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Four measures to stabilize the surface tension of flexographic printing plates
In the flexographic plate-making process, achieving a printing plate with consistent surface tension is essential. A stable surface tension ensures that the printing plate can maintain an effective and reliable interface with the ink, which is crucial for high-quality print results. The question then becomes: how does the plate-making process ensure this stability?
One key approach is to strictly follow the guidelines provided by the flexographic plate supplier. This includes adhering to their recommended procedures for solvent distillation, measurement, and compensation. Taking shortcuts might seem tempting, but it often leads to long-term issues. Instead, it's important to prioritize quality and reliability, even if it means following a more thorough process. When using solvents, balancing commercial interests with proper practices is vital. Although the methods suggested by suppliers may not be perfect, they are currently the most viable solutions available.
To ensure consistency, regular monitoring of the finished printing plate’s surface tension is necessary. A simple yet effective method involves using a corona pen to test surface tension, combined with a high-powered magnifying glass to inspect the smoothness of the plate’s recessed areas.
Another factor in maintaining surface tension is the stability of the plate-washing solvent. Traditional solvents like tetrachloroethylene and n-butanol offer good solubility stability, but their high toxicity raises environmental concerns. Flexographic printing is known as an environmentally friendly method, so the use of such toxic solvents is increasingly questioned. However, there may still be reasons to use them, such as cost or quality considerations. It’s important to focus on the principle of directional solvent measurement and supplementation, rather than rejecting them solely based on environmental concerns.
Using water-soluble washing solutions is another option. These solvents have higher boiling points and are less volatile, which helps mask some of the solvent balance issues. However, as the solution absorbs more solids from the uncured resin, its concentration decreases, leading to fluctuations in surface tension. This requires careful monitoring. Some claims suggest that ethanol is safe after water-based washing, but in practice, swelling has been observed. In such cases, suppliers may recommend alternatives like a 1:1 mixture of isopropanol and methanol. This highlights the need for continued research into water-based systems, especially regarding the toxicity of additives used.
Thermal plate-making technology offers a promising alternative by eliminating the need for liquid solvents altogether. In this process, the uncured photosensitive resin is liquefied through heat, then pressed against a roller covered in non-woven fabric. This allows the resin to be separated without dissolving, resulting in a printing plate with a surface tension that accurately reflects the material itself. This method avoids the fluctuations caused by solvent interactions during traditional plate washing.
Despite its environmental benefits, thermal plate-making still faces challenges. Current operational data suggest that the precision of the plates is not yet optimal, and pressure settings remain a concern. Excessive pressure can damage delicate dot structures, reducing print accuracy. Additionally, the properties of non-woven fabrics—such as their ability to absorb liquid resins—are complex and require further study.
Ultimately, as the plate-making process advances toward providing stable surface tension, the next challenge lies in matching it with the right ink. Whether it's solvent-based, water-based, or UV ink, the goal is to develop inks that effectively interact with the plate’s surface. This task should be entrusted to the ink industry, which has the expertise to refine and adapt formulations accordingly.