0 FOAMINK TECHR310GIES, 1991

AN E N V I R O N M E N T A L L Y F R I E N D L Y I N K

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FOREWORD

The FOAMINK Technologies Division of The CNF Corporation offers an environment a I I y friend 1 y a Iter n a t i ve to t ra d it i o n a I h yd roc a r b o n so I ve n t- b a s e d ink technology.

FOAMINK has developed an aqueous foamed i n k for use in the gravure and flexographic printing industries. The product, Rotofoam@, contains less than 0.5% volatile organic compounds (VOC), and is characterized by faster drying time, simple clean-up, and the use of less ink volume. Concentrated i n k and extenders can be diluted with conventional tap or press washLup water, and all ink wastes, if disposal is required, are non-hazardous. Existing presses , currently configured for solvent-based inks , require a minimum retrofit to accommodate foam generation equipment and containment.

Foamink@ printing quality, by comparison, is equal to tha t of other currently accepted ink processes; cos ts and hazards associated with conventional printing methods are reduced.

A growing world-wide consciousness toward the use of environmentally accepted manufacturing techniques, resulting products, and subsequent was te disposal processes ( " G R E E N " technology) create a distinct marketplace for FOAhllNK products and services.

FOAMINK Technologies facilities are headquartered in Exton, Pennsylvania with manufacturing a n d distribution centered in nearby West Chester.

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NOTICE: The informat ion contained herein is, t o the best of our knowledge, accurate. It represents general guidelines only, and users are cautioned t o mod i f y each instal lat ion as appropriate t o m e e t specif ic appl icat ions or environments. Because of this and because the condit ions of handiing and of use are beyond our control, LVS make n o guarantee of results and w e assume n o liabil i ty, or responsibi l i ty for loss, damages or penalt ies resulting from fol lowing our suggestions or recommendat ions. Users are also c a u t i m e d t h a t all applications m u s t conform w i t h applicable federal, state or local l aws or regulations which may supersede the procedures set for th “rein.

TABLE OF CONTENTS

SECTION 1. INTRODUCTION

1.0 General. 1 .1 Using this Guide. 1 ,1 I 1 The Format. 1.1.1.1 Paragraphs. 1 , I . I .2 Figures. 1 .1 .1.3 Tables. 1.1.1.4 Cross-references. 1 .1.1.5 Safety Information. 1.2 Further Inquiries.

SECTION 2. INK

2.0 General. 2 . 1 Standards 2.2 Handling. 2 .2.1 Ammonia Precaution. 2 . 2 . 2 Non-Flammability. 2 .2 .3 FreezingTThawiri;!. 2.2.4 Pumps, Hoses, and Piping. 2 .3 Color, Strength/lntensity. 2.3.1 Draw Downs Liquid/Foam. 2.3 .2 Extensions and Mixing. 2.4 Shading o f Colors. 2.5 Operation/Running. 2 .5 .1 Doctor Blade Setting. 2 .5 .2 Paper Web Feeding. 2 .5 I 3 Hot Cylinders. 2.5.4 Skipping. 2 .5 .5 Overexpansion/Underexpansion. 2.5 I 6 Viscosity. 2.5.7 Expansion Ratio. 2 . 5 . 8 Foam Stability. 2.5,9 Electrostatic Assist (E.S.A.).

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TABLE OF CONTENTS (Cont 'd)

SECTION 3 . E Q U I P M E N T

3.0 General. 3 . 1 Retrofit. 3 . 1 , l Lamellar Flow Preventer (LFP) Pre-wipe Blade and Holder. 3 . 1 - 2 Sealing Side PlatedShaft Seals. 3 . 1 . 3 Door and Sealing. 3 . 1 . 4 Doctor Blade Area Sealing. 3 . 1 . 4 . I Flexible Back. 3 . 1 . 4 . 2 Sliding Flexible Back Doctor Blade Seal. 3 . 1 . 5 False Bottom. 3 . 1 . 6 "P" Trap. 3 . 1 . 7 Sump/Reservoir Sump Pump. 3 . 1 . 8 Weekend Shutdown. 3 . 1 . 9 Cleaning Procedures. 3.1 -10 Maintenance. 3 . 2 Foam Generation. 3 . 2 . 1 Foam Generation Principles. 3 . 2 . 2 Typical Foam Generation Installation. 3 . 2 . 3 Foam Generation Flow Logic. 3 . 2 . 4 Foam Generator Operation. 3 . 2 . 4 . 1 Press-side Foamink Expansion Ratio Measurement. 3.2.4.2 Foam Generator Cleaning Procedures. 3.2.4.3 Foam Generator Maintenance. 3.3 Level Control. 3 . 3 . 1 Ultrasonic Level Control Principles. 3.4 FOAMINK Operation Set-up. 3 . 5 FOAMINK Equipment Cleaning Procedures. 3.6 FOAMINK Equipment Maintenance. 3 . 6 . 1 3 . 6 . 2 3.6.3 3.6.4 3 . 6 . 5 3 . 6 , 6

Mechanical Devices. Electrical Devices. Pneumatic and Hydraulic Devices. Sonic Devices. General. Troubleshooting.

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I . ' I Y

TABLE OF CONTENTS (Cont'd)

SECTION 4. CYLINDER PREPARATION

4.0 General. 4.1 Cutting Curve. 4.1.1 Cell Reduction. 4.1.2 Line Screen. 4.1.3 Stylus Angle. 4.1.4 Cell Configuration. 4.2 Proofing. 4.2.1 Proofing in Copper/SpeciaI Inks. 4.2.2 Yellow Cylinders. Suggested Starting Parameters for Helio

Klisc hograph K-202. 4.2.3 Cylinder Corrections. 4.2.4 Hot Cylinders.

SECTION 5. MAINTENANCE

5.0 General. 5.1 Preventive Maintenance. 5.2 General k4aintenanc.e. 5.3 Cleaning. 5.3.1 Importance of Cleaning. 5.3.2 Cleaning Solvents. 5.3.3 Cylinder Cleaning. 5.3.4 Press/Retrofit Equipment Cleaning 5.3.5 Foam Generator Cleaning.

SECTION 6. TROUBLESHOOTING

6.0 General

APPENDIX A. FOAMINKNENDOR EQUIPMENT INFORMATION ( i f required)

GLOSSARY OF TERMS

TABLE OF CONTENTS (Cont 'd)

LIST OF ILLUSTRATIONS

Figure 2-1 , Foam Structure Doctored into Cell/Lamella Figure 2-2 . Conventional Liquid Ink Cell Filling Figure 2-3. Typical Material Safety Data Sheet Figure 2-4. Hazardous Material Identification System (HMIS)

Label Figure 3 -1 , Replaceable Pan Retrofit Configuration Figure 3-2. Motter-type (deep fountain) Press Unit Retrofit Configuration Figure 3-3. Hoe-type Press Unit Retrofit Configuration Figure 3-4. Typical External Sump/Reservoir Configuration Figure 3-5 . Lamellar Flow Preventer (LFP) Pre-wipe Blade and

Holder Figure 3 -6 . Typical Flexible Back Doctor Blade Installation Figure 3-7. Typical Sliding Flexible Seal Doctor Blade

Installation Figure 3-8 . Typical Foam Generation Flow Diagram Figure 3-9. Typical Ultrasonic Level Sensor Installation

LIST OF TABLES

Table 5- 1 . Table 6-1 . Table 6-2. Print-Related Troubleshooting Procedures

Preventive Maintenance Requirements Foam-Related Troubleshooting Procedures

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. SECTION 1 INTRO D UCTlO M

7 .O GENERAL. This Guide provides information pertaining t o the features of FOAMINK materials, equipment, and principles. The foamed ink process is different f rom conventional liquid systems in that n e w habits should be developed and some old habits forgotten.

The objective of this Guide is to provide a comprehensive source of information a t the site of operatioii and to provide a continuing reference after a working knowledge of Foamink has been achieved.

Subjects include the following:

a. Characteristics, handling, and equipment associated with generating, containing, and recovering foamed ink (Section 2);

b . Type, design, use, and handling o f foamed ink retrofit, foam generating, and level controlling equipment (Section 3);

c. Specifics on cylinder pre;iaration, cutting curve, surface smoothness, and proofing (Section 4);

d . Procedures pertaining 'io the cleaning and general maintenance of fcamed ink equipment and press retrofit components (Section 5);

e . 1ndicato:-3, symp.roms, and malfunctions identified wi th foamed ink , e q u i ip rli e n t, press retrofit compo n e n ts a n d recommend e d troubleshooting. techniques/procedures (Section 6 ) ;

f. FOAMINK equipment maintenance documentation pertaining to a specifically configured equipment package (Appendix A ) ;

g. Additional related vendor documentation (Appendix A) .

'I .% USING THiS GUIDE. This Guide is intended t o give an overall knowledge of Focrinink and its use. I t is also designed for use as a continuing reference to FOAMINK technology.

Appendix A, if required, provides a stand-alone FOAMINK equipment rnaintenance section that describes all features specific t o a particular site installation, The appendix is supported by vendor documentation.

1-1

SECTION 1 INTRODUCTION

1 . I . I THE FORMAT. The devices used in this document t o provide information in a concise and organized manner include numbered paragraphs, figures, and tables, Each of these is given a numerical identity to ensure that no confusion emerges in the interaction of text, figures, and tabulated data. Each device is designed t o provide orderly information and effective, accurate cross-referencing.

1, 1. I . 1 PARAGRAPHS. Text is organized into numbered paragraphs (or groups of paragraphs) which contain specific information. Each paragraph number begins wi th a designated section number followed by subsequent numbers that imply indents (material provided that supports the main paragraph). An example would be this paragraph 1.1.1.1 , which provides details supporting the subject addressed in 1 -1 .1 . The following rules apply:

a. Only the first, or lead, paragraph in any group is numbered. Subsequent paragraphs within that group are not numbered Numbering begins again wi th the next group of paragraphs.

b. Paragraphs providing listed information are indented further and are designated with a lower case letter as this paragraph shows (a, b, c, e tc . ) .

c . Each section (1 through 6) uses the same format. However, the lead paragraphs in each section begin wi th respective section numbers.

d . Appendices also fol low the same format except that instead of a numerical classification, the lead paragraphs begin wi th a letter.

I . I . I .2 FIGURES. Each figure is identified by a specific number fol lowed by a dash number which is assigned, in order of appearance, for all subsequent figures (1-1, 1-2, 1-3, etc.). Figure numbers and titles appear centered at the bottom of each ar t page or area. Any figures provided in an appendix are lettered rather than numbered (A-1 , A-2) .

1 . I . I .3 TABLES. Tables are numbered and tit led precisely the same as .figures except that the titles (and numbers) appear a t the top of the tE5ulated data. Tables provided in an appendix a re lettered.

