Successfully printing a newspaper requires a large amount of material. A newspaper's price of five dollars (about four Hong Kong dollars) is only enough to cover the cost of paper and ink, and most of the other expenses are dependent on advertising revenue. Therefore, how to make proper use of materials while maintaining the same printing quality requires great effort. The cost of printing ink is second only to labor and paper expenses, making it the third highest material cost for newspapers.
The Chattanooga Times Free Press in Chattanooga, Tennessee, USA, conducted a study on how to use the ink's efficacy to the limit level. The ideal method is to reduce the consumption of ink while maintaining the printing standard. This reflects the right balance between cost, efficiency and quality.
The black ink that we received in the printing room was concentrated (ie, "raw" ink). Prior to the printing of newspapers, the printing ink must be filled with fresh water and sometimes added to the circulation and then diluted with ink to become ink. Printing presses generally use several hours to complete the printing of newspapers, followed by cleaning, and after a few hours, another printing process. It is not surprising that we clean the press twice or three times a day, four times, and the amount of water consumed is astonishing. At the same time, it means that the quality of water after cleaning has a large amount of recycled ink, which is only needed to remove the clean water and residues. A thick layer of recycled ink is used for immediate display, including some original ink. However, it is not enough for printing after diluting the recycling and printing ink, and only need to add additional original printing ink.
Chattanooga attempts to systematically evaluate the proportion of the original ink and the amount of recycled ink to obtain the most appropriate cost and print quality relationship. This is to be evaluated. Since most flexographic newspaper printing companies spend millions of dollars each year on printing ink, the printing method that can save the original printing ink will be a major discovery.
The above-mentioned assessment will not be too complicated. It is only by adjusting the proportions of the two inks to find out all possibilities in order to improve the amount of ink used. The assessment focused on two main variables: the mixture weight of the ink (including recycled ink, original ink, and water volume); and the standard of print quality that can be achieved. Therefore, whether the test is successful or not depends on whether the following two requirements can be met: the consumption of the original ink must be less than the current consumption; the new mixed ink must reach the level of print quality standards.
The test method is to print inks with different specific gravities (recycled inks, original inks and water volumes), record the printing characteristics of various inks, and review the results according to the printing standards. After screening out mixed samples that meet the printing criteria, it is possible to find the best printing quality with the least amount of ink consumption. In the future, we will implement the daily printing process.
Set the standard
We need to set standards for testing and daily printing processes. The "original" ink used to mix ink must be less than what is currently consumed by ink. The quality can be measured by the field printing density. The higher the density, the better the printed ink coverage of the printed matter.
The ink density readings were read using a reflective spectrometer density instrument, and the ISO solid print density for non-coating offset and letterpress printing standards was 1.05 (ISO and classified in the newspaper flexo category). Therefore, the density of 1.05 is the required level for all successful test samples, which shows the best black effect. It makes a good contrast between fonts and halftones as well as gamut and dot.
As for the newspapers printed by Chattanooga, their density readings ranged from 0.98 to 1.18. In the past, whenever the density decreased during the printing process, the printing machine would tend to add more concentrated ink. Our test is about to determine whether this move is still the best way to increase ink density.
Daily printing process
In order to facilitate the presentation of the testing process, the following is a summary of the Chattanooga printing process. First, the original ink is pumped into the daily ink tank, mixed with fresh water in the ink tank, and/or recycled ink is used to prepare the ink. When needed, the mixed ink is pumped from the day tank to the second pipe loop in the printer. During printing, ink continues to wash the anilox roller through the fountain fountain. Printing will not only be sucked away, but can also be returned to the daily ink tank via a pipe loop.
“The density of recycled ink and original ink is not the same, and the gap cannot be expected. For the printing press, when the density is low, the original ink can act as a buffer, and the printing machine can also use recycling and printing with ink. Low-density prints."
After the printing is completed, the daily ink tank piping ring will be sealed and the cleaning circulation system will be activated to clean the printing press, anilox roll and ink tank. The water left after cleaning will be discharged to another holding tank (water tank) to make recycled ink. The recycling system sucks all the water left after cleaning into the filtration system every week. The role is to separate clean water, and use thick ink for recycling. After the recycling system completes the cleaning and separation process, the remaining recycled ink is then stored in the tank for mixing the materials used to prepare the ink.
Our study involved two pipeline systems. One of them is the printing machine's ink system, which is the bridge between the printing press and the daily ink tank to transport ink and clean the printing press; the other system is the daily ink in the ink room. Slot system. In the test, we see both systems as ink processing and conveying systems.
Each step performed by these systems requires a certain amount of ink consumption and changes in the amount of ink to meet the requirements of the next step and transport. For example, after the manufacturer ships the original ink, it is transported from the storage ink tank to the ink room to prepare the printing ink, which is then transported to the printer for use. The printer converts the ink into a sheet through an anilox roller and a squeegee, and finally transfers it to the printing plate and paper. For testing purposes, we will adjust or modify the system when needed.
