Introduction to systems of

printing
Printing systems
Printing systems are mechanisms that make it possible to transfer ink onto
the support.
Each printing technique is more or less suitable for certain types of jobs, as each
it allows printing different qualities of image, as well as working with some inks or on
some surfaces or others.
Each method has a higher or lower fixed initial cost, which makes each system more
or less suitable for long or short throws.
There are two main types of systems depending on whether they use a printer or not.
matrix to carry out the ink transfer operation.

Systems with matrix

For the image to be printed on the medium, it has to be drawn on another medium, which
it receives the name of printer or matrix form.
The ink is applied from the machine's inkwell to the printing plate so that it can then be
transferred to the print support.
The initial fixed cost is high since the manufacturing of the printer mold has to be
to do whether many or few copies are printed.
The setup of the machines is quite slow.

According to the characteristics of the printer type, the system can be:
-Planographic: the printable and non-printable areas are found in the same
level.
In relief: the printable areas are higher than the non-printable areas.
-In low relief or engraving: the printable areas are more fused than the
non-printable areas.
According to the way of transferring the image from the printing method to the support, it can be:
-Direct printing: the method of printing hits directly on the paper transferring the
image that reproduces a mirror figure of what is in it.
-Indirect printing: the method of printing transfers the image to another medium (rubber, canvas,
etc.) and from here it is transferred to paper.

Systems without matrix

The image is printed directly onto the paper without the need for a matrix.
The initial cost is lower, as the fixed expense of the printing method is eliminated.
The setup of the machine is faster.
It is more cost-effective for short runs of few copies.

Offset printing
Offset printing is a planographic process, it works on the surface, as the image areas
In the printer form, the matrix is at the same height as the non-image areas. For reasons
The ink adheres only to the image areas of the printer shape.
while the non-image areas, being wet, reject it. The ink film is
then transmitted to a soft rubber surface that, when in contact with the paper,
he/she transfers the image.
For this reason, it is said to be an indirect printing system.
The offset machine, also called an offset press, is a mechanical system that has been designed
to press an inked plate against a sheet of paper or another material that
it must be printed. The technique derives from lithography, with the difference that it is a
rotating and not flat system, since the ink transfer and pressure elements are
cylindrical. In addition, its printing shape is an aluminum plate covered with a thin layer
of photosensitive emulsion, which does not come into direct contact with the substrate since there is a
intermediate element, for transferring ink, between both.
In terms of systems, formats, and automation, it has progressed in reproduction quality and in
printing speed. There are offset presses that can produce 30,000 copies per hour or
more.
Reprography, or the reproduction of printed materials of small size (up to double leaf) was traversing
while
so many parallel paths using alcohol multicover machines, cliché multicover machines,
etc.
The technique derives from lithography, with the difference that it is a rotary system and not.
plan, since the ink transfer and pressure elements are cylindrical. Additionally, its
The printer form is an aluminum plate covered with a thin layer of photosensitive emulsion,
that does not make direct contact with the support since there is an intermediary element,
ink transfer, between both.
On the surface of the plate, two areas are differentiated: the printing areas, consisting of
emulsion and receptive to the ink, and the non-printing areas, of exposed metal and receptive to
water.

Obtaining the printer form

It can be indirect (through movies) and another direct (digital or CTP).
Indirect: Movies can be positive (darkened image) or negative (image
transparent) .
Direct: Virgin sheets are marketed in corrugated cardboard boxes,
separated from each other by sheets of parchment paper and isolated from the light. At
they should be manipulated to avoid exposure to UV radiation sources, such as tubes
fluorescent lights or sunlight.
For the generation of the print shape, the information from the RIP goes to a
digital flatbed copier. In this, a laser hits the photosensitive emulsion and generates
the point-to-point images. In the same copier, the developing is done and the plate is obtained
ready for use.
The advantages of this process are evident: the film and the number of operations are eliminated,
with a consequent reduction in times. The quality of the product is also improved, since
smaller dot sizes can be obtained (and larger line screens, consequently) and
better compensate for the point gain.