1-2

. INTRODUCTION SECTION 1

I . I .I .4 CROSS REFERENCES. Because no t w o paragraphs, figures, or tables have the same number (or let ter) designation, cross- referencing is simplified.

1.1.1.5 SAFETY INFORMATION. Various DANGER, WARNING, and CAUTION sianal words appear within the text t o alert personnel to a situation, or condition that may be dangerous or potentially dangerous t o personnel, equipment, or materials. Notes are provided t o augment existing tex t wi th additional helpful or clarifying information. Signal word selection is based on hazard classification.

The International Alert Symbol - signal word itself to gain and direct operating personnel attention to each signal word.

- is used in conjunction with the

Personnel operating and maintaining equipment must familiarize themselves with each o f the following signal words:

DANGER A signal word indicating an extremely hazardous situation which, if not avoided, will result in death or serious injury to the operator.

WARNING A signal word indicating a potentiallv hazardous situation which, if not avoided, could result in serious injury, or death t o the operator.

CAUTION A signal word indicating the following:

1, A potentially hazardous situation which, if not avoided, may result in minor or moderate injury;

2 . A potentially hazardous situation which, if not avoided, may damage or destroy equipment or cause a loss o f operating effectiveness;

3. Alert operating personnel t o unsafe practices.

NOTE highlighted to clarify or detail previcjus information.

A signal word indicating information which must be

SECTION 1 INTRODUCTION ' . 'I

_L

All signal words (except NOTE) will appear in procedural text BEFORE any directions are provided. This is to ensure that all personnel are.alerted before performing any tasks.

1.2 F U R T H E R INQUIRIES. Any inquiries as to FOAMINK technology or the use of this Guide should be addressed to:

Cu s to mer Service Depart ni e n t FOAM INK Technologies 150 Gordon Drive P.O. Box 270 Exton, PA 19341-1350

Phone: 21 5-363-6403 Fax: 21 5-692-7947

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t * . INK SECTION 2

2.0 GENERAL. Foamink is sold under the Registered Trade Name o f Rotofoama. Rotofoam is a dispersion foam in which the ink film provides all the same inherent quality, printed appearance and durability o f conventional printing ink wi thout any comparative drawbacks,

The ink is initially in liquid form until foamed at the press. It contains normal pigment/binder ingredients in addition to viscosity modifiers, foam stabilizers, foaming agents, and leveling agents. The solvents in Foamink are water and ammonia.

Ink concentrates are extended (before foaming), i f necessary, to accommodate specific printing requirements. This is accomplished through the use of extenders (ink composition without pigment) which are part of the system.

Foamink uses less ink than conventional ink formulas because of the foaming process. I t is introduced into the press fountain as foam, and the foam is applied to the gravure printing cylinder as non-homogenous bubbles then doctored to form a lamella (film) across the cell opening as shown in Figure 2-1, This ink-saving technique is contrasted to conventional liquid ink filled cell as .hewn in Figure 2-2. The foamed ink is then transferred to the substrate in ihe normal manner .

Foamink presents no special handling problems, and is less hazardous than comparable solvent inks (Paragraph 2.1). The inks should be stored a t room temperature. In the event Foamink is frozen, thawing wil l restore the ink t o s t a n d a r d q ua I i t y ( Pa r a g r a p h 2 . 2 . 3 ) .

Refer t o Figure 2-3 for copy o f Material Safety Data Sheet (MSDS) and Figure 2-4 for the Hazardous Material Identification System (HMIS) label that accompany each shipment of ink.

2.q STANDARDS. Foamink:

a. is Volatile Organic Compound (VOC) free (less than 1 %),

b. is non-flammable, Non-combustible (OSHA and DOT classification),

c. provides a low health hazard.

SECTION 2 INK 1 r l .

FOAM STRUCTURE

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D O C T O R BLADE

I N K L A M E L L A ( F I L M )

E N G R A V E D C Y L I N D E R

Figure 2-1. Foam Structure Doctored into Cell/Lamella

F L U I D I N K

E N G R A V E D C Y L I N D E R

Figure 2-2, Conventional Liquid Ink Cell Filling

2-2

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L SECTION 2 INK

Material Safety Data Sheet for

Section I I Manufacturers Name and Address: Emergency Telephone :

Fruunink Techdogies (215) 363-6403 150 G d n Drive P.0. Bar 2 70 Datc Prepared: 7/27/90 Ellon, PA 19341 -1350

Scri0.r 3 Scvcrc ......_._.-._.... 4

Tbe s@fz cbcrniul idcntilier and axraponding weight peranh of YMU: rubshnm involved i n the formulation of this produd arc comidcFed a pqniehry nadc =ret and are no( disclased on this MSDS. To comply wih Ibc back +md pmvisioos 31 &ling Community and Worker Rigbi-To-Knm laws, gcncnc chemical identities for some of the ingredients in &is product save b c c n provided. Lnformatioo about the spcif ic chcmiul ick.u!i!ics is available to attending health professionals in the cvcnf of a medical mcrgency. In 2 wn-cmcrgerq siruation, t ! h information is available to olher h u l l h professionals, employees or heir ksignrted rcpracntativa, 8s FEW~XX~ by the OSHA H m r d Cominuniution Standard, 29 CFR 1910.1#x) and I h c PA y o k c r and Community Right-Yo-Koow Arc

f ie PA Worker and Community Fu'phI-to-Kncw A d n q u i r a Lbc listing ofall ingdima wh'kh a p p r in tbc produn ai grakl than 3%. T b c follow'cg ir tbc Iut in order of riccruaing qwntiry:

*lWC cr*rk: JbcsJcol Identity Uater

Losin Ester Rain

LAOT Diarylide 'cllow Pigment X s # 1 1 3 6 - 2 1 4

t y W A c r y l i c d y m a

<:&HA OSHA ACCIR

None None None

Estab1 is bed E h M i s h c d Ertlblisbed

PEL S7.EL TLV

Figure 2-3. Material Safety Data Sheet (1 of 4)

2-3

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SECTION 2 INK

I Material Safety Data Sheet for

Sectjon II Ilnzardous Ingredients'Identity Informntion (Continued)

Ammonium Hydroxide 35 P W Aqua Ammonia CAS W 1336-214

Spcclflc/GeMrk Chcmlcal IdenUIy:

Ammonium Hydroxide Aqua Ammonia CAS W 1136-214

OSIU P E L

OSIM S I F L

ACGIII TLV

This produd mobins tbc following toxic chemicals subject lo r c p d o g rquiremcnls of Sedow 313 of be Emergency Planning and Community Righi-to-Know Act d 1986 and 40 CFR Pa5 372.

SpcclfldGenerlc C h e m l d IdenUty

OSILA

PEL ACGIII % BY TLV WElGNT

Ammonia 9 PPm 35 ppm 25ppm <1.W

CAS A, 77644 1-7

(From Ammonium Hydroxidc)

Section lII Physical Chemical Chamcteristics of P d u c t

PH 9.5 Spxilic Gravity 1 .M Solubility in Water DisFniblc Evaporation Rara(Buty1 Amtale = 1) <1

Vapor P r c u u ~ c N/D V a p r Dcarify N/D Boiling Poini N/D Melting Point N/A

A p p u n n a and Odor:

N/D denota Not Determined.

Yellow Opaquc Liquid, Ammoniaca l Odor

N/A deoorej Not Applicable.

Figure 2-3. Material Safety Data Shee t ( 2 of 4)

2-4

INK SECTION 2

Material Safety Data Sheet for

Section IV t'fenlth II& Dsltu Thu product is coosljercd mxic u p x i n p a t i o n due b rhc ammonium hydmxidc COoIcnL Avoid inhalation of v a p which an cons&rcd mxkn tc ly toxic (LDSO - loo0 pp& hn human). Irritation of cy-, skin, and mucous membranes u n occur.

M e d k l conditions gcncrally rggnvatd by erposurc: existing cyc or skin sensitivity may bc agjpvated by expasure.

Emcrgcocy Fin1 Aid P d u r n :

Skin colltacl: Flush skin w.16 scup and water for IS minutes. Apply hand C r u m b mtorc oib.

Eyes: Flush eyer immedirkly wilh copious amounts of water for 15 minutes. Contact physician if problcm pcnirk.

Conruou pcroon, l i m i k d cxpcure; rcmovc from contamilutod area.

Unconscious p c n o n ; apply artificial m p i n t i w i f nccesury and uy oxygen when breathing is restored. GI1 physician a t mcc.

lrrigitc nme and mouth lor 15 m i n u b and havc patient drink large amounb oC water if coosciws and ablc. Do no! induce vomiung. If weak or so! brathing apply artificial r ap inbon GI1 phyrician at ma.

Inhalation:

Ingcstioa:

Section V FIR and Explosion Ilazard Data

Flash Point N O X f i m m b k Limin Clcvcland Opcn Cup LFL NIA

UFL NfA

Extinguishing Media: If involved i n a fin from another caw, a spray or fog of watcr is c f f d v c in removing ihc gcneralcd ammonia gas from thc atmosphere.

Special Fire Fighting Proccdurc: la a b e circumsianm fireman should use selfcontained bntllhing apparahs, keep containers cool with wa& r b u m DT spray.

Unurual Fire and Explosion Hwrds: Nooe

Section VI Reactivity Data b b i l i t y : Unrtabk 0 Stable a 3onditions io Avoid: None

;ncomptibility; Materials to Avoid: C o d a coppcr, zinc rad tbcir alloys

Yazardow Polymctization: Kay occur 0 will not occur Ix]

Figure 2-3. Material Safety Data Sheet (3 of 4)

2-5

Material Safety Data Sheet for

Step to be Taken if Malerial ir Rckaacd OT Spilled: Contain spills, where pOaaiMc, to wold draining into wattr and w a g e ryalcnrr. C k a n up by UK: of t b rohcn t s . D k p l should bc in accoTddncc with State and Lmal regulations.

Waste Dispcal Method:

D L p l rbouM be in d n c c with Statc and Lncll regulations.

Section MI Precautions for W e Handling and Us

R a p i r a q Prowtion: b p i r a t o n with artridga nppmved for ammonia can be U s e d in a r e a where Lrge

concentrations OC ammonia may aocumulate.

Ven tiln tion: Mechanial ventilation, to outride, in arras where thir product k used.

Protective Clorhing: Rubber or PVC gloves rccomroeodaj

Eye Probtion: Safety gla-, goggles, or bcr shield

WorWHygcinic Pracricu: Avoid inhalation, ingcstion, or skin contad. Avoid mntact With eyes.

