The October 2022 edition of the GravurExchange
Your source for news and events
AIMCAL R2R USA Huge Success in spite of Hurricane Ian!
The AIMCAL R2R USA Technical Conference scheduled for Sept. 26-29 in Orlando, FL was shortened to only the 26th & 27th before it became a mass exodus event as Hurricane Ian came ashore on the west coast of Florida and moved toward Orlando. However, there is still a lot to share as over 200 attendees enjoyed the networking, keynotes and sessions.
First it was announced the AIMCAL board approved changing the associations name to “Association for Roll-To-Roll Converters”
To learn more and why the name change was needed to reflect to full inclusion of all the diverse membership go to: AIMCAL announces name change, rebranding
2022 GAA Golden Cylinder Awards Winners announced!
Congratulations to the 2022 Golden Cylinder Winners
Category PACKAGING AND LABEL A1 Paper
Bush’s Best Flavor Fusions Baked Beans
delfort-Mundet TN Inc.
Category PACKAGING AND LABEL A2 Film-Film Lamination
Maliban Double Twist Cookies
Category PACKAGING AND LABEL A4 Film-Surface/Reverse Printed
Category PRODUCT B4 Giftwrap
American Greetings Corp.
Category PRODUCT B7 Vinyl Substrates
O’Sullivan Films Inc.
Category PRODUCT B8 Decorative Laminates
OMNOVA Solutions Inc.-A Synthomer Business
Category INNOVATION D1 Image Preparation (Prior to Engraving)
Clif LUNA® ECG
American Packaging Corporation
Category INNOVATION D4 Press
Advanced Register Control for Precision Printing and ECG in Gravure
Bobst Italia S.p.A.
2022 Golden Cylinder Best in Show
“Best in Show”
Bush’s Best Flavor Fusions Baked Beans
delfort-Mundet TN Inc.
Category INNOVATION D4 Press Honorable Mention
ENULEC for its ESA (electrostatic assist) Static Loop 360 system
Represented by Enulec partner for North America, Steingraeber, LLC
To read the GAA honors Golden Cylinder Award winners news release please go to: https://aimcal.sharefile.com/d-s91d33d7132cb4b028861565dc0d6d14c
To view the video that was displayed at the awards ceremony go to: https://aimcal.sharefile.com/d-sf7cf14f554324ccfaad7c8f50c7fc88b
The 2021- and 2022-Cylinder Society inductees were announced and the ones present were presented their lapel pin by Hubert Metzger the chair of the Cylinder Society Committee.
Congratulations to the newest members:
2021 Inductees: Prof. Robert Eller of R.I.T. and John Muehlbauer American Packaging
2022 Inductees: Dan Kyle SGS (Southern Graphics Systems), Bill Poulson Harper Corporation of America and Tony Donato GAA-Committee.
Pictured Left to right: Chris Kerscher (Executive Director of Association for Roll-To-Roll Converters), Tony Donato, Dan Kyle, John Muehlbauer, Bill Poulson and Hubert Metzger president of Chema Technologies.
AIMCAL News Video is back and can be viewed at:
The AIMCAL News Video’s are produced and available every two weeks go to www.aimcal.org for more AIMCAL news.
Wisconsin Printing Industry Council (WPIC)
At the September WPIC meeting (GAA-Committee supports the WPIC), Mark Fisher the President and CEO of the Council of the Great Lakes Region presented an update to the Circular Great Lakes Initiative that was launched last year and his update was titled “Circular Economy for Plastics”. The bi-national Council of the Great Lakes Region in launching the Circular Great Lakes initiative, has a mission of informing the region the actions necessary to forge a future without plastic packaging waste and litter in the region and the Great Lakes themselves. Important background data is as follows:
- The bi-national Great Lakes region spans eight states, two provinces, and many First Nations.
- 107 million people, the 12th largest nation in the world by population, if the region was a country.
- With a GDP US$6.0T, it would equal the 3rd largest national economy in the world.
- Generates more than 50% of the cross-border trade between the U.S. and Canada every year.
- 52 million jobs, or one-third of the combined American and Canadian workforce.
- Largest freshwater system in the world, holding 21% of the world’s and 84% of North America’s surface freshwater.
- Over 11,000 miles of coastline, which equates to the distance between Chicago, Illinois and Perth, Australia.
- More than 3,500 species of plants and animals inhabit the Great Lakes basin, some globally rare.
- Provide clean drinking water for 40 million American and Canadian households.
- Less than 1% of the waters of the Great Lakes are renewed on annual basis by precipitation, run-off and groundwater.
Many of our members have facilities in the Great Lakes region so we wanted to support the Circular Great Lakes initiative by providing the “Circular Economy for Plastics” presentation and the applications for a business to become a “Corporate Activation Partner” and for Universities and associations to become a “Knowledge Partner” available for download :https://aimcal.sharefile.com/d-s6bb33461d1f84bfd9900efb582b87ff7
Gravure Days at Universities and Colleges have started.
