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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. Only when the surface tension of the plate remains stable can it provide a reliable platform that aligns with the ink's surface tension. So, how does the plate-making process ensure this stability? The answer lies in following proper procedures and using the right materials.
It's crucial to adhere strictly to the guidelines provided by the flexographic plate supplier. This includes following the recommended environmental solvent distillation, measurement, and compensation protocols. Taking shortcuts may seem tempting, but it often leads to long-term issues. Instead, we should focus on sustainable practices that protect both commercial interests and the environment. While the methods suggested by suppliers might not be perfect, they are currently the most viable solutions. To ensure quality, it's important to monitor the surface tension of the finished plates. A simple yet effective method is to use a corona pen for testing and pair it with a high-powered magnifying glass to check the smoothness of the plate’s recessed areas.
The solubility of the plate-washing solvent plays a key role in maintaining surface tension. Traditional solvents like tetrachloroethylene and n-butanol offer good stability, but their high toxicity raises environmental concerns. Since flexography is marketed as an eco-friendly printing method, the use of such solvents seems contradictory. However, factors like cost and plate-making quality might still justify their use. It's similar to how some in the gravure industry prefer toluene inks over benzene-free alternatives due to better printability. What matters is adopting a directional approach—measuring and supplementing mixed solvents appropriately while avoiding those that are harmful to the environment.
Another alternative is using water-soluble plate washers. These solvents have high boiling points and are less volatile, which helps mask solvent balance issues. However, as solids accumulate, the concentration decreases, and the brush action becomes more critical, potentially affecting the plate’s surface tension. Some claim that after washing with water-based solutions, the plate can safely come into contact with ethanol without swelling. But in practice, swelling has been observed, leading suppliers to recommend a 1:1 mix of isopropanol and methanol instead. This highlights the need for further research into water-based systems, especially regarding the toxicity of additives used.
Thermal plate-making technology offers a promising solution by eliminating the influence of washing solvents altogether. In this process, uncured photosensitive resin is liquefied through heat, then pressed against a roller covered in non-woven fabric, which absorbs the excess material. This method avoids the surface tension fluctuations caused by solvent interactions, ensuring a more stable plate. Despite its environmental benefits, thermal plate-making currently faces challenges in precision and pressure control. Excessive pressure can distort dots, reducing print accuracy. Additionally, the adsorption properties of non-woven fabrics—beyond just fiber length—are still not fully understood. Further refinement of this technology is needed to achieve high-quality plates with consistent surface tension.
Once a plate with stable surface tension is produced, the next challenge is matching it with the right ink. Whether it's solvent-based, water-based, or UV ink, the goal is to find a formulation that effectively interacts with the plate’s surface. This task should be left to the ink manufacturers, who are best equipped to develop suitable solutions. Ultimately, the success of flexographic printing depends on a combination of precise plate-making and compatible inks.