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Gravure Printability From Laser and Electromechanically Engraved Cylinder

Article · January 2004

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Xiaoying Rong J. Pekarovic

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 GRAVURE PRINTABILITY FROM LASER stable highlight tone values. A zoom optics allows for a screen
resolution from 178 to 1016 IpL Direct laser engraving is a
AND ELECTROMECHANICALLY ENGRAVED
non-contact method, which does not cause wear of engraving
CYLINDER tool and is therefore capable of producing consistent engraving
Xiaoying Rong, Jan Pekarovic, and [5]. It seems that laser engraving offers multiple benefits. The
Alexandra Pekarovicova laser system operates 17 times quicker than current engraving
Department of Paper Engineering, Chemical Engineering and machines [I] and reaches speeds of 70,000 cells per second.
Imaging, Western Michigan University, A-2I7 Parkview, Compared ioeIectromech:iriicar'sysiems;-laserpioviOi,s-for'
Kalamazoo, MI 49008-5462 higher and more uniform quality and shorter make-ready, with
ABSTRACT a minimum of color shift and moire [2]. With the laser process,
Gravure printability comparison of laser engraved and there is no traditional rosette pattern dot and, therefore, nO'"
electromechanically engraved cylinders was done on five limitations on screen angles and a more neutral gray balance is
different substrates. Ink transrer was less reduced on laser print created. The vignette is printed as a continuous tone, even
than electromechanical when printed without electrostatic down to a 20 percent step. Although expensive to install, laser
assist. Print mottle was significantly lower at yellow, magenta
technology should not increase the cost of gravure printing,
and black laser engraved images, while cyan print from laser
and because ofgreater repeatability, it will automatically show
engraved cylinder had higher mottle on some substrates (SCB,
cq§tsavings to the converter [I]. The aim of this work was to
SCA and freesheet). Overall, the print from the laser engraved
image had better print quality than that from the compare printability results for electromechanically and laser
electromechanically engraved one. engraved gravure image carriers.
EXPERIMENTAL
RESUME Four publication substrates [Light Weight Coated, 42 Ib/ream
La. comparaison d'imprimabilite de grawre des cylindreslaser (LWC), Supercalendered B, 35 Ib/ream (SCB),
graves et electromecanique graves a ere.faite sur cinq substrats Superealendered A, 35 Ib/ream (SCA), Freesheet, 45 Ib/ream
differents. Le transfert d'encre a ere moins reduit sur la copie de (FS) and one packaging Solid Bleached Sulfate, 81 Ib/ream
laser qu'electromecanique quand imprime sans aide (SBS) board] were used in this experiment. Some of their
electrostatique. La marbrure d'impfession etait sensiblement papermaking properties are listed in the Table I, and optical
inferieureau jaune, magenta et noire images grave'es par- Jaser properties in the Table U.
landis que cyan imprimez du cylindre grave par laser a eu une
plus haute marbrure sur quelques substrats. De fa90n generale, Table I: Selected papermaking properties
la copie du laser grave l'image a eu une meiHeure qualite
d'impression que cela de eIectromecanique gravee. PPS PPS PPS
Roughness Roughness Porosity
Substrate at500kPa atlOOOkPa [mL/min]
INTRODUCTION
[ill [ill
Laser engraving of gravure cylinders is the latest and most LWC 2.13 1.63 7.12
exciting development introduced by the Daetwyler laser
SCB 2.02 1.55 14.15
engraving system [I]. The Daetwyler Direct Laser System
(DLS), now being used in the gravure market, features SCA 221 1.65 23.31

galvanic plating of the zinc/chrome layers that meets the FS 1.98 1.48 . 16.46

surface structure and durability requirements for the gravure SBS 3.58 2.53 1.46

process [2]. The laser beam, focused onto the cylinder surface,
melts and vaporizes the image-carrier material and produces
A Cerutti pilot-plant rotogravure web printing press (Cerutti Model
the cells. Laser engraving allows for larger variability in cell
118, Italy) was used to print test samples. Two sets of cylinders were
shapes and their sizes. These new shapes can result in higher used for printing: electromechanically engraved (EE) and direct laser
print densities. By dynamically controlling the laser beam engraved (LE). The screen ruling was 140 Ipl (lines per linear inch)
diameter, width and depth of cells can be individually for yellow, 175 for magenta, 175 for cyan and 225 Ipi for black
COnfigured for publication and package printing. Laser­ cylinder, with compression angles 45 0, 60°,
~ngraved cells are actually spherical in shape, providing
unproved ink release. For example, to achieve a comparable Table U: Selected optical properties
Printing density, the depth of a laser cell is only approximately
213 of an electromechanically engraved cell [3]. Consequently, Specular Brightness Opacity
finer screens are possible, while still obtaining the required Substrate Gloss [%] [%]
Print density. With laser technology, it is possible to create also 60°
Variable shape cells, not achievable with electromechanical LWC 17.16 71.50 86.89
engraVing [4]. These new shapes actually provide for higher
SCB 14.51 65.78 88.56
P?nt density and it is possible to use higher viscosity inks than
~Ith .traditional electromechanically engraved cylinders. SCA 15.88 68.19 87.42
. xpenments showed that laser engraved cylinders reduce the FS 20.46 79.32 92.65
lntIuence of press printing speed on print quality [4], and keep SBS 14.25 83.75 95.59

