Profi TipRollers in Inking and Dampening Systems

Issue 1/2007• • • • • • • • • • • • •• • • • • • • • • • • • •• • • • • • • • • • • • •• • • • • • • • • • • • •

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Issue 1/2007

Roller Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Shore Hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Roller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Inking/Dampening System Adjustment . . . . . . 8

Press Strip Adjustment . . . . . . . . . . . . . . . . . . . . . . . 9

Alcolor Dampening System . . . . . . . . . . . . . . . . . 10

Alcolor Dampening System Adjustment . . . . . 11

Pre-/Post-Dampening with Alcolor . . . . . . . . . . 12

IPA-Free Ecocolor Dampening System . . . . . . 14

Quickmaster QM 46-2 . . . . . . . . . . . . . . . . . . . . . . 16

Printmaster GTO with

Direct Film Dampening System . . . . . . . . . . . . . 17

Printmaster PM 52/Speedmaster SM 52 . . . . . 18

Printmaster PM 74 with Ecocolor . . . . . . . . . . . 19

Speedmaster SM 74 with Alcolor . . . . . . . . . . . 20

Speedmaster CD 74 . . . . . . . . . . . . . . . . . . . . . . . . 21

Speedmaster SM 102/CD 102 . . . . . . . . . . . . . . 22

Speedmaster XL 105

Hycolor Ink and Dampening System . . . . . . . . 23

Contents

Foreword Dear Reader, in our current Profi Tip we focus on theinking and dampening systems of your Heidelbergpresses. We give you some information on the criticalimportance of the rollers for the quality and efficien-cy of your print processes.The articles explain the principles of the manufac-ture and use of rollers. And we answer the questionof how they have to be inserted, adjusted and main-tained. Using this knowledge you can make cost savings and will obtain an impressive consistency ofprint quality. On top of that, you will increase rollerservice life as well as print shop productivity. We aresure you will find this of great interest.Yours, Bernd Schopp

Bernd Schopp,Director ot the

Print Media Academy

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PROFI TIP

3Rollers in Inking and Dampening Systems

Roller Manufacture

Synthetic rubber is used inroller manufacture: a complexmix of natural rubber and var-ious chemicals that obtaintheir stability and elasticitythrough the vulcanization pro-cess. It is the raw rubber thatgives the rubbery material itsbasic characteristics. To thisare added the vulcanization

agents for the subsequent vulcanization process. Plasticizers (fluid oils) play a major role as they – along with the extenders and the vulcanization agents –determine the subsequent degree of hardness of the material. The more plasti-cizers are added, the softer the rubber after the vulcanization process.

• If possible, do not expose rollers to direct natural or artificial light.• The special paper that the rollers come delivered in prevents light penetrating

and therefore helps retain the rubber’s characteristics. For this reason, donot remove the paper before inserting the roller in the printing press.

• Always put the roller with its pivots on a frame support: Putting it down directlyonto the rubber can result in permanent deformations (pressure marks).

• Store rubber rollers in a cool and dry place.• Under certain circumstances ozone causes microscopic scratches on the

rubber surface. For this reason do not store rollers in the vicinity of motorsor other electrical devices.

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Issue 1/2007

Shore Hardness

• In line with their task of transferring ink, inking rollers must be adjusted to beoil-friendly (or oleophilic). In an inking system with conventional inks, rollersof Shore A hardness between 30° and 35° are used. For UV inks, rollers withShore A hardness of 25° and between 40° and 45° are used.

• Dampening rollers should be water-friendly (hydrophilic). For alcohol damp-ening systems, Shore A hardness of between 25° and 30° is suitable. In directdampening systems, hard rubber rollers are used.