Figure 2-3 . Material Safety Data Sheet (4 of 4)

2-6

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SECTION 2 , .. I INK

EA

HAZARD RATINGS

Minimal. . . . . . . . . . . . . . . . . .O Slight ..................... 1 Moderate ............... .2 Serious., ................ .3 Severe.. . . . . . . . . . . . . . . . . . .4

Figure 2-4. Hazardous Material Identification System (HMIS) Label

2-7

SECTION 2 INK u

2.2 HANDLING. Foamink is easily handled. No inordinate precautions are necessary other than those required for the presence of ammonium hydroxide (ammonia) used in manufacture. Foamink is non-flammable, and associated equipment (necessary to contain and/or carry) requires no special considerations.

2.2. I AMMONIA PRECAUTION. Ammonia is a highly irritating chemical, which becomes apparent even in concentrations well below OSHA limits. Concentrated vapors should be avoided even though no long-term ill effects should result f rom exposure t o the ink products.

CAUTIO N

Ammonia odor will be encountered when opening sealed drums or wherever initial introduction to ambient air is achieved. Normal careful handling and ventilation wil l eliminate any hazard or discomfort. Foamink contains less than 1 .5% ammonia ( N H J .

NOTE

Actual ammonia levels in the press area are well below OSHA guideline l im i t s as documented in typical MSDS shown in Figure 2-3.

2.2.2 NOM-FLAMMABILITY, Foamink and its ingredients are non- flammable and require none of the precautions or special handling associated wi th this threat. Foamink is considered VOGfree (contains less than 1 % organic solvents).

NOTE

Foamink electrical devices can be designed to be intrinsically safe. This may be necessary if the devices are installed in close proximily t o flammable solvents.

2-8

i

* n SECTION 2 I N K

2.2.3 FREEZING/THAWING. Foamink is freeze-thaw stable, but as with any large mass, a full drum may take several days t o thaw completely from a fully frozen state. After thawing, full use may be made of the ink, and there wil l be no negative effect in appearance or application.

I t is advisable to store Foamink at room temperature and not allow product to freeze. Drum rupturing could occur.

2.2.4 PUMP§, HOSES, AND PIPING. Pumps, hoses, and piping that transport Foamink ingredients (liquid or foamed) need no special maintenance other than normal cleaning, preparation, and attachment. Piping is normally PVC or other plastic material in order to avoid any possibility of corrosion; stainless steel may also be used. Brass or copper should be avoided.

NOTE

It is not good practice to leave product in idle foam generation equipment for a period o f more than one shift (8 hours). Material should be removed, the system purged, and cleaned of residue i f no further use is intended,

2.3 COLOR, STRENGTM/INTENSITY. Inks are usually provided in high-pigment concentrations and should be extended t o accommodate the requirements of each job. Color intensity is controlled by the amount of extender added t o the ink formulation.

Extenders may also be provided as concentrates that can be reduced on-site w i th wa te r or press washes.

2.3.1 DRAW DOWNS LIQLJID/FUAM. Draw downs are performed on opaque velum papers using a Meyer bar (wire wound) and/or draw down knife to determine color strength and shade versus known standards.

2-9

> SECTION 2 INK

1

2.3.2 EXTENSIONS AND MIXING. Ink is extended through the use of _I-- -

special extenders which may add up to 60% of the total volume (60 parts extender, 40 parts ink) under normal situations. Extenders control the amount of color intensity obtained in printing.

NOTE

If any further extension (above 60%) is needed repeatedly, contact FOAMINK Technologies for a formulation check. High extensions are an indication of too much ink consumption, which can cause drying problems.

2.4- SHADING OF COLORS. This process takes place in the liquid phase before foaming.

CAUTION

Only FOAMINK toners should be used in color shading.

2.5 OPERATIBN/RUNNIMG. The items described in Paragraphs 2.5.1 through 2.5.9 are t o be considered during a "run".

2.5 . I DOCTOR BLADE SETTING. Proper doctor blade setting is essential and traverse mechanisms should be parallel and in good working condition. Minimal pressure should be required for good wipe and low blade wear .

NOTE

FOAMINK products are not abrasive and contain no clays or fi l lers.

2.5.2 PAPER WEB FEEDING. Special care should be taken when threading a new web into a press unit. The impression roll should not be allowed to run against the cylinder without the web in place. Failure to fol low this procedure wil l result in ink being transferred to the impression roller and an unnecessary wash-up of the roller. Cornstarch or anti-offset

,compound may be used sparingly on the roller if the unit must be engaged t o pull the web.

2-10

INK SECTION 2 1 - e

2.5.3 HOT CYLINDERS. Warm cylinders should not be taken directly f rom chrome plating tanks to the press. Cylinders should be cooled with cold tap water for five (5) minutes before being put into service. A hot cylinder will cause foamed ink to become tacky on the cylinder surface and be difficult to doctor and clean.

2.5.4 SKIPPING. Foamink must be applied to the cylinder in a manner tha t prevents the foam from moving away due to cylinder speed and the l ight foam density. If the ink does not apply properly, skipping (streaks of non-printed area) will result. This is prevented through the use of the lamellar f low preventer (LFP) pre-wipe blade which is installed below the ink level in the fountain. Refer t o paragraph 3.1.1 and Figure 3-5 for details,

2.5.5 OVEREXPAMSION/UMDEREXPANSION. After the ink is foamed by the generator, an expansion ratio of approximately 7:l (air t o l iquid) should exist; the press action wil l refine the expanded ink.

Too high an expansion ratio wil l result in the foam being too stiff to circulate properly in the fountain which may cause skipping. Severe overexpansion wi l l result in poor lubricating properties which may cause premature cylinder and doctor blade wear .

Too low an expansion ratio wil l produce a wet, heavy, non-economical printed product which wil l consume ink at an excessive rate. To avoid any o f these conditions, refer to Paragraph 2.5.7 and to the Troubleshooting Charts provided in Section 6, Tables 6 - l a n d 6-2.

2.5.6 VISCOS1TY. Viscosity, preset by FOAMINK, plays an important role in the ink fi lm that is t o be successfully transferred to the substrate. Foamink requires a pseudo-plastic or shear-thinning viscosity for proper application. These characteristics are controlled in formulation. Because of these factors, viscosity does not need constant monitoring.

NOTE

Viscosity control of extended ink should only be monitored through the use of a Brookfield viscometer; Zahn and Shell cup viscometers are not effective with the type of liquid viscosities used in this process. Viscosity specifications are available from FOAMINK.

2-1 1

SECTION 2 INK I . I

_- NOTE

It is acceptable to use a small amount of water t o reduce Foamink; however, the reduction should not exceed 5 % . If reduction is needed repeatedly, contact FOAMINK for a formulation check.

NOTE

Cylinder cell size, screen count, and whether a cylinder is chemically etched or electromechanically engraved, are important factors affecting viscosity requirements. In the event any of these change, contact FOAMINK for a formulation adjustment.

2.5.7 EXPANSION RATIO. Inks are formulated t o produce a foam with an expansion ratio (volume of air to volume of liquid) within a 6:l t o 8:l range. Inks will not ”grow” beyond these limits when subjected to the turbulence encountered in the press fountain with cylinders running at high speeds.

Proper foam making may require the periodic evaluation of the foam quality and necessitate the taking of samples from the sampling tube or from the fountain in order t o perform an expansion ratio measurement.

NOTE

Press experience enables the operator t o judge the expansion ratio visually wi th a great deal of accuracy

The expansion ratio measurement requires a laboratory balance or other small weighing device (a postal scale), an open-top container of about one quart capacity, and a spatula. The following steps should be followed in order to conduct a proper on-site expansion ratio measurement:

a. Weigh the empty container.

b. ’ Fill the container t o the top with water.

c . Weigh the water-filled container.

d. Record the weight of the water minus the container

2-1 2

1

. INK SECTION 2 . \ '

e. Empty the container.

f . Fill the container with foam taken from the sampling tube.

g, Level the foam wi th the spatula.

h. Weigh the foam-filled container.

i. Record the weight of the foam minus the container.

j . Divide the weight of the water by the weight o f the foam. The result is the expansion ratio which should be from 6 to 8 (6:l t o 8:l air volume to liquid volume).

Example:

450 grams (container filled with wa te r ) - 80 grams (weight of container)

- 370 grams (weight of water )

128 grams (foam leveled to top of container) - 80 grams (weight of container)

- 48 grams (weight of foam)

370 grams (weight of water) divided b y 48 grains (weight of foam)

= 7.7 (expansion ratio)

2.5.8 FOAM STABILITY, Foamink should remain semi-stable (expanded) for a period of twenty (20) minutes after a press shutdown a t wh ich time some foam collapse may hc apparent. This collapsed ink will be returned to the reservoir for refoaming. The ink is completely resoluble in itself and wil l attain immediate efiective printability (and foamability) when the system is reactivzted.

2-1 3

NOTE

The ink can be refoamed repeatedly because the agents used do not evaporate and are not consumed in the foaming process.

2.5.9 ELECTROSTATIC ASSIST (E.S.A.). Foamink print quality may be improved with E.S.A., and if fitted to the press, should be used whenever possible.

2-14

* ‘ I

3.0 GENERAL. Three primary types of equipment are utilized in a typical FOAMINK equipment installation. They are:

a. Retrofit eauiDment, a kit of parts t o be installed on an existing press to adapt it for foamed ink printing and includes provisions for recovering used material. This retrofit inventory replaces existing components , mod i f ies cur rent configurations, and/or adds parts.

Foam aeneration eau iment , the inventory of components necessary t o convert liquid-state ink into foamed ink. This equipment also transports the liquid from its reservoir and foamed ink to the press fountain.

b.

c. Level-control eauipment, the only inventory of press-side components electrically operated. This equipment is responsible for monitoring and maintaining foamed ink fountain levels.

NOTE

FOAMINK electrical dcvices can be designed io be intrinsically safe. This may be necessary i f the devices are installed in close proximity to flammable sotvents.

3.1 RETROFIT. In order to use Fuamink, a press mcst be modified t o accommodate higher ink levels and additional equipment necessary to deliver, prepare, and recover the ink. Three primary configurations typify an installation. These are:

a. The replaceable pan configuration, shown in Figure 3-1.

b. The Motter-type (deep fountain) press unit configuration, shown in Figure 3-2.

c. The Hoe-type press unit configuration, shown in Figure 3-3.

