coating systems with a broad range of ink compositions and viscosities – water-based, solvent-based, UV inks, metallic inks etc.
  • Maintains the set ink viscosity, extremely responsive to fresh ink additions
  • Rugged, hermetically sealed sensor head. The SRV can be cleaned inline with all standard CIP processes, or with a wetted rag, without the need for disassembly or recalibration
  • No moving parts to age or foul with sediment
  • Insensitive to particulate matter; no narrow gaps to foul with particulates
  • All wetted parts are 316L stainless steel—meets sanitary norms with no corrosion problems
  • Certified under ATEX and IECEx as intrinsically safe for use in hazardous environments
  • Wide operational range and simple integration—Sensor electronics and communication options make it extremely easy to integrate and run in industrial PLC and control systems.

Some images of the RPS InkSight system

  • Rheonics SmartView console integrated in printing machines
  • Some pictures showing the SRV viscometers inline installation inside the press
  • Standalone control cabinet
RPS InkSight – Central Console – Multi Station Ink Viscosity Control For Printing Press
RPS InkSight - Central Console - Multi Station Ink Viscosity Control For Printing Press
Photo 02 03 21, 20 48 50 (6)
Photo 12 01 21, 19 41 43
IMG 9748
Figure 2: Sensor Installed In Ink Line
Fig2. RPTC
RPS InkSight – Central Console – Multi Station Ink Viscosity Control For Printing PressPhoto 02 03 21, 20 48 50 (6)Photo 12 01 21, 19 41 43IMG 9748Figure 2: Sensor Installed In Ink LineFig2. RPTC

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Conclusion

As printing speeds increase, and profit margins get tighter, “getting it right the first time” becomes much more important. An error in initial viscosity setting can result in producing several thousand meters of waste in no time at all. Tight control with an accurate sensor, combined with a responsive control system, has enabled us to streamline our printing process while improving color quality and reducing waste.

What is unique about Rheonics viscosity control?

  • Traditional viscosity measuring methods (like efflux cups) are inaccurate, tedious to use, and prone to errors. Continuous viscosity control with such methods is extremely inefficient and unproductive.
  • Many common viscosity measuring devices do not provide fine enough viscosity control and require high maintenance and frequent calibration.
  • Rheonics RPS InkSight Predictive Tracking Controller and SRV viscometers enable tight viscosity control throughout the print job, due to the the system’s ability to autonomously maintain viscosity within extremely narrow limits.
  • Printers can achieve unmatched color accuracy and quality with the RPS InkSight system and ColorLock software – which is designed in collaboration with printers, for printers.
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