The Shore hardness of a rollerdetermined with a Shore me-ter designates the resistanceagainst penetration of a nee-dle taking the form of either aconic section (Shore A) or apoint (Shore D), pressed witha defined force (1 kp) for a pe-riod of three seconds againstthe rubber surface. Soft rollersare measured with Shore A,and hard rollers with Shore D.The general hardness toler-ances according to DIN/ENare +/- 5° Shore A

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PROFI TIP

5Rollers in Inking and Dampening Systems

Shore hardness can be easily measured and gives the printer information on the condition of the rollers. Rollers tend to become harder with use, as they areexposed to inks, dampening agents and detergents, as well as the atmosphere.Additional hardening of 5° Shore in the first months of use should be regardedas normal. Accelerated hardening in use can be a sign that the rollers are grad-ually shrinking. If you adjust a roller that has been subject to hardening andshrinkage to its original gap width, it may well be that its original transfer char-acteristics will be reproduced. At the same time, however, the gap width is closerthan previously. This leads to higher pressure and higher temperatures – andthereby to higher wear on the roller.

Increased hardness can also indicate that a hard film of paper coating and damp-ening agents has become deposited on the roller surface. This film should be reg-ularly removed to prevent the roller hardening and glazing with use. The clean

and satin-like surface of a roller is even more important than its hardness.

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Issue 1/2007

Roller Maintenance

For optimum maintenance of rollers, the roller manufacturers recommend a uni-versal group AIII agent that can be mixed with water. Alternatively, high solidsalkyd resins or biological detergent may be used. Long service life of the rollerscan only be achieved with proper handling and maintenance. (On UV printing,the service-life is as a rule shorter.)

• The choice of detergent plays an essential role in roller service life. Highlyvolatile cleaners remove the plasticizer from the rubber, which leads to shrink-age and hardening. Other possible consequences of using unsuitable deter-gents are swollen rollers or corroded hoses, seals, machinery paintwork andblankets. Suitable detergents are certified by FOGRA and may be selectedfrom the relevant list (cf. www.fogra.org).

• Various applications (standard inks, UV, hybrid) each require specific rollermaterials and these in turn require detergents that are specially suited to them.

• Along with print chemicals that affect the roller directly, external factors suchas UV light, damp and room temperature may result in premature ageing of the rubber.

Ageing cracks Ozone cracks Cracking due to chemicals

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PROFI TIP

7Rollers in Inking and Dampening Systems

Glazing

Over time, rollers pick up particles from the ink, the paper coating and the damp-ening agent which block their pores. This contamination results in a smoothshiny surface. Inappropriate detergents and hard water contribute to this effect.Transfer of ink and dampening solution is noticeably inhibited as a result.

By using a special decalcifying agent, scaling can be removed and the rollers regenerated. It is recommended you discuss with the roller manufacturer whichagents have the least long-term effects on the rubber.

Clean roller with porous surface Glazed roller with calcification on the sur-

face

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Inking/Dampening System Adjustment

• Carry out adjustment work on rollers once they have run warm, or else calculate in an increase of the adjustment strips.

• As a rule, set the damping form roller and inking form roller nearer to thedistributor than to the printing plate – but not so near that a pressure stripin the form of a cigar occurs with the plate. This would indicate that theroller is being bent towards the cylinder channel.

• Only adjust the rollers according to manufacturer specifications.• Always adjust from minus to plus, so as to eliminate thread play on

adjustment.• On “Vario“ set the ink form roller nearer to the distributor, so that it is

decelerated by the dampener oscillator roller.• When setting the ink form roller to the plate, high pressure is momentarily

exerted (impact), which generates a stronger press strip. For precise adjustment of the print plate, first ink up and set down the rollers after waiting for around 10 seconds.

• Precise roller adjustment is best carried out via the press strip. For this, coat the rollers equally with a light-colored ink (yellow). After the ink hasdistributed and a waiting time of around 10 seconds, with a piece of papersqueeze off the press strip generated.

• Always measure between the dot fringes are these are more evident with increased ink.

• Always set the rollers parallel to each other (tolerance 0.5 mm).

8

Issue 1/2007

Operating end Drive end

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Press Strip Adjustment

Heidelberg provides an adjusting gauge which allows precise measurement of the press strips (can be ordered over the Internet at http://www.heidelberg-selection.com or via the relevant distributor, part no. G2.024.001). A paper template print of the press strip makes measuring easier and can be used fordocumentation purposes.