"'/i:\~temational Printing & Graphic Arts Conference 151

 --+--LWC
30.,.......----------I·-· O·--· SCB

30°, and 45°, respectively. The screen ruling at laser engraved 25 -,*--SCA
cylinders (tone work) was engraved at 254 Ipi (100 Ie lines per ---l(._. FS
centimeter) for ail cylinders. Black engraving, the Line Work (LW) ~20+--­ --)If--SBS
was engraved with the 278 Ic Masterscreen pattern. The laser
engraved cells were angled at 30 degrees. All of the cylinders were .; "15
Cl
engraved at the same angle. The image on both cylinders was the ~

same with small variations (IT 8.7/3 chart was included in laser 8 10
imaged cylinders). Four process colors were printed at 305 m/min 5
(1000 ftlmin) for LWC, SCB, SCA and freeshcet. The speed of600 ftI
min was run for SBS board. Commercial toluene based coated group O.f*--_-_-~--~-..
VI inks were employed. Their efflux time ("printing viscosity") was o 20 40 60 80 100
22 seconds on a Shell #2 efflux cup for yellow, magenta and cyan inks Tone value ['l.i
and 20 seconds for black ink. The same ink viscosity was used for
both sets of cylinders. Thus, ink viscosity was not optimized for laser Figure 1: Mageuta dot gain from· electromechanically

,
engraved cylinders for comparison reasons. Oven dryers were' set to engraved cylinder, ESA ou
60°C at 9000 cfin nozzie velocity. Electrostatic assist (ESA) was
--o-LWC
applied at 4 kV and 1.4 rnA (ESA on), 25% ESA (IkV), and ESA off.
All the settings were kept the same when printed with both sets of
3S

30 --'""'..... "'-"'-­ .....

-·.-·SCB
--*_.
-SCA
FS
cylinders. ~25 -·--:I(····SBS

.
...

~
Parker Print-Surf Model ME 90 (Messmer Instruments Ltd., U.K) e:.,.

" ~
c
was used for both porosity and roughness measurements. Brightness .c; 15
was measured by Brightness-X,Rite 8400 instrument eqnipped with Cl
~ 10
Color Master software. Substrates opacity was measured according to S
TAPPI Standard T 425-om-91. 'III
Image analyses of magenta, cyan, and black dots were recorded at 5 %
-s 0
tone step using a Hitachi HV-C 10 carnera (Hitachi Denshi, Ltd..;
Japan). Computer software Image ProPlus, Version 4.5 was used for Tone value rl.l
image detail analysis. Print density mottle was measured using a
Tobias Mottle tester with reflective density head. Tobias mottle was Figure 2: Magenta dot gain from laser engraved cylinder on
compared to mnttle measured using Verity IA Multifunction 2003 various substrates, ESA on
software. Solid process colors were scanned by HPScanjet 7400C
scanner at 600 dpi resolution as input images for Verity software to Printing without electrostatic assist (ESA oft) affects ink
calculate mottle. For mottle calculation in Verity IA software, tile transfer from laser engraved cells less than from
sizes 2-1024,2-64, 4-1024 and 4-64 were used. According to the electromechanically eugraved cells, which was obvious when
instruction, tile size 4~64 represents visible mottle. Reflective density, subtracting average dot gain values ESA on and ESA off
tonal responses, and dot gain were measured using X-Rite 530 (Table ill). The differences in an ink transfer between ESA on
Spectrodensitometer. Specular gloss was measured by Gardner Gloss and off for E cylinders were between 3.48-1.82 and for L
Meter with 60 degree geometry on solid colors and the gloss was cyliuders between 2.24-0.14, which clearly shows much
calculated as average of five measurements in paper machine and five
smaBer differences in dot gain, thus in an ink transfer, between
measurements in cross-machine direction.
ESA on and off. The smallest difference was found at black
print, which is probably due to higb efficiency of ink transfer
RESULTS AND DISCUSSION
from multi-shot laser engraved cells. Exarnple of dot gain
Selected papennaking characteristics of substrates used in trial
curves at LWC with ESA on, 25% ESA and ESA off are
are listed in the Table I, and Table II. Dot gain curves were
illustrated in the Fig. 3 and Fig. 4.
measured for all inks, substrates and differeut levels (100%,
25% and 0%) ofESA (Electrostatic assist). Dot gain curves for
Table III: Average dot gain ou all paperlboard substrates (E at
laser engraved cyliuders were generally smoother
50% and at L at 40% tone, dot gain for all substrates was
than those from electromechanically engraved cylinders (See
averaged)
Fig. 1 and Fig. 2).
Maximum dot gain for laser eugraved cylinders was found at Color E/ESA EIESA LIESA LIESA
30 to 40% tone, while at electromechanically engraved print it on off on off
was at 50% tone. Maximum dot gain was averaged for all five Yellow [%] 19.98 18.10 24.54 23.94
substrates and each iuk (Tab. III). It was found that dot gain
Magenta [%] 24.80 21.60 29.10 28.70
(laser engraved) cylinders (29.10-24.10 %) was greater
than from E (electromechanically engraved) cylinders (24.80­ Cyan [%] 20.70 18.60 24.10 21.86
19.98) on all substrates and all inks (Tab. III), which was Black [%] 20.80 18.98 27.68 27.54
probably due to slightly higber screen ruling at laser engraved
cylinders.