3-1

1 SECTION 3 EQUIPMENT '' I

&-- I, ,

PRI NTI NG CYLINDER

I REHOVAB LE

1 I NOTE: This assembly lowers and r a i s e s v i a press elevator.

Figure 3-1 , Replaceable Pan Retrofit Configuration

* EQUl PM ENT SECTION 3

REAR S I D E P L A T E

P R I N T I N G CYLINDER

DOCTOR BLADE

F L E X I B L E DOOR SEAL

AND EXHAUST

D O O R S I L L R A D I U S CORNER

ULTRASONIC LEVEL SEMSOR

INFLATABLE DOOR SEAL

PLATE

Figure 3-2. Motter-type (deep fountain) Press Unit Retrofit Configuration

3 -3

SECTION 3 EQUIPMENT I , .. *

/--

DOCTOR BLADE

S W I NG-UP BEARING HOLDER

PRIKTING

PRESS FOUNTAIN i'

,LFP BLADE

ULTRASONIC vy L E V E L SENSOR

CYLINDER SHAFT

DUST COVER (DOWN POSITION)

Figare 3-3. Hoe-type Press Unit Retrof i t Configuration

3-4

a * e

EQUIPMENT SECTION 3

..I

A typical external sump/reservoir that may be used with any o f the three retrofit configurations is shown in Figure 3-4. The usual inventory of equipment that may be required t o retrofit an existing press is as follows:

a. Lamellar Flow Preventer (LFP) Pre-wipe Blade and Holder,

b. Sealing Side Plates and/or Shaft Seals,

c . Door and Sealing arrangement,

d. Flexible Back,

e. False Bottom,

f . "P" Trap Foam/Liquid Separator,

g. Sump/Reservoir/Sump Pump.

NOTE

Because each facility installation is custom, not all retrofit equipment depicted is used.

Paragraphs 3.1.1 through 3.1.7 describe components used in a typical equipment inventory. .

3.7 . I LAMELLAR FLOW PREVENTER (LFP) PRE-WIPE BLADE AND HOLDER. This device, shown in Figure 3-5, is positioned below the level of foamed ink and is designed t o break up lamellar air f l ow that follows the rotating printing cylinder. Without this air disruption, the light density foam would be pushed away from the cylinder causing skipping or voids in printed work.

3.1.2 SEALING SIDE PLATES/SHAFT SEALS. Foamink operating ink levels (in most cases) require the raising of the level above that considered normal for conventional inks. This higher level can cause sealing problems which are solved through the use of side-sealing plates.

These plates cover the roll-in bearing channel against foam leakage (Figure 3-2, Motter-type retrof i t) , Shaft seals, fastened t o the press fountain or bearings to create a seal around the rotating cylinder shafts (Figures 3-1 and 3-3 ) , effect replaceable pan and Hoe-type retrofits.

3-5

EQUIPMENT . SECTION 3 I

LEVEL SENSOR

L I Q U I D FROM STORAGE

OAT-ACTIVATED

RZSERVOI R

G E N E R A T O R

Fig u re 3-4, Typic a I Extern a I S u m p/Res e r VJ i r C o n f i g u rat io n

[;SBAWll w& 3 -6

. . . - .,:..'A,..

DOCTOR BLADE P R I N T I N G CYLINDER

CONTACT P O S I T I O N

---- FOUNTAIN

ASSEMBLY _ c - - - _ - -

E X I S T I N G PRESS FOUNTAIN BOTTOM

CONTACT P O I N T

FALSE BOTTOM

Figure 3-5. Lamellar Flow Preventer (LFP) Pre-wipe Blade and Holder

3-7

' II SECTION 3 EQUIPMENT

*-- 3.1.3 DOOR AND SEALING. In press units using conventional inks, ?

the cylinder dip may be as little as one to t w o ( I t o 2 ) inches. With foamed ink, a larger cylinder dip is required, and may immerse f i f ty (50) percent of the cylinder, This higher level requires an increased ink-level accommodation. A special door, or similar sealing arrangement, may be manufactured and installed as part of the retrofit process.

With a replaceable pan type (Figure 3-11, a new deeper pan is made which may or may not require a door.

With a cylinder drop-in (Figure 3-3, Hoe-type), higher ink levels may be accommodated by using the existing design. If not, a permanent extension of the fountain front may be required. In rare cases, where the cylinder wi l l not clear this extension, a door wil l be needed.

With a cylinder roll-in (Figure 3-2, Motter-type), a retrofit door and seal is necessary, This replaces the existing door which is not constructed to contain fluids, i.e., foams.

The retrofit door consists of a skeleton (frame), an inner panel, an outer panel, an inflatable seal, hinge(s), and devices t o hold the door in place. In most cases, a contoured door sill will be needed. The inflatable seal, inflated to 20 psi press-side, is bonded inside a channel cut into the side and bottom edges of the door.

WARNING

Inflatable seals and door-locking devices are not t o be deflated/released unti l Foamink level is lowered below door sill.

To lower the door, the seal must be deflated (using a three-way valve) and locking devices must be released. The door may then be swung down to permit cylinder removal or installation.

NOTE

The inflatable seal is considered t o be a periodic replacement item. Refer t o Section 5 and Appendix A for further information .

3 -8

t . c

3.1.4 DOCTOR BLADE AREA SEALING. Two basic methods exist to seal the doctor blade area, if required. They are:

a. The flexible back,

b. The sliding flexible seal.

3.1.4.1 FLEXIBLE BACK. This device, shown in detail in Figure 3-6, is a flexible seal consisting of a thin sheet o f plastic or spring steel fastened t o the pan. The loose end fits into a channel o n the doctor blade holder or carriage. The doctor blade and channel slide o n the flexible back to allow efficient oscillation. A rubber edge is bonded to the edges o f the flexible back to complete the seal to the pan sides or press side frames.

NOTE

When lowering the doctor blade, care must be taken to ensure that the flexible back is properly seated into the channel t o avoid a potential leak.

NOTE

if cylinder size varies, the flexible back may have t o be replaced or positioned to accommodate the change, This is requiied to maintain a gentle curve in the seal t o avoid the poyential o f a leak. Refer t o Appendix A for more information.

3.1.4.2 SLIDING FLEXIBLE BACK DOCTOR BLADE SEAL. This configuration, shown in detail in Figure 3-7, calls for the use of the flexible back device (Paragraph 3.1.4.1) bu t alters its installation. In this case, the flexible back is attached to the doctor blade carriage by a linear bearing. This bearing allows the flexible back to remain stationary as the doctor blade assembly moves.

This method permits the seal to move with the doctor blade assembly when raising or lowering the blade. There is no need t o replace or reposition the blade when different cylinder sizes are used. This installation requires a mounting area on the doctor blade carriage and must be lubricated periodically. Refer t o Section 5.

3-9

SECTION 3 EQUIPMENT $ '

ri ' , r '

DOCTOR B L A D E C A R R I A G E

DOCTOR BLADE \ ASSEMBLY

\ PAN

Figure 3-6. Typical Flexible Back Doctor Blade Installation

3-10

.- i' i

EQUIPMENT SECTION 3

DOCTOR BLADE DOCTOR BLADE CARRIAGE

ASSEMBLY

CYLINDER

S E A L I N G BACK WITH L I N E A R B E A R I N G

------4

PAN

Figure 3-7. Typicei Sliding Flexible Seal Doctor Blade Installation

3-1 1

c

, ' I

SECTION 3 EQUIPMENT ,

3.1.5 FALSE BOTTOM. In some installations, an existing fountain may be modified by adding a false bottom. This is required when the existing containment design has too much volume. The false bottom reduces the volume and decreases the distance between the cylinder and the new fountain bottom. This feature ensures good foam circulation by the rotating cylinder thus reducing liquid drainage. Refer to Figure 3-5 for an example of this type of installation.

3.1.6 "P" TRAP. This retrofit device is installed between the fountain and the sump/reservoir to recover liquid ink by separating it f rom the resident foam. I t requires no power and operates through the use of simple physics. Refer to Figure 3-4.

3.1.7 SUMP/RESERVOIR SUMP PUMP. The existing circulating pump is not required and is removed as part of the retrofit process. Liquid ink can be supplied to the reservoir through the normal ink supply system. Piping may be changed t o PVC or stainless steel to prevent any rusting. The foam generator strainer and pick-up tube must be mounted into the reservoir along w i th the liquid return line and "P" trap. Refer to Figure 3-4.

Liquid ink is pumped through the foam generator where i t is foamed and introduced into the press fountain. Any liquid that drains f rom the foam will pass through the "P" trap back into the reservoir. When the liquid level in the reservoir becomes too low, a float switch (or similar device) activates the ink supply components to refill the reservoir.

3.1.8 WEEKEND SHUTDOWN. In the event the system is shut down for a prolonged period of time, the following practices should be ,observed:

a. Foam generation equipment subjected to idle periods exceeding one shift (8 hours) should be flushed with water or cleaning solution (See Paragraph 3.2.4.2).

b. The press irnit need not be cleaned out. Upon start-up, the Foamink will have redissolved in itself (even in cylinder cells) before register has been obtained. Unit will require cleaning if the color is being changed.

3.1.9 CLEANING PROCEDURES. Any cleanups found t o be needed, may be performed with the use o f diluted clear household ammonia. Refer to Paragraph 5.3.2 for cleaning solvents specifics.

:I

v SECTION 3 EQUIPMENT ' \

3. I. 10 MAINTENANCE. Retrofit equipment should be maintained and repaired in accordance with manufacturer information provided within the appendix portion of this document . Equipment or structural additions provided by FOAMINK Technologies shall be repaired and maintained in accordance wjth procedures and recommendations within t h e main body of t h i s manual as well a s in Appendix A.

3.2 FOAM GENERATION. Foam generation equipment transforms liquid ink into foamed ink. Various configurations are available depending upon specific application requirements; all information presented here is in general terms. Specific configurations used in this installation are offered, Appendix A.

in

Three primary topics must be addressed in order to provide a thorough understanding of the application of foarned ink to the printing function.

a . Foam generation principles

b. A typical foam generator installation

c . A typical foam generation logic flow

3.2.1 FOAM EENERATJON PRINCIPLES. After a specific retrofit has been completed, the press units are ready to receive foamed ink and begin printing. The production of foamed ink requires t he mixing of liquid aqueous ink and air through the use of air-driven equipment. Primary functions include:

a . A pumping function in which liquid ink is drawn from a reservoir, delivered to the foaming devices, and propelled a s foam to the press unit;

b . The use of normal press-side compressed air (70 psi minimum) that provides power to the equipment and air t o t h e foaming devices;

c . Valves that control air and ink proportions;

d . A mixing chamber that unites air and ink ;

e . A tubular foam-refining device (improver tube) that produces finished foamed ink;

3-1 3

SECTION 3 EQUIPMENT . I

P-- f . A delivery system comprising tubes, piping, and fixtures that

introduce the foamed ink into the press unit fountain; $

g. A recovery system in which liquid ink (below the foam level in the fountain) is returned to the foam generation equipment;

h. A foam level sensing system that maintains fountain foamed ink levels and actuates foam generation equipment, when required.