By making a professional adjustment, the printer ensures the right pressure between the rollers. This then ensures ink distribution and a consistent supplyof dampening agent.

PROFI TIP

9Rollers in Inking and Dampening Systems

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Issue 1/2007

Alcolor Dampening System

Print quality starts with the interaction of the inking and dampening system: Consistently good results assume a stable ink-water balance. Precise adjustmentensures thin and equal distribution of the dampening agent film on the printingplate. This reduces sheet drying time, allowing the sheets to get through the finishing process sooner.A responsible printer checks the adjustments every three months and adjusts inline with the operating manual.

The dampening agent ideally has a water hardness of 8° to 12° on the Germanscale (dH) and a pH value of 4.8 to 5.5. The usual dampening agent temperatureis deemed to be between 10°C and 15°C. To prevent the occurrence of print prob-lems, it is recommended that the dampening agent be renewed every 14 days.

15

E14

12

13

12 | Damping form roller

13 | Intermediate roller

14 | Tipping roller

15 | Application roller

E | Dampener oscillator roller

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PROFI TIP

11Rollers in Inking and Dampening Systems

Alcolor Dampening System Adjustment

Basic adjustment of the dampeningsystem should be performed with aclean roller with two thin paperstrips (approximately 0.05 mmthick). The wide paper strip coversthe rubber roller, while the narrowstrip acts as a feeler gauge. Thismeans that the greater resistance of the rubber roller is not felt. Thenarrow strip slips between the wide

paper strip and the smooth distributor roller. There is an exact description of themethod in the operating instructions.

If the Alcolor dampening system is adjusted or checked with ink, be aware thatwhen the strip is formed an unintended rolling movement occurs from the appli-cation roller to the damping form roller. This makes the press strip wider. If thereis a suitable waiting time (approximately 30 seconds), the “inner” strip can beproperly assessed.

12 | Damping form roller

15 | Application roller

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Issue 1/2007

Pre-/Post-Dampening with Alcolor

Using automatic pre-dampening, the Alcolor dampening system ensures there isadequate dampening agent film on the printing plate. Where printing is inter-rupted (washing, stopper etc.) the dampening system is automatically switchedoff by the plate as part of a post-dampening phase. The duration of the automaticpre- and post-dampening phases can be set by via the machine control systemand thereby adapted to the many different materials in use and the conditionsthat exist around the world. Good adjustment ensures an optimum amount ofdampening agent when printing starts and after printing has been interrupted.

To avoid excess dampening agent on the printing plate, the pre- and post-damp-ening phases should be set to the minimum.

Mode

Pre-dampening phase 1

Pre-dampening phase 2

Post-dampening phase 1

Post-dampening phase 2

Standard settings

RevolutionsAdjustmentrange max. revolutions

18

18

50

100

Adjustmentrange min. revolutions

0

0

0

0

3

2

15

45

3

2

15

45

The pre- and post-dampening phase with Alcolor

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PROFI TIP

13Rollers in Inking and Dampening Systems

Fe

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100

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22

E1

24

25

27

26

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Issue 1/2007

IPA-Free Ecocolor Dampening System

100 % IPA-free printing with the Ecocolor dampening system reduces emissions,improves the print shop atmosphere and at the same time saves alcohol costs.Ecocolor ensures quick and stable ink/water balance. Dampening agent controlis via a potentiometer. Dampening agent temperature is set to 18 to 20°C.

22 | Damping form roller

23 | Intermediate roller

24 | Tipping roller

25 | Application roller

26 | Transfer roller, large

27 | Transfer roller, small

E1 | Dampener oscillator roller

8305_PROFITIPP_E.qxd 19.04.2007 14:22 Uhr Seite 14

On IPA-free printing, the degreasing action of the alcohol in the dampening agentis not present. This means that oily detergent residues may remain on the rollers,and these can inhibit dampening agent transfer. This is why absolutely faultlesswashing procedures are needed. The basic cleaning agent must under no circum-stances contain aromatic compounds, as these may damage the rollers. Youshould ask your ink supplier about a suitable cleaning agent.

