Professional Documents
Culture Documents
Specifications
Chiawei Wu
Engraving Manager
Packaging corporation of America, Waco, Texas
Electro-
Mechanical Engraving
87-inch Langston
Corrugator
60-inch Lux (Roll-to-Roll)
Laminator
Asitrade Litho Laminator
5 Single facers
C, B, E, & F Flute
E/B, B/C Double Wall
Split Roll Technology
Barrier Coatings
Tear and Reinforcement
Tapes
Direct Drive Knife
Narrow Roll
4
Rotogravure is
the premier,
cost effective,
printing method
for higher
volume, high
resolution
packaging and
displays.
10
11
1. De-chrome
plating
2. Cut off Image
Rough & Fine cut
3. Copper plating
To final size
4. Light Polishing
4. Engraving
5. Engraving
5. Chrome Plating
6. Engraving
6. Chrome Plating
6. Proofing
7. Chrome Plating
7. Proofing
7. Printing
8. Proofing
8. Printing
1986 ---2000
1. De-chrome
plating
2. Cut off Image,
Rough cut
3. Copper plating
Over final size
4. Polishing to size,
Rough & Fine cut
5. Light Polishing
3. Light Polishing
9. Printing
13
Cylinder specifications
Part I:
The Five Elements of Cell Specifications
Part II:
Process Specifications & Ink Transfer from
Electro-Mechanical Engraved Cell
14
Cylinder specifications
Part I:
The Five Elements of Cell Specifications
15
1.
2.
3.
4.
5.
Stylus
Angle
Wall
Channel
Line Screen
16
GRAVURE Cell
17
18
19
20
Measurement 101
1. Inches
2. Microns
3. Billion Cubic Microns
4. Cylinder Square Inches
5. Meters
21
2.54 x 10-2 m
1 x 10-6 m
2.54 x 104m
25,400m
22
Stylus
Besides putting holes in copper, what is its
significance?
23
Stylus continued
The steeper the stylus angle, the greater the depth.
(Illustration based on same size cell opening.)
105
110
115
120
125
130
160m
37m
46m
56m
130
120
110
24
Electro-Mechanical Engraving
Cell Width vs. Cell Depth
CELL DEPTH VS. CELL WIDTH
FOR A GIVEN STYLUS DEPTH
DEPTH
110o
1.8
3.5
5.3
7.0
8.8
10.5
12.3
14.0
15.8
17.5
19.3
21.0
22.8
24.5
26.3
28.0
29.8
31.5
33.3
35.0
DEPTH
115o
1.6
3.2
4.8
6.4
8.0
9.6
11.1
12.7
14.3
15.9
17.5
19.1
20.7
22.3
23.9
25.5
27.1
28.7
30.3
31.8
DEPTH
120o
1.4
2.9
4.3
5.8
7.2
8.7
10.1
11.5
13.0
14.4
15.9
17.3
18.8
20.2
21.7
23.1
24.5
26.0
27.4
28.9
DEPTH
125o
1.3
2.6
3.9
5.2
6.5
7.8
9.1
10.4
11.7
13.0
14.3
15.6
16.9
18.2
19.5
20.8
22.1
23.4
24.7
26.0
DEPTH
130o
1.2
2.3
3.5
4.7
5.8
7.0
8.1
9.3
10.5
11.7
12.8
14.0
15.1
16.3
17.5
18.6
19.8
21.0
22.1
23.3
DEPTH
135o
1.0
2.1
3.1
4.1
5.2
6.2
7.2
8.3
9.3
10.4
11.4
12.4
13.5
14.5
15.5
16.6
17.6
18.6
19.7
20.7
DEPTH
140o
0.9
1.8
2.7
3.6
4.5
5.5
6.4
7.3
8.2
9.1
10.0
10.9
11.8
12.7
13.6
14.6
15.5
16.4
17.3
18.2
DEPTH
145o
0.8
1.6
2.4
3.2
3.9
4.7
5.5
6.3
7.1
7.9
8.7
9.4
10.2
11.0
11.8
12.6
13.4
14.2
15.0
15.8
25
26
Stylus continued
Example:
lpi
angle
stylus
38
38
38
110
120
130
150
150
150
8
8
8
75
62
50
215
215
215
16.0 bcm
13.2 bcm
10.7 bcm
If:
Then:
Therefore:
27
Angle of Compression
Controls cell shape and depth
30
45
60
Ranges from 30 to 60
30 :
45 :
60 :
30
Compressed
45
Normal
60
Elongated
29
angle
30
45
60
stylus
120
120
120
channel
30
30
30
wall
8
8
8
depth
73
54
39
width
253
187
133
volume
15.5 bcm
11.5 bcm
8.2 bcm
If:
Then:
Therefore:
30
31
Walls
Leave them alone; 8m is a great number for
100% cell!