3.2.2 TYPICAL FOAM GENERATION INSTALLATION. A typical installation is depicted diagramatically in Figure 3-8. This example provides representations of the equipment that perform the functions given in paragraph 3.2.1. Typical components may be:

a. A pump which is the power unit that moves the liquid ink;

b . A filter/regulator that controls air flow;

c . Valves to regulate f low of air and liquid ink;

d. A mixing chamber that combines air and liquid ink;

e. An improver tube which produces the final foam consistency;

f. Pipes and fixtures designed to create the network through which air, liquid ink, and foam progress;

g. A skid (or cabinet) supporting foam generation components;

h. Panel and controls for actuating and contrclling all foam generating functions;

I. Related equipment necessary to support normal operations.

3.2.3 FOAM GENERATION FLOW LOGIC. A generalized flow diagram is provided in Figure 3-8. This graphic displays the sequential functions that comprise the foam generation process.

3-1 4

- . -_

P I C K

ON/OFF V A L V E

F I L T E R R E G U L A T O R

\ A I R L I N E O I L E R

A I R - O P E R A T E D D U A L 3 - W A Y

/ B A L L V A L V E A S S E M B L Y

P I C K - U P

STJU

-LIP T U B E

S T R A I N E R

vajv' HISI?(C F O U N T A I S PRESS \

. Y Y L

E ' f = / l r - L L E V E L D I A P H R A G M

M A K I N G FOAM

F I L T E R E EC U LATOR ON/OFF V A L V E

R E L I E F O F B A C K P R E S S U R E

B A L L V A L V E

T W E L I Q U I D

A I R / L I Q U I D PUHP

I H E R R E S ERVO 1 R a FOAH

SYSTEM O F F

Figure 3 - 8 . Typical Foam Generation Flow Diagram . -

5BANI J%wi%+W --

3-1 5

SECTION 3 EQUIPMENT ' , I

3.2.4 FOAM GENERATOR OPERATION. Operation of foam generating equipment is dependent upon the specifics of the installation. This is provided under separate cover within Appendix A . In all cases, regardless of installation, some typical tasks must be performed. These are:

F- C t.

a. Performing an occasional press-side expansion ratio measurement;

b. Cleaning and maintaining all equipment.

3.2.4.1 PRESS-SIDE FOAM//VK EXPANSION RATIO MEASUREMENT. In order to check expansion ratio of Foamink, it may be necessary to perform a press-side expansion ratio measurement. Refer t o Paragraph 2 .5 .7 for actual procedure.

NOTE

Press experience enables the operator to judge the expansion ratio visually wi:h a great deal of accuracy.

3.2.4.2 FOAM GENERATOR CLEANING PROCEDURES. The foam generator should be flushed of foamed ink in the event of a press shutdown that is expected to last more than one shift (8 hours). Clean-up is easy and requires only a few gallons of water.

3.2.4.3 FOAM GENERATOR MAINTENANCE. All foam generator components (removed from assembly) are to be maintained in accordance w i th documentation provided within Appendix A . All foam generator equipment in operation should be maintained in accordance wi th standard company equipment maintenance procedures.

3.3 LEVEL CONTROL. In the FOAMINK system, ink is not constantly recirculated. Liquid ink is pumped from the reservoir, foamed and introduced into the press fountain. The bulk of the foam remains in the press fountain until used. Any liquid that drains from the foamed ink, as it collapses, is returned to the reservoir for regeneration into foam.

The foam level can be monitored through the use of an ultrasonic device mounted or) a bracket a t the front of the press fountain, as shown in Figure 3-9. This device maintains the proper foam level by turning the foam generator on and of f .

3-1 6

LFP BLADE

Figure 3-9. Typical Ultrasonic Level Sensor Installation

3-1 7

1.

. , SECTION 3 EQUIPMENT ,

3.3.1 ULTRASONIC LEVEL CONTROL PRINCIPLES. The level 6- t. control device utilizes an ultrasonic principle in which sound waves are emitted and bounced off a distant object. The response time is measured t o determine the distance.

The level control operates o n this sonar principle t o control the level of foamed ink between high and low level set points. Regulation is provided through a sensor that controls a solenoid which, in turn, activates or deactivates the foam generator.

On and off levels are preset into the system, and both high and low level alarms are incorporated to warn press operators in the event levels reach critical points. Refer to Figure 3-9 and Appendix A for details.

3.4 FOAMINK OPERATION SET-UP. In order t o set up FOAMINK equipment, it is necessary to address the following:

a. Ink is provided from drums or stationary containers (tanks) as are extenders. The storage facility may be large or small depending upon the extent of Foamink use. A f e w drums t o a complete tank farm may be required, and the inter/intra network of conduits, level gauges, monitoring equipment, and supply devices may be extensive as in present liquid systems.

b. The principles governing the storage of liquid ink/extenders are simple. All materials and storage facilities may be those used for conventional wa te r systems.

NOTE

PVC and other plastics should be used as much as possible.

c . Ink/extender storage, recovery, and transport may be in close proximity to the printing machinery or considerably removed,

d. Normal plant compressed air (70 psi minimum) is required press-side and is supplied through convenient quick-disconnect fittings, unless installation is permanently piped.

3-1 8

‘EQUIPMENT SECTION 3

e. Electricity must be available to power the level controller. It is important t o note that all FOAMINK electrical equipment can be made intrinsically safe. This may be necessary if devices are installed in close proximity to flammable solvents.

3.5 FOAMINK EQUIPMENT CLEANING PROCEDURES. All foam generation components must be cleaned in accordance with procedures set forth in Paragraph 5.3. Peripheral equipment, supplied by vendors, is to be cleaned in accordance with procedures referenced in Appendix A. General cleaning procedures for support equipment not supplied by FOAMINK Technologies (or i ts vendors) must be performed in accordance wi th company guidelines.

NOTE

Water and a spray hose should be provided at each unit to facilitate easy cleanup.

3.6 FOAMINK EQUIPMENT MAINTENANCE. FOAMINK equipment falls into five classes: mechanical, electrical, pneumatic, hydraulic, and sonic. Each is maintained in a specific manner and requires one or all of t he fol lowing: oil/grease for lubrication and/or water/ammonia solution for cleaning. Periodic, inspections and tests may be required t o maintain all equipment in good working order. A preventive maintenance program must exist as well as a repair capabiliry to facilitate component replacement and/or overhaul of FOAMINK equ;pment. Refer t o Section 5, Table 5-1.

3.6.1 MECHANICAL DEVICE§. Mechanical devices fall into t w o groups, active and passive. Active mechanical devices comprise valves, doors, and other equipment which must be cycled in USE. Passive mechanical devices comprise all static containment, sealing, or structural items. Active mechanical devices require-lubrication and cleaning in order to remain functional. Passive mechanical devices require paint or other protective finishes, and/or periodic replacement such as seals.

3.6.2 ELECTRICAL DEVICES. Electrical devices require a certain minimum/maximum power input and must be maintained internally as well as externally, Wiring integrity must be checked and all connections must be secure, Paint and other materials that protect components must be in good condition.

.

3-1 9

SECTION 3 EQUIPMENT ' 7 I

3.6.3 PNEUMATIC AND HYDRAULIC DEVICES. Pneumatic and ,a-

hydraulic components must be free of deposits that may prevent or retard f low. Hoses should not be crimped. Fittings must not leak. Quick- disconnects must be checked for ease of use and complete sealing,

,

3 .6 .4 SONIC DEVICES. Sonic devices (level controller) must be tested and/or inspected periodically to ensure proper operation.

3.6.5 GENERAL. All repairs must be performed in accordance with vendor recommendations/requirements provided in Appendix A. Preventive maintenance schedules must be observed and required tasks and inspections performed. Specific installation configurations, not addressed within this document or provided within supplied vendor materiai, must be maintained in accordance with company policies and procedures.

3.6.6 TROUBLESHOOTING. Troubleshooting procedures (at assembly level) are to be performed in accordance to procedures provided in Tables 6- I and 6-2. At component level, consult Appendix A documentation.

3-20

CYLINDER PREPARATION SECTION 4 4 . . j *

4.0 GENERAL. The following data applies t o YELLOW cylinder use only. On non-coated and super-calendered stocks for the Sunday Supplement market. The engraver used in this sample is a Helio-Klishchograph K-202.

SPECIAL NOTE

All recommendations are to be used as guidelines only and are to serve as starting points f rom which t o work.

Cylinder preparation for Foamink usage varies from conventional solvent ink applications:

a. Surface smoothness is critical, and any roughness over 0.5 microns will trap ink. As the ink is highly pigmented, this trapped ink will transfer to the web, as scum or haze. The cylinder is not to be sanded as part of the finishing process.

b. Cylinder must be chrome-plated and polished.

c. Chrome must be continuous and not contain cracks or "crows- feet " .

d. Cell configurations may need to be adjusted; experience with yellow has been with a compressed cell or zero (0) screen angle. This is recommended for all yellow work.

4.1 CUTTING CURVE. The statistical curve representing color density t o cell size, the cutt ing curve, is an important modification in foamink cylinder preparation. Foamink, as with most water systems, has different transfer properties from solvent inks. This requires a slightly different cutt ing curve.

4.1 . I CELL REDUCTION. Cells may be shallower and smaller in cylinders prepared for foamed ink application.

4.1.2 LINE SCREEN. A line screen of 175 line or finer is recommended. Unlike conventional inks run on cylinders prepared with fine screens, no snowflaking will be evident.

4.1.3 STYLUS ANGLE, A diamond stylus angle of 130-140 degrees is recommended.

SECTION 4 CYLINDERPREPARATION / :’ 1

a’-- 4.7.4 CELL CONFIGURATION. A compressed or zero (0) screen angle t, cell is recommended for best smoothness and ink usage for yellow.

4.2 PROOFING. This is an important phase of cylinder preparation. The fol lowing printing functions are assessed:

a, initial Proof:

I . Color quality

- Balance

Uniformity

Color density

2. Color separation

3 . Register from color to color

4. Defects

b. Reproof:

1 . Match to original color copy

2. Recheck of register, layout and imposition

3. Panel uniformity

4. Proper ink lay

NOTE

Gray scale evaluation may be performed during proofing,

With aqy proofing, impression, doctor blade angle, and ink extension must be controlled.

CYLINDER PREPARATION SECTION 4 i . 6 .

4.2.1 PROOFING IN COPPER/SPECIAL INKS. Proofing may be performed using copper surfaced cylinders provided special FOAMINK supplied proofing inks are used. Production application still must be performed using chromed cylinders.

CA UTI 0 N

S t a n d a rd Fo amin k a p p I i c a t i o n s w i I I c o r r o d e c o p p e r cylinders.

NOTE

Before proofing or installing cylinder in the production press, clean all grease and oils from cylinder surface with an approved solvent; wipe dry. Foamink is a 100% water based product and will not dissolve this residual grease. Print quality wil l be affected i f the oils are not removed.