Internatioual Printing & Graphic Arts Confereuce

 m

-+--ESAON
~
55,---,---------,
"
~
30,----------1
••• .[J- •• ·25% ESA I!IlEE-K
25 _ ..•.. _ESA OFF 50

~ 20 -I------;=""'t"!'.}i---~il====,--' ~ 45 -I-._L_E_..I(-..J-----~
~
c ~
.. 15 -I--_~l.Ji.li'lll~----=::m=----1 ,g 40 +--------­
CO

------J
CO
8 10 ~""'=------------lIi'---1 _. ~---:35 ...
5W---------~-1irl u
&30 !I

I
Ul
O.....-~-~-~-~_...
o 20 40 60 80 100 25

Tone Value r/~ 20

Figure 3: Dot gain at LWC from electromechanically engraved ~tJ v~ 0"

v Cj ~tl/

I
cylinder at various levels ofESA ,,~.
y
Substrate
35 , - -r-=4.;:=:"jES~AG05iNNl
Figure 5: Specular gloss ofblack solids printed from

.
···O···25%ESA

t=J~~~~~-; ~.=.=.-~ES~A~O~F~F
electromechanically and laSer'engi-aved cylinder (ESA-off)
30
~
25

.'"
~
CO 15
20 160
140
DY-EE .Y-LE
t==========iiF==e=====i
I!IM-EE GM-LE

'0
c
10
.i .g.E 120 +----­
CD 100+----­
5
~ 80
0 :;; 60
0 20 40 60
Tone Value rio]
80 100
! 40

20

lk Figure 4: Dot gain at LWC from laser engraved cylinder at o

m various levels ofESA LWC SCB SCA FS SBS
m Substrate
,ff Reflective density of solid prints was higher printed from
electromechanically engraved cylinder than from laser Figure 6: Tobias Mottle of yellow and magenta on different
engraved one for yellow, magenta and cyan (Data not shown). substrates from E and L cylinders
Only solid black showed opposite trend - much higher
reflective density was achieved from LE cylinder, and this was
true for all substrates. Higher optical density of black print
Was most likely due to multi-shot black laser engraved cells. 120
Again, the ink viscosities were not· optimized for laser x
engraved cy Hnrlers for comparison reasons. 100
'" .VL

Specular gloss was measured at solid print areas. In most cases,

different substrates printed with laser engraved cylinders gave
slightly higher gloss values, and this was most apparent on
black print, especially with ESA off (Fig. 5). This means that
80
60
40
• - .TL
AVE
x TE
ink film is berter leveled at laser print- which may be due to
round and shallower shape oflaser engraved cells.
Print mottle can be measured as unevenness in print density,
20
o
o
~
50
•
100 150
gloss or color. The higher the mottle index number, the worse ESAl"1oi
the unevenness. In this work, Tobias density mottle index and
Verity mottle were measured. Figure 7: Comparison of mottle measured on solid 'cyan
(TL=Tobias/laser engraved, TE = Tobias/electronic engraving. VL=
Verity/laser engraved; VE= Verity/electronic engraving)