Types of offset systems

The offset system offers three variants: sheet-fed, web-fed, and dry.
1. Offset a sheet
Suitable for high-quality and high-resolution prints.
He is employed in editorial printing, commercial stationery, forms, flyers, brochures,
advertising and cans.
The printing body is composed of three cylinders, an inking roller system, a
wetting roller system, an ink pot, and a wetting solution source.
The printing process for each ink color is as follows:
Moistened: the iron holder cylinder comes into contact with the moistening rollers, which
they deposit water in the non-printing areas of the plate.
Inking: the inking rollers deposit the ink (from the inkwell) in the areas
printers. In non-printers, the water will be rejected due to the repulsion between water and oil.
Transfer to the blanket: the inked image is transferred to a rubber blanket.
(mounted on the holder cylinder).
Printing: the substrate is taken by the grips of the printing cylinder and is introduced between
this and the holder for producing the printing.
Sheet output: after a superficial drying, the printed sheets are deposited one
about another. The air that remains between the sheets helps with the final drying, which usually takes several.
hours.
2.Offset the coil
The offset printing press is a descendant of the letterpress printing and has displaced it from the market.
editorial. Basically, the products made correspond to this market: newspapers,
newspapers, magazines, catalogs, and books. It is profitable for print runs starting from 10,000.
prints, while for smaller print runs, sheet-fed offset is usually used; in print runs
For amounts below 2000, digital systems may be convenient.
The printing process is carried out in four colors (CMYK) and on both sides of the substrate,
simultaneously.

3.Dry offset
This system is indirect and consists of three cylinders: the blanket cylinder, the plate cylinder, and the impression cylinder.
The fundamental difference lies in the printer form that, instead of having a layer of
photosensitive emulsion, it has a photopolymer layer: once the matrix has been engraved,
The image areas made of this material are raised.
The inks used are more viscous, quick-drying, high gloss, and highly resistant to
rotor.
By not using water, it is the ideal system for printing security products, such as
paper money, stocks, bonds, checks, etc. It is also very useful for making
special designs, such as microletters and guilloches (drawings formed by continuous lines and
intertwined, that can be observed,
for example, in banknotes and identity cards).

In addition, with this technique, products such as yogurt cups, buckets, jars are also printed.
soda cans and plastic lids, using UV inks (that dry when exposed to them)
rays).

Image reproduction technique

The image reproduction using this system employs the technique of image halftoning.
This consists of breaking down the image into points, arranged homogeneously forming
rows or point lines. These points will have a maximum expansion space, that is,
they will only occupy a certain space, which will depend on the density of the image to which
reproduce. In other words, the different densities of the image to be reproduced will be
printed in dots of different sizes. Thus, the bright areas of an image will present, in
the printed image, a smaller size, while the dark areas the points will occupy more
surface. This surface is measured by percentage of mesh, for example a mesh point
will be at 50% when it is occupying half of its own space. The shape of the point can be
square, round or elliptical, each with its own characteristics.
These lines can be more or less dense, that is, in a unit of area there can be
more or less lines. This is what is called screen ruling. Consequently, with higher ruling
greater naturalness will present the printed image, that is, a greater feeling of modulation of
tone has. The printed image may have a greater number of details and consequently
greater number of tones.
This system is capable of reproducing screen resolutions of around 180 - 200 lines per inch,
although the maximum usual is 150 lines per inch. The high screens require a
rigorous control in the preparation of the printing form and at the same time a leveling
exquisite of the printing mechanisms.
In general throughout the printing process.
Types of images in relation to line screen:
Black and white illustrations; 133 pages (52 illustrations per page).
Four-color process; 150 lines per inch (60 lpcm).
Quality reproductions; 200 lpi Very controlled printing, fine coated paper, etc.

Ink
The ink used is greasy in nature to interact with the wet solution.
viscosity is a very important aspect, it will allow the correct distribution along the
inking battery in a thin uniform layer. Tack is another aspect to consider, it is the
the ease with which the ink detaches to be attracted by the support, or between the different
transmission elements. The characteristics of inks vary according to their use; for
exteriors, interiors, for food use, anti-rust, flexible, filmable, etc.
The ink layer is not very thick, so the concentration of pigments is high.