4.2.2 YELLOW CYLINDERS. SUGGESTED STARTING PARAMETERS FOR HELIO-KLISCHOGRAPH K-202: The following parameters are recommended for a properly prepared cylinder:

NOTE

Alignment of the burr cutter is important. Proper burr cutter function will produce a cylinder thai needs no further finishing. Do not sandpaper cylinder.

a. Diamond angle - 130-1 40 degrees

b. Cell sizes - highlight 35, shadow 156 (max use 177)

c. Compressed cells; zero (0) screen angle

d. 70 Raster reduced 10%

e. A step-wedge graduation scale wi th 11 steps

4-3

SECTION 4 CYLINDER PREPARATION .t

4.2.3 CYLINDER CORRECTION. Cylinders for use with Foamink are t o be corrected in the normal manner. I f color density needs t o be increased, c f-

h re-etch copper in conventional way. Lacquering should be done using only Red Stop-off (STAN-CHEM) 66x-2866 or equivalent. This lacquer will not be affected by Foamink.

CAUTION

Etching through chrome is not acceptable, as it will expose copper to the ink solution.

4.2.4 HOT CYLINDERS. Warm cylinders should not be taken directly f rom chrome plating tanks t o the press. They should be cooled with cold tap wa te r for five (5 ) minutes before being put into service. A hot cylinder wil l cause Foamink t o become tacky on the surface and diff icult to doctor and clean.

4-4

5.0 GENERAL. Three types of maintenance must be performed on FOAMINK equipment.

a. Preventive maintenance - (scheduled maintenance) is the periodic maintenance and inspections to be performed on equipment to prevent malfunctions and breakdowns.

General maintenance - (unscheduled maintenance) is the removal and subsequent repair, replacement, adjustment, alignment of components in the event of a malfunction or breakdown.

b.

C. Cleaninq - is the maintaining of reliable operation through scheduled and unscheduled cleaning of components and systems I

and

5.1 PREVENTIVE MAINTENANCE. Scheduled maintenance performed on a typical FOAMINK installation is to be performed in accordance with specifics set forth in Table 5-1, Detailed preventive maintenance is to be performed in accordance with specific FOAMINK information provided in Appendix A. Scheduled inspections are as follows:

a. Perform visual inspection of al l seals and fittings for leaks or tears before startup; a t least once during prolonged operation; and a t shutdawn. This includes air, liquid ink, foamed ink, and recovered product.

b. Perform visual inspection of all containers, reservoirs, fountains, and sumps for leaks before startup; a t least once during prolonged operation; and a t shutdown. This includes liquid ink, foamed ink, and recovered product. Inspect all filters.

c, Perform visual inspection of all hoses and valves for leaks before startup; a t least once during prolonged operation; and a t shutdown. This includes air, liquid ink, foamed ink, and recovered product.

d . Perform visual inspection of f i l ter regulator gauge to confirm operatir-ig pressure a t startup.

e . Perform visual inspection of al l mechanical devices a t leas t once during prolonged operation.

5-1

1 ; t SECTION 5 MAINTENANCE

f .

4.

h .

i.

j .

Perform visual inspection of al l electrical wiring, junction boxes, and connections for irregularities before startup and a t shutdown.

Perform visual and physical inspection of all mounting points o f hardware. This includes nuts, bolts, brackets, and stand-offs.

Perform visual inspection of al l painted and protected surfaces to ensure integrity.

Perform visual inspection of foamed ink process t o ensure proper operation.

Perform visual inspection of all interfacing systems that support the foamed ink process. This includes electrical, mechanical, pneumatic, and hydraulic devices and systems.

5.2 GENERAL MAINTENANCE. Maintenance should be performed on all FOAMINK equipment in accordance with the FOAMINK documentation designed specifically for this installation and the supporting vendor manufacturer manuals in Appendix A. Documentation should be consulted in the following order:

1. A GUIDE TO FO.AMINK for general parameters for operation and maintenance.

2 . The FOAMINK information addressing the component and unit operationlmaintenance specific to an installation (Appendix A ) .

3 . Manufacturer's manuals specific to a component addressed in the FOAMINK information and referenced in Appendix A.

NOTE

Components removed from a FOAMINK installation are t o be rebuilt in accordance with manufacturer's recommendations; returned to FOAMINK; disposed of in accordance wi th company policies (if not t o be rebuilt or reconditioned); or returned to manufacturer.

5-2

Jbricate valves. As needed. Replace hoses . As needed. Clean s u m p filter.

Perform specific tasks In compliance. See Appendix A. according to installation.

Visually check for leaks. Daily. Check normal press As needed.

Daily or as needed.

' - ' I

-_ functions.

Check Nipco rollers for Daily. See Caution. leaks, -.

MAINTENANCE SECTION 5

As required.

Table 5-1. Preventive Maintenance Requirements

See Appendix A. See

Task

- I -

4s needed or if low foam dolume is evident from foam

Lubricate components.

Off-line task , Add oil t o airline lubricators. Replace improver tube packing.

~. .

4s required. Wear indicated. Potential

-ubricate door seal. 3eplace door seal.

See Appendix A .

.ubricate sliding seal ( i f tpplicable) ieplace cylinder shaf t seal.

eplace LFP blade

Time

Wear indicated. Potential leak indicated (wet ) . As needed, if skipping becomes evident, or if wear

Re marks

Note 1 and Note 2.

Dailv.

Jenerator. I

sak indicated (wet) . Iaily. ( i f required)

1 is indicated.

CA UTI 0 N

NIPCO fluids that leak into the fountain can overexpand the foam and destroy print quality.

NOTE 1

Normal press greases will not be affected by FOAMINK products and may be used for general lubrication.

5-3

* MAINTENANCE .(

j , ’

SECTION 5

NOTE 2

These greases should not come in contact with any part o f the cylinder surface. Greases are not water soluble and will affect print quality.

5.3 CLEANING. Cleaning of equipment after use and at periodic intervals is essential as a preventive maintenance measure and as a good housekeeping habit. Even though Foamink will dissolve in itself and will become completely usable almost immediately, equipment should be cleaned if a shutdown is expected to be prolonged, Any projected period of non-use of equipment should signal a complete cleaning o f all components.

NOTE

Foam generation equipment should be flushed if a shutdown is expected to last longer than one shif t (8 hours).

5.3.1 IMPORTANCE OF CLEANING. The process of cleaning equipment is the most important preventive maintenance task t o be performed. This task eliminates unnecessary stress on components and reduces potential downtime d u e to breakdown.

NOTE

Cleaning is easily accomplished and should be performed regularly.

5.3.2 CLEANING SOLVENTS. No cleaning solvents other than water or cleaning solution are used wi th Foamink. A water spray hose should be provided for each unit for cleanup.

Cleaning solution can be made by diluting t w o (2) gallons o f household ammonia in f i f ty (50) gallons of water.

NOTE

Cleaning solution is environmentally safe. Dispose of waste cl3aning solution in accordance wi th company w a s t e materials policies and procedures.

5-4

-. 5.3.3 CYLINDER CLEANING. If necessary, wipe down cylinder surface with cleaning solution. In the event, the cylinder is still wet with foamed ink, only water will be required. Use appropriate solvent to clean grease and oil from the cylinder face.

5.3.4 PRESS/RETROFIT EQUIPMENT CLEANING. Retrofit equipment may be cleaned with plain water and/or a cleaning solution. See Paragraph 5.3.2.

5.3.5 FOAM GENERATOR CLEANING. FOAMINK foam generating equipment is to be cleaned in accordance with procedures provided in Appendix A.

. 5-5

6.0 GENERAL. Malfunctions must be diagnosed and remedied to decrease any lost production time. Table 6-1 contains the most probable causes of foam-related problems. Table 6-2 contains the most probable causes of print-related problems. The remedy for each problem is also provided.

Table 6-1. Foam-Related General Troubleshooting Procedures

Malfunctionlindication

Foam too stiff.

Foam wet and heavy. (liquid)

No foam ink flow from generator.

Probable Cause

Expansion ratio too high.

Ink contamination.

Leaking NIPCO roller. Expansion ratio too low.

Foam generator failure.

Ink contamination. Failed air supply.

Level sensor failure.

Valve failure.

Pump failure.

Plugged improver tube.

Plugged pick-up tube or strainer.

Crimped or restricted hose.

Remedy

Reduce air f low a t foam generator.

Replace ink.

Replace NIPCO seal and ink. Increase air f low at foam generator.

Flush foam generator with cleaning solution.

Replace improver tube. Repack off-line.

Replace ink. Restore air pressure.

Review Operator’s Manual and check level sensor.

Clean sensor and splash shield.

Replace level sensor.

Replace faulty valve.

Replace pump.

Replace tube. Repack off-line.

Clean or replace.

Straighten or replace.

(Continued on next, page)

6-1

-1

I SECTION 6 TROUBLESHOOTING

Probable Cause

Same as "No foam ink f low from generator". Low air pressure.

Restricted pick-up tube or strainer.

Crimped or restricted hose.

Partially closed valves.

Partially plugged improver tube.

Pump failure. Float switch failure.

Empty tank.

Supply pump failure.

Faulty valve. Low or no air pressure.

Puncture in seal. Puncture in seal.

Remedy Malfunctionlindication

Low press fountain ink level. Reduced foam flow.

Loss of ink supply at reservoir.

Door seal. ( foam leaking)

Door seal not inflating. (air leakage) Loss of air supply.

Press fountain leak.

Filter regulator failure

Ruptured air line.

Quick disconnect failure.

Air compressor failure. Seal failure.

Check air pressure set at 70 psi min.

Replace or clean.

Straighten or replace.

Check valves for setting

Replace if faulty

Replace tube. Repack off-line.

Replace pump. Replace switch.

Refill.

Replace pump.

Replace valve. Check air pressure.

Replace seal. Replace seal.

Replace filter regulator.

Replace line.

Replace fitting.

Reoair air comDressor Replace seal.

(Cont inued on next D a w )

6-2

,

Table 6-1. Foam-related General Troubleshooting Procedures (Cont'd)

Malfunctionlindication

Press fountain overflow.

&amink level too high or too low.

Abrasion.

Probable Cause

Level of foam too high.

Level sensor failure.

Excessive foam growth. (Contamination of ink.)

Level sensor failure.

Table 6-2. Print-Related General Troubleshooting Procedures

Problem

Bleeding.

Remedy

Change high level setting on sensor. .

Operate system manually.

Replace sensor.

Check foam generator for l ow expansion. (Replace contaminated ink.) Operate system manually.

Check level sensor setting.

Clean level sensor and splash shield.

Replace level sensor.

Indicator

Cylinder wear.

A color bleeds into another on printed substrate.

Probable Cause

No doctor blade movemen (oscillation)

Doctor blade wear

Poor chrome. (Dull or cracks)

Ink contamination. Ink not drying.

Insufficient air f low.

Incompatible inks.

Remedy

Adjust doctor blade.

Replace doctor blade.

Rechrome.

Replace ink. Correct heat and/or air f low.