Rochester Institute of Technolgy has scheduled their “Gravure Day” event on November 7th. . R.I.T.’s 2022-23 “Gravure Day” theme is “Continuous Improvement”. The industry speakers include Bobst a 2022 Golden Cylinder Winner for Press Innovation and Steingraeber-Enulec Americas 2022 Golden Cylinder Honorable mention for Press Innovation both are members who support printing education. We will have a report on the R.I.T. Gravure Day from a student in next months GravurExchange.
If any University or College is planning on holding a gravure day and needs help recruiting speakers please contact Tony Donato at firstname.lastname@example.org
From the October Issue of SmallBiz@EPA
Below is an article from the October 2022 issue. To download the September and October issue PDF, go to: https://aimcal.sharefile.com/d-s79e4c5294ede498a8ca4719eefd0239a
Proposed Reconsideration of Fugitive Emissions Permitting Rule
On September 7, 2022, EPA Administrator Regan signed a rule proposing revisions to the Clean Air Act’s New Source Review (NSR) permitting regulations. This action would require facility owners/operators of all existing industrial facilities considered “major sources” to include “fugitive” emissions of air pollutants when determining whether a physical or operational change at their facility is a “major modification” which would need a major NSR permit before starting construction. The permit would include required emission control measures to ensure that changes at the facility would not degrade air quality. “Fugitive emissions” are emissions that could not reasonably pass through a stack, chimney, vent, or similar opening. EPA has reconsidered a 2008 rule requiring only certain types of industrial source categories to include fugitive emissions when determining whether a change is a major modification. EPA is proposing to fully repeal the 2008 rule by removing certain remaining stayed provisions of the regulations adopted in 2008. EPA also is proposing to remove a related exemption for modifications that would be considered major solely due to the inclusion of fugitive emissions.
As a result of the proposed changes, all existing major stationary sources would be required to include fugitive emissions in determining whether a project is a major modification. These changes would more effectively carry out the purposes of the NSR program to preserve and/or improve air quality and will provide greater clarity to all stakeholders. EPA will accept comment on this proposal for 60 days after the notice is published in the Federal Register. A pre-publication version of the notice, along with a summary fact sheet are available at: https://www.epa.gov/nsr/proposed-reconsideration-fugitive-emissions-rule.
The Gravure Tech Corner!
CONTROLLING INK TEMPERATURE ON PRESS
By Gary Silvers of GSP Specialties
When not controlling ink temperature on press; it’s been determined throughout the Gravure & Flexo printing industry, most printing problems occur after a few hours into a production run. During this crucial time many variables are changing; such as encountering print issues coupled with making ink or press adjustments resolving these problems.
These variables include:
- Adjusting the Doctor blade due to excessive wear from too much pressure.
- Solvent evaporation due to the increasing ink temperature.
- Heat that is transferred from the dryer ovens to the printed stock; transfers that same heat (high web temperature) to the cylinder, then to the ink.
- Increasing press speed generates more air flow around the cylinders.
- Heat generated from electric ink pump motors to the ink tanks; these electric ink pumps can transfer 40–60-degree F more heat than air driven ink pumps.
- Excessive impression pressure against the cylinder generates heat.
- Hot ambient room temperature in the press room can contribute to the engraved cylinder and ink temperature increasing.
- How do we reduce or eliminate making all these variable changes after a few hours of production running?
- Eliminate the heat buildup in the ink tank that’s how!
- How do we reduce or eliminate the heat buildup without sacrificing drying the printed ink on the substrate?
- Cooling the ink temperature will reduce or eliminate all the variables that are creating your print problems.
I’m not saying it’s the cure all and there will still be print issues; however, I will say there will be fewer compared to what you encounter without some form of Ink Cooling Unit.
High ink temperature is a year-round issue in the press room.
When this takes place, the ink and cylinder could reach temperatures well over 105 degrees Fahrenheit. When an Aqueous or Solvent ink temperature increases over 80 degrees Fahrenheit the amines, alcohols, or solvents accelerate evaporation and cannot be replenished at the specific measurement as when it was first made. Each solvent has its own evaporation rate after it reaches 80-degreeF. This creates an imbalance in the ink while evaporating off the needed faster drying solvents first with-in the ink formula.
When the engraved cylinder’s surface temperature increases; the chrome surface will expand and contract with the change in temperature causing imperfections in the chrome surface. To help reduce these problems from occurring most printers have installed either chill rollers, compressed air-cooling units, chilled water SS cooling coils in the ink sumps or purchased chilled water Heat exchangers installing them between the ink sump and applicators.
One issue with chill water cooling is hoses on the floor leading to the cooling device and water leaking causing safety issues. Most pressmen not knowing the importance of the cooling device, will disconnect the unit and remove it all together. Some press manufacturers have started offering cooling ink sumps as an option but those can cost $50-200K depending on the press and number of units. There are cooling units on the market operated by compressed air that don’t require chilled water or electricity that are press operator friendly and safe. The cost of the compressed air-cooling system is very competitive compared to a chilled water system or other types of refrigeration systems that require electricity.