32
Walls continued
Example:
lpi
angle
stylus
150
38
120
30
62
235
13.2 bcm
150
38
120
30
16
55
219
10.4 bcm
150
38
120
30
24
47
193
7.9 bcm
If:
Then:
Therefore:
channel
wall
depth
width
volume
33
Walls continued
150lpi 38 120(S) 30(C) 8(W)
34
Channel
Channel measurement is not your choice
Channel measurement is a direct result of the
specified angle
30 :15% of the width of the cell
45 :10% of the width of the cell
60 :2% of the width of the cell
35
Channel continued
For all angles between 30 and 60, for every 1 of change, the width of the cell
changes 1/3 of one percent.
Example:
lpi
angle
150
30
stylus
120
channel
43
wall
8
cell width
240 * 0.15
150
38
120
31
214 * 0.113
150
45
120
22
195 * 0.10
150
60
120
159 * 0.02
30 :
33 :
38 :
45 :
60 :
Channel continued
Example:
lpi
angle
stylus
channel
wall
depth
150
38
150
120
10
68
38
120
20
65
150
38
120
30
62
If:
Then:
Therefore:
width
volume
37
Channel continued
150lpi 38 120(S) 10(C) 8(W)
38
Line Screen
Cell openings are always measured in microns
1 inch = 25,400 microns
0.001 = 25.4 m
Measuring methods create confusion in actual
number of lines per inch
Example:
150 lpi at 45 angle = 109 cells per inch
39
45
Normal
40
Electro-Mechanical
Engraving
Screen Angle with
Screen Factor
Screen
Angle
Vertical Screen
Factor
Horizontal
Screen Factor
Resulting Cell
Shape
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
1.303
1.208
1.257
1.235
1.213
1.192
1.171
1.150
1.130
1.111
1.091
1.072
1.054
1.036
1.018
1.000
0.983
0.966
0.949
0.933
0.916
0.900
0.885
0.867
0.854
0.839
0.824
0.810
0.795
0.781
0.767
0.767
0.781
0.795
0.810
0.824
0.839
0.854
0.867
0.885
0.900
0.916
0.933
0.949
0.966
0.983
1.000
1.018
1.036
1.054
1.072
1.091
1.111
1.130
1.150
1.171
1.192
1.213
1.235
1.257
1.208
1.303
Compressed
Compressed
Compressed
Compressed
Compressed
Compressed
Compressed
Compressed
Compressed
Compressed
Compressed
Compressed
Compressed
Compressed
Compressed
Normal
Elongated
Elongated
Elongated
Elongated
Elongated
Elongated
Elongated
Elongated
Elongated
Elongated
Elongated
Elongated
Elongated
Elongated
Elongated
41
Example:
lpi
angle
stylus
150
38
120
175
38
200
38
If:
Then:
channel
wall
depth
width
volume
30
62
215
13.2 bcm
120
30
51
176
10.7 bcm
120
30
42
147
8.8 bcm
Therefore:
44
45
56.25 %
(43.75%)faster*
46
47
= 8.800 x pi x 57
= 8.800 x 3.1416 x 57 = 1575
63,000,000
11,520,000
11,520,000
5.47 hours
48
If:
Then:
If:
Then:
If:
Then:
50
Cylinder Specifications
Part II:
Process Specifications & Ink Transfer from
Electro-mechanical Engraved cell
52
Density
Yellow
1.00
Magenta
1.45
Cyan
1.35
Black
1.70
Black
122 lpi
214 lpi
135 lpi
236 lpi
143 lpi
250 lpi
Yellow:
x Base
3
Black:
10
x Base
1.414
x Base
1.732
0.816 x Base
1.432 x Base
7
Magenta and Cyan: Base at 60 or Base at 30
1.432 x Base at 30
54
lpi
angle
stylus
channel
wall
volume
magenta 150
30
130
35
12.2 bcm
cyan
150
60
110
12.0 bcm
yellow
122
45
130
27
12.4 bcm
black
214
30
110
30
11.2 bcm
If:
Then:
Therefore:
Tone Scales:
Why are they necessary?
What do they mean?
Which percents should be printed?
100% : Establishes density
75% : Prints dots
50% : Prints without flooding
25% : Prints strongly
5% : Prints smallest dot that prints 100% of the time
3% : Prints most, but not all, dots
56
57
Ink Considerations:
Choice of cell and screen is dependent on the ink
that is to be used.
Substrate Considerations:
59
Examples:
1. A 20% cell on the cylinder may be required to
obtain a 3% dot on paper.
2. A cell at 95% of full size may lay down so much
ink that the adjoining cells flood together and
the paper is covered 100%.
61
62
63
64
65
Q&A
66