Turn on or increase air f low.

Reformulate (contact FOAMINK).

(Continued next DaQe)

6-3

SECTION 6 TROUBLESHOOTING I

Table 6-2. Print-Related General Troubleshooting Procedures (Cont 'd)

Problem

Cobwebs.

Crawling.

3locking.

Doughnuts.

Drying-in,

indicator

FYI my , web - I i ke build-up on doctor blade, impression roller & press frame.

Poor ink lay.

Adhesion exirrs between surfaces.

Prints only circumference of screen dot.

This is not a problem with ROTOFOAM 0

Probable cause

Air drafts at nip.

Dried ink.

Slow press speed.

Doctor blade birdmouthing.

Poor wipe (worn blade)

Too much impression.

Low ink viscosity.

Ink application too high. (cylinder etch too deep.)

Coated paper used with Group One ink. Improper drying.

Web rewound too warm.

Excessive pressure in rewind. Cylinder.

Surface tension too high.

Viscosity too high

Remedy

Correct excessive air f low from dryer cover.

Check ovens for down draft on cylinder. Increase speed.

Reduce doctor blade pressure.

Replace doctor blade,

Change angle of blade.

Adjust pressure.

Replace ink.

Re-etch or lacquer cylinder.

Replace with Group Five ink. Increase drying.

Decrease oven temperature.

Reduce tension.

Re-etch cylinder.

Replace ink.

Reduce ink viscosity. See Paragraph 2.5.6 (NOTES)

(Continued next page)

e

Tab le 6 - 2. Print -Re1 a ted Genera I Troubleshooting Procedures (Con t’ d )

I Print not smooth.

Problem

Grainy print.

Haze.

Pick-off

>in holes. :snow flaking)

’icking in nulticolor NOrk.

Indicator

Scum on unprinted area.

Build up of ink in hig solid areas on first UI

roll.

Appearance of small holes in printed area.

Previous ink picks ofi sheet or on roller.

Probable Cause

Press too slow.

Rough paper.

Cvlinder Poor wipe.

Slight roughness to cylinder.

Poor chrome. Too much ink on web.

ink not drying.

High humidity in press room. Imperfection in stock,

1 st-down ink drying too slow.

Bad wipe.

Remedy ~

Increase speed.

Increase impression.

Vary temperature of stock.

Re-etch cylinder, Check blade for dirt or paper.

Lower blade pressure.

Replace blade.

Polish cylinder. See Section 4.. “Cylinder Preparation”

Rechrome. Re-etch cylinder or lacquer.

Increase drying.

Slow press s p e d .

Adjust blade angle.

Increase impression.

Change stock.

Check electrostaiic assist function. Increase drying on 1 st-down ink.

Adjust doctor blade.

!Con tinu ed next p a g e )

6-5

Table 6-2. Print-Related General Troubleshooting Procedures (Cont'd)

Problem

Railroads.

Skipping.

Intermittent skipping.

Indicator

Continuous line showing in unprinted area.

Areas of cylinder not printing.

Areas of cylinder not printing during or shortly after generator has cycled.

Probable Cause

Blade scratches.

Doctor blade trapping foreign particles.

Cylinder high spots or chrome deposits.

Scratched cylinder.

Foam level is too l ow

LFP blade out of adjustment.

Foam expansion is too high.

Grease on cylinder. Air blow-by from generator becoming trapped behind LFP blade and doctor blade.

Remedy

Replace blade.

Clean blade.

Remove burr and polish cylinder.

Polish, fill or remake cylinder. Increase level.

Adjust blade.

Replace ink. See Table 6.1 "Foam Too Stiff."

Clean cylinder. Lower expansion setting on generator.

Check position of foam discharge hose in press fountain.

Replace improver tube. ReDack off-line.

6-6

I

1 -

1 . ’ GLOSSARY OF TER

The fol lowing is an alphabetical compilation o f terms appropriate to general printing and Foamink application.

AGE STABILITY - A test performed by FOAMINK t o accelerate the age of the ink product t o determine shelf-life expectancy.

ANILOX - A fully engraved cylinder (roller) that applies ink.

BLOW-BY - A volume o f air that passes through the foam generator without being incorporated into foam. This can be caused by too much air entering the mixing chamber or a partially plugged improver tube.

BROOKFIELD VISCOMETER - An electrical device used to measure viscosity using a rotating spindle. This device allows some evaluation o f pseudoplasticity and thixotropy. Also see NEWTONIAN, PSEUDOPLASTIC, RHEOLOGY, THIXOTROPY, VISCOSITY.

COBWEBS - A filmy web-like build up of dried ink which sometimes can be found on doctor blade, impression roll or press frame.

COVERAGE - Usually refers to the amount of ink or color covering any specific area.

CRAWLING - Poor lay of ink on substrate. The inability to wet substrate evenly.

CROWS FEET - Random surface cracks found on poorly chromed cylinders.

CUTTING CURVE - A curve representing color density to cell size; mechanical engraving machine settings.

CUTOFF - Indicates the place a t which the stock is to be or has been cut off after printing. Also refers to cylinder circumference.

CYLINDER - Round, cylindrical, copper-faced and/or chromed roller which carries etched image on the printing press, revolving to print on the moving web o f paper,

DEFINITION - Commonly referred t o as the degree of sharpness in a negative or print.

DESIGN - A sketch or pian of copy to be printed - the arrangement of details which make up a work of ar t .

GLOSSARY OF TERMS-I

GLOSSARY OF TERMS GLOSSARY OF TERMS ' * I

DENSITOMETER - A device that shines a focused light on a printed sample and measures the amount of reflected light under specific conditions. e+--

e DENSITY - A numerical measurement of color strength.

DISPERSION FOAM - A foam created by the mixing of air (gas) and liquid through the use of a mechanical device.

DOCTOR BLADE - Thin flexible blade that contacts the printing surface o f the cylinder, wiping of f excess ink before cylinder impression is made with the paper.

DOUGHNUT - When only the circumference of the screen dot is transferred to the stock.

DRAINAGE TIME - A test for foam stability, resistance to foam collapse. The results are expressed in the time (minutes) it takes for the first drop of liquid to drain f rom a foam mass.

EXPANSION RATIO - Ratio of air t o liquid ink by volume; recommended ratio 6: l t o 8:l for Foamink.

EXTENDER - Ink components wi thout color, usually resin, solvent (water) and modifiers (waxes, levelling agent, etc.). Extenders are liquids that are mixed wi th inks to reduce color strength. Foamed ink extenders do not contain clay fillers.

FOAM - A mixture of air and liquid.

FOAM CONTROL AGENT - A modifying additive used to control foam growth in the press unit.

FOAM GENERATOR - Assembly composed of pump module and nozzle assembly; used to generate Foamink.

FOAMING AGENT - Chemical used to produce foaming into Foamink formula.

FORM - Multiple pages set up t o represent layout of one or more cylinders. They conform to press imposition, permitting accurate cut-offs and folds for proper delivery and binding.

GLOSSARY OF TERMS-2

.GLOSSARY OF TERMS GLOSSARY OF TERMS

FREEZERHAW STABILITY - A tes t performed by FOAMINK t o determine the ability o f an ink system to undergo freezing and thawing cycles. Three full cycles are considered satisfactory without causing a change in performance.

t I '

HAZE - An appearance of scum (color) on unetched areas of cylinder, Can be transferred to the web as a background tone.

HELIO-KLISCHOGRAPH - A high speed engraving machine that cuts cells in the copper stage o f a cylinder using a diamond stylus. The information input that controls the engraving heads can be either film or digital.

IMPRESSION ROLLER - A rubber-coated roller on a printing press which presses the moving web or sheet of paper against the cylinder t o create a print on the paper.

IMPROVER TUBE - A tube used in foam generation that refines the foam t o its final consistency.

INTAGLIO - Printing through the use of incised or sunken areas in the plate (etched or engraved) surface.

LAMELLAR FLOW PREVENTER (1J-P) BLADE - Thin flexible blade used t o remove air layer f rom rotating cylinder.

LAMELLA - A film or meniscus; the film produced across cylinder cells by a doctor blade in foamed ink printing.

LEVELING AGENT - A chemical to aid ink f low on the printed surface during ink transfer.

MENISCUS - Curved (up or down) interface between liquid surface and adjacent container side. Also see LAMELLA.

MIDDLE TONES - Tones or color values that fall between highlights and shadows. Usually represent 30% t o 7 5 % values of color.

MIXING CHAMBER - Foam generating equipment component where air and liquid are combined.

MOIRE - An undesirable checker-board or plaid effect caused by the improper relationship of the screen angles used on the various single-color positives that make up the four-color print.

GLOSSARY OF TERMS-3

MONOTONE - Black and white copy or its photographic counterparts. Refers t o a single color reproduction of any type of art work. The monotone portion of a publication is that part which is reproduced in one color only.

MULTICOLOR - More than one color.

NEWSPRINT - A grade of paper containing about 85% groundwood and 15% unbleached sulfite. These proportions vary somewhat among different manufacturers, however. Usually between 30 and 34 Ib. and has coarse and often absorbent finish or surface.

NEWTONIAN LIQUID - A fluid whose viscosity does not change as the force of agitation (shear) changes. Viscosity is the same regardless o f shear rate. Also see PSEUDOPLASTIC, RHEOLOGY, THIXOTROPY, VISCOSITY,

jd-J - A measure of the amount of acidity or alkalinity o f a substance, pH - 7 is neutral, below 7 is acid, above 7 is alkaline or basic.

PICKING - Imperfection in print with noticeable areas wi th no ink. Also see SN 0 WFLAKl N G .

PICK-UP TUBE/STRAINER - A strainer mounted on a flexible tube found in the press-side reservoir. Used t o draw ink into foam generator.

PLATE - A general term x e d to describe a number of items o f the Gravure and other Graphic Arts processes, including negatives, positives, copper etchings, etc. For example: The Red Plate may describe the Red Positive or Red Copper Etching and so on,

PRIMARY COLORS - Four colors used in process printing to reproduce the full range of color. They are yellow, red (magenta) blue (cyan) and black (key). Each plate or cylinder deposits a single color t o be overlayed successively t o obtain the desired print.

PSEUDOPLASTIC - A fluid whose viscosity decreases instantly as the force of agitation (shear) increases, but regains viscosity instantly after force (shear) is removed. Shear thinning. Also see NEWTONIAN, RHEOLOGY, THIXOTROPY, VISCOSITY.

RAILROADS - A continuous printed line running in the direction of cylinder rotation, Sources may include nicks in, or foreign matter under the doctor blade or a scratched cylinder.

GLOSSARY OF T E R M S 4

for 200 line.

REGISTER - a term used to describe the fit of one color t o another, or of one positive or negative to another carrying the same image.

RETROFIT KIT - Components installed in existing presses t o accommodate Foamink production and distribution.

