Apex Academy

3 Tips for Improving the Margins of Your Offset Coating Operation

Offset professionals know that coatings and varnishes can bring a printed piece to life, or ruin it completely. Whether you use a high-gloss UV lacquer, a drip-off or soft-touch coating, an acquous lacquer for protection, all coatings are applied in order to create some additional value to a print.

The application of offset coating is done by an anilox roll, it transfers the right amount of lacquer from A to B. Nevertheless, the right amount of lacquer requires a very accurate approach and printers who properly manage this process can provide additional value to a simple print and command higher margins for the entire operation. 

1. More lacquer isn't necessary for a more glossy appearance.  But it will hurt your bottom line.

It is a misunderstanding to think that ‘more gloss’ automatically means ‘apply more lacquer’. Gloss is measured using a Gloss Meter which directs a light at a specific angle to the test surface and simultaneously measures the amount of reflection. The more light is reflected, the more glossy the appearance of the surface.  

It is not about the amount of lacquer applied onto a print, which determines the level of gloss you achieve. It is all about creating a smooth and consistent layer that reflects the light in a homogenous way. The images below show this in practice, whereas the below example results in a higher # gloss points, because more light is reflected.

ApexOffset-GlossMeter.jpg

2.Maximize visual coating results

To maximize visual coating results, avoid issues like (micro-)foaming, orange-peel and pinholing from the start. Orange peel effect refers to a coating layer that can be characterized by a surface that is similar to an orange peel and the reason for this almost always is too much volume. Pinholes (trapped pockets of air within the conformal coating) and foam (extreme bubbling) are similar defects that should be avoided in order to maximize the visual coating result. However, this is a very complicated process as it is highly dependent on many variables: the type of coating (lacquous, UV, dispersion), the substrate to apply the coating onto and the drying equipment. The anilox manufacturer needs to take all these parameters into consideration while giving proper volume advice for the transfer of wet coating. The below micro-photographs show the difference between non-homogenous and homogenous coating application.

Apex-CoatingLayers.jpg
Image: Left: non-homogenous coating layer (reason: air inclusion) and Right: homogenous and even coating layer (no air)

3. Avoid press downtime

Want to ensure longer print cycles without having to stop the press?  There are various ways to achieve this:

  • Make use of standardized anilox rolls that are suitable for applying different types of coating.
  • Keep your rolls clean on a regular basis in order to avoid having to deep-clean them.
  • Keep your rolls in good shape, avoid damages while changing them.
Bringing all these tips into practice means your cost go down and your print quality is increasing in quality, automatically resulting in a better price. Ask your Anilox manufacturer for advice on the right amount of coating to be transferred, and the correct surface profile. 

Second-Generation Anilox Rolls versus New technology Anilox rolls

Many Offset printers today rely on second-generation anilox surfaces made up of closed-cell geometry, basically holes into which coating is doctored. Problem is, this geometry can create turbulence, foaming and uneven coating release. The result is a disturbed laydown and pinholing among others. GTT’s new Open Slalom Ink Channel geometry instead allows coating to flow calmly and transfer precisely with stunning results. This technology is approved and embraced by all leading Offset Coating Machine manufacturers.