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.
- 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
Dr. Sunil Kumar
CEO @ Rheonics
Sunil Kumar has extensive experience in the sensors and energy sector, having worked in a variety of roles in engineering and research in his early career. Most recently Sunil worked at Baker Hughes where he led global engineering for drilling Services. Sunil founded companies in US and UK that successfully commercialized innovative products. He graduated with Bachelors in Aerospace from Indian Institute of Technology, Kharagpur, Masters in Mechanical engineering from University of California, Irvine and Ph.D in Electrical engineering from Imperial College, London where he developed the Seis-SP seismometer that is part of the main payload for the NASA Insight mission to Mars. He is a prolific inventor with over 25 patents and multiple peer reviewed papers. Sunil’s vision of creating sensors for fluid property measurement that revolutionizes in-line process monitoring, control and optimization serves as the charter for rheonics.
Explore Rheonics' developments in this Industry
Association of International Metallizers, Coaters and Laminators (AIMCAL), founded in 1970, is a global nonprofit trade association representing converters of metallized, laminated and coated flexible substrates and their suppliers. AIMCAL announced Rheonics InkSight as a winner of the 2022 AIMCAL Award in the “Technology of the Year” category. Rheonics InkSight is a breakthrough multi-station ink viscosity & color control system…
AIMCAL’s Converting Quarterly Magazine features Rheonics Technology – “Ink viscosity optimization and automation – The key to quality, efficiency and sustainability in printing and coating”
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…
Rheonics awarded Sustainable Innovation Packaging – Innovation Prize 2021 by European Rotogravure Association
Rheonics wins a Sustainable Packaging Innovation Award by the European Rotogravure Association. Dr. Sunil Kumar received the award at the Annual & Packaging and Decorative Gravure Conference in Thessaloniki, Greece on 21-23 September, 2021. “Gravure – the sustainable print process” was the theme of the conference, which pointed out an encouraging perspective for gravure’s future. Our viscosity automation technology ensures…
FTA Flexo Magazine features Rheonics FTA Technical Innovation Award winning Technology – “Excellence via Viscosity Control”
Flexographic printing focused magazine - Flexo (https://www.flexography.org/flexo-magazine/) publishes an in depth article showcasing the Rheonics SRV viscometers and the RPS InkSight Multi-Station Ink Control solution and how it enables excellence in color control in printing. Find the link to the publication.