A tip:

Clean the rollers by hand after each wash. To do this, run the press to washspeed, switch the intermediate roller on the press to connect by double-clicking(it flashes) and using a spray bottle, spray a water/alcohol mixture (80 % / 20 %)onto the rollers. Set wash-up blades via the service menu and wipe. Clean thetipping roller and applicator roller with alcohol (on the front surfaces as well).

PROFI TIP

15Rollers in Inking and Dampening Systems

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54

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Issue 1/2007

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PROFI TIP

17Rollers in Inking and Dampening Systems

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Issue 1/2007

3.5

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PROFI TIP

19Rollers in Inking and Dampening Systems

4.5

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8305_PROFITIPP_E.qxd 19.04.2007 14:22 Uhr Seite 19

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Issue 1/2007

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12

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PROFI TIP

21Rollers in Inking and Dampening Systems

Spee

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Issue 1/2007

21

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PROFI TIP

23Rollers in Inking and Dampening Systems

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Issue 1/2007

Are you missing a copy of Profi Tip from the Print Media Academy in your peronal collection?

Profi TipDampening Solutions in Offset Printing

Issue 1 /2005

• • • • • • • • • • • • •• • • • • • • • • • • • •• • • • • • • • • • • • •• • • • • • • • • • • • •

Issue 1/2005Dampening Solutions in Offset Printing

Ausgabe 1/2005Feuchtmittel im Offsetdruck

Issue 1/2006Tips for Problem Cases in the Pressroom

Ausgabe 1/2006Tipps bei Problemfällen im Drucksaal

Issue 1/2007Rollers in Inking and Dampening Systems

Ausgabe 1/2007Walzen in Farb- und Feuchtwerk

Profi TipTips for Problem Cases in the Pressroom

Issue 1/2006• • • • • • • • • • • • •• • • • • • • • • • • • •• • • • • • • • • • • • •• • • • • • • • • • • • •

Profi TipRollers in Inking and Dampening Systems

Issue 1 /2007• • • • • • • • • • • • •• • • • • • • • • • • • •• • • • • • • • • • • • •• • • • • • • • • • • • •

At www.print-media-academy.com you can order any past issue free of charge.Just tell us the issue and your address and you will get your personal copy directly.

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PROFI TIP

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The latest technologies and up-to-date management know-how from the printmedia industry – these are the two focal points of the comprehensive trainingand seminar provision of the Print Media Academy, which is represented in Germanyand across the world in 16 locations.We provide in-depth knowledge enabling you to master the increasingly rapidchange process in the industry. Vocational outlines, software, machines and, especially, client requirements are all subject to a permanent and ongoing trans-formation. In the Print Media Academy you will acquire the competencies thatyou need for your success: From training on machines to management seminars,you will not just update and improve your professional knowledge, but also be-come qualified in “soft” factors such as the capacity for teamwork, team leader-ship and company management. Why not order our current seminar programme?

In-Depth Knowledge:

From Training on Machines to Management Seminars

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Issue 1/2007

Notes

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1,5

2

2,5

3

3,5

4

4,5

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0 1 2 3 4 5 6 7 8

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1,5

2

2,5

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3,5

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4,5

5

5,5

6

6,5

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0 1 2 3 4 5 6 7 8

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00.9

93.0

199/

01

Heidelberger Druckmaschinen AG

Print Media Academy

Kurfürsten-Anlage 52–6069115 HeidelbergGermanyTel.: +49-62 21-92-0Fax: +49-62 21-92-49 29www.print-media-academy.com

ImprintPlatemaking: CtPPrinting: SpeedmasterFinishing: Stahlfolder, StitchmasterFonts: Heidelberg Antiqua, Heidelberg GothicPrinted in Germany

TrademarksHeidelberg, Print Media Academy, and the Print Media Academy Logo are registered trademarks of Heidelberger Druckmaschinen AG in Germany and other countries.

Technical and other changes reserved. Allinformation is presented without warranty. All liability for errors of information is barred.

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