Dirty Print? – Is Clean Plate Technology the Answer?

You are not alone!

I don't believe there are many flexographic printers that have not experienced dirty print at one time or another. As a matter of fact, more printers report that dirty print is an ongoing issue. Part of the reason this issue is so widespread in our industry is because of the number of different root causes that can create this print defect. These causes include but are not limited to the following issues;

• Unbalanced BC dryers
  • air blowing on plate
• Shallow relief within screens on the plate
  • inadequate plate processing
• Tacky/sticky plates (high dyne level)
  • insufficient UV-C light finishing (detack)
• Viscosity, pH, temperature, humidity
• Dried ink in relief area coming out of storage
  • inadequate plate relief cleaning
• Ink build-up on plate
  • Ink transfer issue(s) from plate to substrate
• Too much ink to plate
  • anilox BCM too high for plate LPI
  • anilox LPI too low for plate LPI

The issues above just scratch the surface. So it is safe to say you are not alone if you too are experiencing dirty print issues. Because this problem is so widespread, MacDermid Graphics Solutions have developed a line of photopolymer plates that are formulated to combat this printability issue. A couple of nice side-effects to what MacDermid calls their Patented Clean Plate Technology, is that these plates take ink transfer from plate to substrate to the next level. Some printers report that the Clean Plate Technology is so effective delivering ink to the substrate the plate appears as if it hardly needs to be cleaned at the end of the press run. I can personally vouch to the fact that plate cleaning is so much easier with these plates.

Straight from the Developers

MacDermid describes the product as Patented Clean Plate Technology improving plate cleanliness on press. The clean agent is included in most of MacDermid's LUX ITP™ photopolymer plates with inherently flat-top dots plus their Digital MCP plate for round top dot applications. Clean Plate Technology not only reduces ink build-up in-between dots and reverses, but it also makes the plate easier to clean when cleaning is required. The result is beneficial in plate efficiency, allowing for longer run lengths without cleaning. The reduction in ink build-up allows for smoother vignettes with less tendency for ink to print that has accumulated on the sidewalls of dots providing for smoother tonal gradations and a more aesthetically pleasing print result. Clean Plate Technology also improves plate life by reducing the physical cleaning requirement that ultimately impacts plate integrity regardless of how the cleaning is conducted.  

My Experience and Others

The description above is exactly what I have experienced time and time again at many flexographic converters as they move to this technology. The specialized photopolymer is formulated to have a high enough dyne level to effectively transfer ink from the anilox cells while releasing a higher percentage of the ink film thickness to the substrate. In short, the ink transfer rate is enhanced. In my opinion, when it comes to plate technology, aside from the movement to flat-top dots in the last decade, this Clean Plate Technology is one of the most significant advancements in the past few years.

Considering the variety of root causes, this technology is not a cure-all for all dirty print issues. However, if you want to best position yourself to see the many benefits users of this unique photopolymer are experiencing don't hesitate to reach out to us for further discovery. If you want to learn more about this subject, please feel free to reach out to us by calling 1-800-445-4017, or by e-mail at [email protected].

All Printing Resources has formed our Technical Solutions Group (TSG) to encompass our full range of expertise in all critical areas of the flexo process. This team is made up of industry professionals dedicated to being up-to-date on new technologies along with best practices. They are armed with the latest in diagnostic tools and are experienced in problem-solving that can achieve sustainable results. The TSG has walked in your shoes, and have felt your pain.