The Chattanooga Times Free Press in Chattanooga, Tennessee, USA, conducted a study on how to use the ink's efficacy to the limit level. The ideal method is to reduce the consumption of ink while maintaining the printing standard. This reflects the right balance between cost, efficiency and quality.
The black ink that we received in the printing room was concentrated (ie, "raw" ink). Prior to the printing of newspapers, the printing ink must be filled with fresh water and sometimes added to the circulation and then diluted with ink to become ink. Printing presses generally use several hours to complete the printing of newspapers, followed by cleaning, and after a few hours, another printing process. It is not surprising that we clean the press twice or three times a day, four times, and the amount of water consumed is astonishing. At the same time, it means that the quality of water after cleaning has a large amount of recycled ink, which is only needed to remove the clean water and residues. A thick layer of recycled ink is used for immediate display, including some original ink. However, it is not enough for printing after diluting the recycling and printing ink, and only need to add additional original printing ink.
Chattanooga attempts to systematically evaluate the proportion of the original ink and the amount of recycled ink to obtain the most appropriate cost and print quality relationship. This is to be evaluated. Since most flexographic newspaper printing companies spend millions of dollars each year on printing ink, the printing method that can save the original printing ink will be a major discovery.
The above-mentioned assessment will not be too complicated. It is only by adjusting the proportions of the two inks to find out all possibilities in order to improve the amount of ink used. The assessment focused on two main variables: the mixture weight of the ink (including recycled ink, original ink, and water volume); and the standard of print quality that can be achieved. Therefore, whether the test is successful or not depends on whether the following two requirements can be met: the consumption of the original ink must be less than the current consumption; the new mixed ink must reach the level of print quality standards.
The test method is to print inks with different specific gravities (recycled inks, original inks and water volumes), record the printing characteristics of various inks, and review the results according to the printing standards. After screening out mixed samples that meet the printing criteria, it is possible to find the best printing quality with the least amount of ink consumption. In the future, we will implement the daily printing process.
Set the standard
We need to set standards for testing and daily printing processes. The "original" ink used to mix ink must be less than what is currently consumed by ink. The quality can be measured by the field printing density. The higher the density, the better the printed ink coverage of the printed matter.
The ink density readings were read using a reflective spectrometer density instrument, and the ISO solid print density for non-coating offset and letterpress printing standards was 1.05 (ISO and classified in the newspaper flexo category). Therefore, the density of 1.05 is the required level for all successful test samples, which shows the best black effect. It makes a good contrast between fonts and halftones as well as gamut and dot.
As for the newspapers printed by Chattanooga, their density readings ranged from 0.98 to 1.18. In the past, whenever the density decreased during the printing process, the printing machine would tend to add more concentrated ink. Our test is about to determine whether this move is still the best way to increase ink density.
Daily printing process
In order to facilitate the presentation of the testing process, the following is a summary of the Chattanooga printing process. First, the original ink is pumped into the daily ink tank, mixed with fresh water in the ink tank, and/or recycled ink is used to prepare the ink. When needed, the mixed ink is pumped from the day tank to the second pipe loop in the printer. During printing, ink continues to wash the anilox roller through the fountain fountain. Printing will not only be sucked away, but can also be returned to the daily ink tank via a pipe loop.
“The density of recycled ink and original ink is not the same, and the gap cannot be expected. For the printing press, when the density is low, the original ink can act as a buffer, and the printing machine can also use recycling and printing with ink. Low-density prints."
After the printing is completed, the daily ink tank piping ring will be sealed and the cleaning circulation system will be activated to clean the printing press, anilox roll and ink tank. The water left after cleaning will be discharged to another holding tank (water tank) to make recycled ink. The recycling system sucks all the water left after cleaning into the filtration system every week. The role is to separate clean water, and use thick ink for recycling. After the recycling system completes the cleaning and separation process, the remaining recycled ink is then stored in the tank for mixing the materials used to prepare the ink.
Our study involved two pipeline systems. One of them is the printing machine's ink system, which is the bridge between the printing press and the daily ink tank to transport ink and clean the printing press; the other system is the daily ink in the ink room. Slot system. In the test, we see both systems as ink processing and conveying systems.
Each step performed by these systems requires a certain amount of ink consumption and changes in the amount of ink to meet the requirements of the next step and transport. For example, after the manufacturer ships the original ink, it is transported from the storage ink tank to the ink room to prepare the printing ink, which is then transported to the printer for use. The printer converts the ink into a sheet through an anilox roller and a squeegee, and finally transfers it to the printing plate and paper. For testing purposes, we will adjust or modify the system when needed.
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