Screen printing
Screen printing is a direct printing system that works through permeability or mesh. Its
matrix, known as a screen printing frame or stencil, consists of a frame made of wood or metal
on which a synthetic fabric permeable to ink is stretched. This fabric is treated in order to
make the non-image or non-printer areas waterproof, so that the ink can only
go through the image or printer areas.
Currently, this system is used for both artistic production and for the
commercial, and there are manual machines (very low cost) and industrial ones (automated).

Obtaining the printer form

There are different ways to generate images in the template. If it concerns flat images
(such as those used in signage), it is possible to create a vinyl mask
self-adhesive (manually or using a cutting plotter) to adhere it to the fabric and seal the
non-printing areas. Instead, if the images are screened, one must work with films and
photo-sensitive emulsions. Depending on the type of emulsion, positive or negative films are used.

Printer machine
There is a wide variety of screen printing machines. The simplest ones consist of a table.
on which the support is based, which also has certain perforations to generate vacuum and
keep the support fixed during printing.
Screen printing allows for printing on flat surfaces as well as on cylindrical or conical shapes (such as
for example buckets, glasses, bottles, jars, pens, etc.). In these last two cases the
Counterpressure is exerted by the same support, while the squeegee is fixed and it is the template.
the one who moves.
On the other hand, rotary screen printing is a system that is applied to fully processes.
automated. The template is cylindrical and inside it are the roller and the ink.
Support must be placed on a spool, to pass between the template and a printing cylinder.
This system is used in printing.
of fabric rolls and in hybrid flexographic machines (which have printing bodies from other
systems), for high-quality label printing on PVC.

Printing process
Screen printing consists of making the ink travel, under pressure, across the surface of a
stretched screen that allows the passage of pigment in the areas corresponding to the image and
that was deposited on a support, this process assuming that it is about
print originals with fine detail and the best quality, in a run as large as possible
possible.
The essential for a good print is to be able to control its rhythm. The finer it is,
Detail to print, the greater the importance of the speed of work.
Before the operator starts, he must ensure that he has everything on hand.
you will need. Any pause during printing causes the ink to dry on the
screen.

Flexography
Flexography is a relief printing system, rotary and direct, meaning that the form
the printer makes contact with the support to be printed on, in addition to using a printer form in
relief where the graphics are located on a plane higher than the counter-graphics. Its matrix
it is much more flexible, diverse, and contains a relative hardness, which allows, for example,
printing on materials like corrugated cardboard without destroying its structure. The printed form
it is inverted (read from right to left). Its acquisition is achieved through a
negative film using a photochemical method. It uses liquid inks in addition to being a
continuous printing system (the substrate is provided in a continuous roll).
In general terms, the flexographic printing process starts with a continuous supply of ink to
the printing method using a textured roller that is semi-submerged in a container
with ink. This roller, called anilox, is drained of the excess ink using a blade.
that is in continuous friction in its rotation, providing only the ink gathered in the alveoli of
on its reticle, the support is pressed
between the printing plate and a pressure cylinder, transferring the image.

Obtaining the printer form

The beginning of the matrix was made of rubber, with the invention of the photopolymer (gelatinous material that
acquires elastomeric consistency when exposed to UV radiation) the productivity of the system is
he was able to start generating plots.
The initial consistency of the photopolymer {blank plate} is gelatinous and is based on a
transparent polyester film. Under the action of ultraviolet radiation, the material becomes
it polymerizes, hardening and acquiring elastic consistency.
Since the plate is copied in a flat shape and then curved for printing, the images
they suffer a slight deformation according to the direction of bending (the amplitude of which will depend on the
thickness of the plate and the diameter of the plate holder cylinder.
To compensate for the distortions, data must be introduced when filming the movies.
correct in the RIP program that generates the images.
The acquisition of the printer shape can be done indirectly (with film) or directly.
(digital)

Printer machine
A flexographic machine has the following parts:
Unwinder: loads the spool of material to print.
Printing bodies: this is where the actual printing takes place.
Drying ovens: they accelerate the drying of the inks.
Reel: winds the printed material.