RHEOLOGY - The study of viscosity versus shear rate (force of agitation). Also see NEWTONIAN, PSEUDOPLASTIC, THIXOTROPY, VISCOSITY.

SCANNERS - Electronic instruments used t o make color negatives or positives.

SCREEN - Crossed fine lines used to convert a continuous tone image into a screened image suitable for etching and printing. The number o f lines per inch varies considerably dependent o n the reproduction process or the stock t o be printed on.

SEPARATION - Breakdown of colors in a piece of copy into primary printing colors or special colors.

SHADOW - Area of copy or printed matter in which little or no light is desired, hence maximum ink is used to create full print density. Also applied to darkest areas o f positive and clearest areas of negative.

SHEET FEED - Method o f printing in which paper is fed into press in sheets rather than in a rolled web.

SKIPPING - Areas o n the cylinder where ink does not transfer t o the web.

SOLIDS - Areas carrying 100% of color.

SNOWFLAKING - Random, generally minute spots, or unprinted areas where no ink is being deposited (missing dots).

. STOCK - Any material used to receive the printed image, i.e., paper, board, foil etc.

GLOSSARY O F TERMS-5

c-." STRIPPER - One who does film stripping or layout work - assembles elements for making composite films. Also, referred t o as set-up or layout person.

SUBSTRATE - Material printed upon, i.e., stock.

SURFACE TENSION - The ability or inability of ink to wet a surface (i.e.: chrome, plates, paper, etc.). Lower surface tensions wet better.

SURFACTANT - Chemical that alters surface tension.

THIXOTROPY - A fluid whose viscosity decreases as the force of agitation (shear) increases but regains viscosity after the force (shear) is removed. These changes are not instantaneous, but take time. The higher the degree of thixotropy, the longer time it takes to change. This property allows inks t o flow before the viscosity is regained. Also see NEWTONIAN, PSEUDOPLASTIC, RHEOLOGY, VISCOSITY.

VEHICLE - Ink components without color, usually resin, solvent (water) and modifiers (wax, levelling agents, etc.) i.e.: extenders.

VISCOSITY - The property of a fluid that makes i t resistant t o f low. Low viscosity f lows easily, while high viscosity is very resistant t o f low. Also see NEWTONIAN, PSEUDOPLASTIC, RHEOLOGY, THIXOTROPY.

WEB - Paper or other stock from the roll in a printing press, the full length of paper contained in a roll of stock as it passes through the press.

WEB FEED - Describes presses which are supplied by a roll o f stock.

.. . . . ..

GLOSSARY 0 F TERMS -6

M r . J o h n Byzel.: - E n g i n e e r i n g E n v i r o n m e n t a l P r o t e c t i o n Agency, EPA 3825 B a r r e t t D r i v e S u i t e 300 P.U. Box 27687 R a l e i g h , NC 27611

. June 3, 1991

FOAMINK Technologies 150 Gordon Drive P.O. Box 270 Exton, PA 19341-1350 21 5-363-6403 FOX 215-692-7947

EPA. WD

Dear Mi-. B y z e k :

I a p p r e c i a t e d y a u r c a l l t h i s m o r n i n g . Messages h a v e b e e n l e f t i o r M r . F l e i s c h m a n a t h i s home a n d h i s o f f i c e i n W a s h i n g t o n .

I n t e r e s t i n o u r p r o c e s s , u s u a l l y f r o m a p r i n t e r , i s s l a n t e d m o r e t o w a r d p r e s s a p p l i c a t i o n a n d p r i n t q u a l i t y r e q u i r e m e n t s t h a n t h e i n k w a s t e d i r e c t i o n . A s w e d i s c u s s e d , t h e R o t o f o a m i n k s u s e d i n p u b l i c a t i o n r o t o g r a v u r e a r e r e s o l u a b l e in t h e m s e l v e s a n d c o n t a i n n o i n g r e d i e n t s t h a t w i l l c r o s s - l i n k a n d make waste disposal a p r o b l e m . T h e s y s t e m i s d e s i g n e d t o u s e e v e r y s c r a p o f wash w a t e r a n d p r e s s r e t u r n s t h e r e f o r e c r e a t i n g n o i n t e n t i o n a l was t e i n t h e n o r m a l c o u r s e o f o p e r a t i o n s .

W e h a v e e n c l o s e d a Foamink G u i d e w h i c h w i l l g i v e y o u a d e q u a t e b a c k g r o u n d i n t h e e n t i r e s y s t e m . T h e r e is a l s o an a r t i c l e by M T . M a r s h a l l W a l s h t h a t s h o w s s o m e of t h e p i t f a l l s o f t h e l i q u i d water s y s t e m s . P l e a s e n o t e F i g u r e 3, F o a m i n k w i l l n o t d r y i n t h e c y l i n d e r cel ls . F i g u r e 4 s h o w s a r e g u l a r i n k t h a t h a s f o a m e d , n o t p l a n n e d ! F i g u r e 5 s t a t e s n L e f t p a g e weak i n d e n s i t y d u e t o f o a m i n g . T h i s F i g u r e 5 is v e r y i m p o r t a n t t o u s a t F o a m i n k . I t s h o w s t h a t when a n o r m a l i n k h a s b e e n u n i n t e n t i o n a l l y f o a m i t w i l l d e p o s i t less color on t h e p a g e j u s t b e c a u s e i t is a f o a m . t h i s is r e a l l y t h e k e y t o t h e s o l u t i . o r i a s a p r o p e r l y f o r m u l a t e d a n d p i g m e n t e d i n k w i l l d e p o s i t t h e same c o l o r a s a fcrarn t h e r e f o r e r e d u c i n g t h e t o t a l l i q u i d in t h e p r i n t i n g p h a s e Gy a t least 30%. T h i s a l l o w s f o r all t h o s e g o o d p l u s e s t o h a p p e n when less wa te r is r e q u i r e d , i e , l ess d r y e r r e q u i r e d , l e s s p e n e t r a t i o n o f t h e s t o c k , b r i g h t c o l o r w i t h l e s s p i g m e r j t p i l l i n g , a l l r e s u l t i n g i n f a s - t e r p r e s s s p e e d s t h a n c o n v e n t i o n a l s y s t e m s .

- .- - m@fl@! The Electrmcs Group

9

1- I'

9 1 1 '

UNVGOLD2. WD Page 2

J o h n , s h o u l d you h a v e a n y q u e s t i o n s a f t e r y o u ' w i t h t h e G u i d e , p l e a s e g i v e u s a call. W e w o u l d a p p r e c i a t e t h e n a m e s of o t h e r s a t y o u r d e p a r t m e n t who s h o u l d b e k e p t i n f o r m e d o f o u r p r o g r e s s .

C h a s e R o s n e r P r e s i d e n t

cc: M r . D . U . B u n c e M r . R . J. W i l l i s

/ m t m

' * 1

9 '* I

8

SUCCESS WITH GRAVURE WATER

BASE5 INKS

Point of View: User

by Marshall Walsh Diversified P r i n t i n g Cor p .

-._. In .. the . early . . . part . . of 1980, - Diversified Printing Corpo- ration instituted a program for the development cf printing with water based gravure inks. As a result our pressroom has converted one (1) press line to an alco- hcl and ammonia free water based yellow ink. Thus far over two hundred million Sunday supplement maga- zines (see Fig. 1) have been printed at speeds of over 1800 feet per minute using a water based yellow ink that is comparable to hydrocarbon inks presently used.

Diversified concluded that production use of water based inks is essential to insure the future growth of its organization. The probability of strict environmental regulations, the rising cost of hydrocarbon solvent base inks and the improved safety in handling water base inks all favored the development of this program.

The initial concept of this program intended DPC and its inks suppliers to be equally committed in devel- oping a high quality, problem free water based ink. Specifically, DPC provided press production time and equipment modification while the ink suppliers pro- vided research and expertise. As a result, a 1980 goal of converting one (1) press line to a water base yellow ink was achieved. A total of three (3) press lines of yel- low and one (1) press line of red will have been con- verted by year end. Given the results so far, we expect to reach these goals and, in doing so, address the com- biced issue's 'Of environmental regulations, rising costs G: hydrocarbon inks and improved safety in handling 1.vitar inks in a truly progressive fashion.

TESTING PROCEDURE: During the first six (6) months of testing, numerous

drum tests were conducted to obtain information for ink and equipment modifications. A black water ink was first attempted but discontinued due to a lack of gloss and poor trapping properties upon solvent printed inks in a four color process. A change to yellow was made because it is a first impression which allows absorption before the subsequent solvent printed inks seal the substrate.

PROBLEMS AND SOLUTIONS: Problems have occured with the use of water base

inks and they all have been reduced to a level whereby we have been able to print continuously with a water yellow ink since October of 1980.

Drying properties of these inks was initially poor. In- sufficient drying increased in build-up on steel rollers immediately following the water unit. Web wrinkles and web breaks eventually developed. The next down color did not print over this semi-wet yellow water ink film (see Fig. 2). To complicate matters further, it can be noted in Fig. 3 that ink which remained in the cylinder cells during downtime "dried-in" and was very difficult to remove. The ink manufacturer solved these prob- lems through formulation changes using different resin systems.

Foaming, as can be seen in Fig. 4, was a primary problem that affected our automatic viscosity controls and allowed internal air bubbles to prevent ink transfer, resulting in a weak print (see Fig. 5). Anti-foam ingredi- ents have aided dramatically. One ink manufacturer has produced an anti-foam in a solid form that, when

103

Fig. 5 Left page weak in density due to foaming.

Fig. 6 Water base curl (top), hydro-carbon ink printed book (bottom).

added to the fountain, will dissolve itself in the ink in a delayed fashion and thereby control foaming for a longer period of time.

Note in Fig. Gthat curling of the substrate has been a continual problem. Web breaks have occured as the substrate curls while passing over angle bars or en- tering subsequent printing units. Pages with a heavy yellow coverage are found with edges that curl inward toward the center of the page. After a short period of time a small portion of this curl is released by the sub- strate. However, in terms of quality, the remaining curl ’ is undesirable.

,7

We have determined by use that the heat employed to dry this water ink film increases substrate curl. By substituting increased air circulation for heat, dry rate will remain adequate and in turn curl will be decreased.

It has also been determined that substrate curl is caused by a lack of penetration of ink into the sub- strate. Lowering the viscosity of the ink has increased penetration and has reduced stock curl by a small amount. One ink manufacturer has developed an ink with increased penetration properties. This has been tested with positive results in decreasing curl. Bear in mind, however, that there is a limit to this solution, for increased penetration will increase “show through” which is also undesirable.

106

Fig. 3 Left page weak in yellow density compared to right due to yellow ink that dried-in, in the cells. .

Fig. 4 Foaming underneath printing cylinder. , I

105