International Printing & Graphic Arts Conference 153

 8.r. -- -- -- -- -- -- -1 -- ..-- LE-I.WC engraved cylinders for comparison reas
ons· ink was oPtill ~~liZedi
L::::~=-_~=::::::==::;:-__1--. for electromechanically engraved
7 r
-6-
- - LE-S
EE·LWC
CB and all process color inks, the dot
cylinders. On all sUbstra!el~
~ 6
."
-1 --- --- --- -'- '-- -1
engraved cylinders than from elec
gain was greater from 1.,.,01
~E E- SC B tromechanically engrav,<!;~j
.: 5 -1------------
-1

!: _;;_~~:-:~-~~~.~~":'.:~:~~ _ _ LE·FS ories, which was most likely due to

slightly finer screen ruling.~.
at laser engraved cylinders. The
difference in dot gain With"li
---C -·-E E-F S ESA on and ESA off was much
lower for laser engrav'<!if,
~ 2 r""'=~===;;;;::;:~~------I cylinders for all iriks and substrate
s, which means that ind
1 -1---------
transfer is much better from lase
----1 r engraved image Caniers,'0
Print gloss was slightly higher on
o -l-----~--_----4 images from laser engrav'<! •••.
o cylinders. Las.er engraved cylinder
50 100 150
s produced lower Print ;"
mottle on mos t substrates and colo
ESA fA» rs. Comparing all of thes e'
printability features, it can be conc
luded that laser engraved
Figu re 8: Verity mottle index images produce better print quality
at black print at various than electromechanically
substrates and ESA levels engraved ones.

Verity Multifunction software ACKNOWLEDGEMENT

analyzes digital images,
acquired by a sensitive scanner. Authors would like to thank Kea
The algorithm is built to tings Gravure, Inc. for the
calculate pixel intensity difference donation ofla ser engraving and to
of a scanned image [6, 7]. Max Daetwyler, Inc. for!be
Verity Mottle is a function ofth e mea transportation of the cylinders to
n pixel .luminance and the WMU, Kalamazoo. We are
standard deviation of pixel inten also thankful to Mr. Dou g Cox, Dire
sity. Tobias density mottle ctor of the Printing Pilot
index for yellow and magenta prin Plant, Western Michigan Universit
t from EE and LE cylinders y, for arranging the printing
is illustrated in the Fig. 6. Ima trials and Mr, Roy Rosenberger for
ges from laser engraved the donation of Verity lA
cylinders exhibit lower mottle inde LLC software for mottle evaluati
x, thus show better print on as well as for valuable
uniformity. discussi ons.
Comparison of cyan print mottle at
all ESA levels measured .by REFERENCES
Tobias Mot tle Tester and by Veri
ty software is illustrated at
Fig. 7. Bot h Verity and Tobias show I. Lupano B., "Gravure vs. Flexo: A True
thad aser engraved images Cost Comparison",
give lower print mottle. Low er Gravure Magazine, 54-59, (Wmter
mottle for laser engraved 2000
cylinders was found at all levels of 2, Henning G, and Frauchiger J") "Dir ),
electrostatic assist and all Rotogravure Printing", Gravure Magazineect Laser System for
substrates printed with yellow, mag 2001). , 58-61, (August
enta and black. Cyan print
from LE cylinder had higher mottle 3. Lombardi, D., "Gravure Technology
at SCA, SCB and freesheet
at all ESA levels. In mos t cases, prin Capabilities", Converting Magazine, 17 Forgoes the New
t showed lower mottle at 4. Sterkenburgh T., "Technical Tren in (9) 72 (1999).
ESA on than ESA off (Fig. 8) at
both LE and EE cylinders, for Decorative Printing", Saueressids CYlinder Engraving
which is probably due to better ink
transfer and lesser amount era/decorative/Saueressig ERAVortg,rag2
hrtP://www.eraeu.org{
5. Hennig G, Frauchiger J., "New Engr 003.pdf
ofm issin g dots when ESA on. aving Technique
Opens up New Perspectives for Roto
Flexo and Gravure, 7(3), 20-24, (2001). gravure Printing",
CONCLUSION 6. Rosenberger R, "Gloss Mottle Measure
Printed Areas, and Wet Trap", 2003 ment: Black Dark
Comparison .. of gravure printabi Proc. TAGA, TAGA,
lity from laser and Rochester, NY, 274-293, (2003).
e1eCtromethfu,ic~ljy engraved image 7, Rosenberger, R, "Stochastic Freq
carriers was don e on four uency ,Distribution
publication and one packaging grav Analysis as Applied to Mottle Mea surem
ure pap er substrates. The LLC, Verity Multifunction 2003 ent", Verity IA
same ink viscosity was used for elec www.verityiacomJ help file bttp:!!
tromechanically and laser

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International Printing & Graphic Arts
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