By cooling the inks reducing the temperature between 70-80 degrees Fahrenheit; the advantages are outstanding. The optimum ink temperature would be 70 – 80 degrees Fahrenheit and reducing the web temperature less than 90 degrees Fahrenheit or as much as possible, without effecting the drying of the ink.
Results you will see by reducing your Ink temperature are:
- Reduces cylinder wear • Reduces doctor blade wear
- Helps stabilize viscosity control with less solvent reduction
- Improves printability
- Reduces ink & solvent usage
- Reduces or eliminates soft and hard streaking, hazing, draggers, foaming, screening, dirty print, poor trapping, inconsistent print color, etc.
Water base ink with ink cooling.
Water base ink without ink cooling
• Improves gloss • Improve process printing
• Reduce ink drying in the engraved cylinder cells
• Reduced print spoilage from time spent stopping and starting press to fix print issues.
Most of these results are not always noticed immediately after the cooling devices are installed but can be monitored and the results are always the same. Printers cooling their inks encounter less printability issues; (from the above list) than printers without cooling their inks.
I recommend using Ink Cooling devices for all printers. The savings is different for each printer, depending on the number of presses and cost of downtime that occurs over a production run having printing problems. The printers I have recommended using ink cooling devices; (Refrigeration type units, Chilled water coils or heat exchangers, or compressed air-cooling units) continue to use them with excellent results.
Investigate your Ink Cooling options there are new Ink Cooling devices for printers on the market today that will resolve these problems with a small investment. The initial investment may be a capital expenditure but the pay back in reduced press downtime due to print issues, improved print quality, reduced print spoilage, reduction in solvent and ink usage, reduced cylinder and doctor blade wear will be money well spent.
The above article can be downloaded at: https://aimcal.sharefile.com/d-se4759c0a205f4b9c82d7e806b5866d1a
Gary Silvers can be reached at: email@example.com Cell: (704) 907-4279
With the association new name also comes with new email addresses:
Chris Kerscher: firstname.lastname@example.org
Tim Janes: email@example.com
Kevin Lifsey: firstname.lastname@example.org
Mark Spaulding: email@example.com
Laure Lavore: firstname.lastname@example.org
Lauren Suber: email@example.com
Alex Nevels: firstname.lastname@example.org
The AIMCAL addresses will be active until September 2023.
New Online “Gravure Basics” Video Course available
This course and all GAA-Committee online courses along with the Gravure textbooks are all available at www.aimcal.org, click on “Resources” tab, then pick “Products” from the dropdown. You will also see all the training courses and other products that are offered by AIMCAL.
The Gravure AIMCAL Alliance Committee NEEDS YOUR HELP! The GAA-Committee is looking for individuals who want to become involved in the committee and its sub-committees. We need those who want to become part of the leadership team as well as those who can help with the GravurExchange, promoting the association to companies that use the gravure process, article writers, conference track topics and speaker recruitment, attending virtual meetings w/other associations, and on and on. If interested, contact Tony Donato email@example.com or text to 704-905-5178.
The GAA Committee reviewed the plans for the Basic and Advanced Seminars and decided it would be best to move them to June 2023. The Basic and Advanced “live” Seminars will be held at Interprint in Pittsfield, MA. Moving to 2023 will give time to the members who need to budget the training. The COVID-19 years have caused items that were routine budget lines to be left out, and time is needed to reschedule. More information will be available soon.
Converting Quarterly, the official technical journal of AIMCAL, is a great source of information and current news from members and the industry. Go to https://www.convertingquarterly.com/ to subscribe to the quarterly print magazine, the digital edition, the weekly CQ eNews…or all three.
For all the news you may have missed, go to Archived News (aimcal.org)
If you are looking for new employees or are looking for employment, we encourage you to use the new resources on the AIMCAL website: (Jobs (aimcal.org). Members may post jobs at NO CHARGE. We invite you to see how easy it is to post jobs online today. To maximize your job posting, you should also post on the GAA website at Job Openings | Gravure Association of the Americas (gaa.org)
GAA Services, Training and Products:
On-site Training/On-site Consulting:
Bob Kikkert and Mike Gaffney are ready to help with on-site and/or hybrid virtual training and consulting. Those in need of these services, please contact firstname.lastname@example.org using subject line: “Consultant Services.”
The Gravure Textbook Sale Continues:
We continue to receive orders for the Gravure Process and Technology and the Gravure Specifications and Tolerances (GST) textbooks. They can be purchased at Shop (www.aimcal.org)
Members continue to use the online gravure training program. There are four levels of Certification training. Information and registration for all four levels are available at https://gaa.org/services/training/online-gravure-certification-training/. Special Member pricing has been established for the certifications. For pricing and to register, email email@example.com and use subject line: “Certification.”
Want to become a member?