DRAWDOWNS : FILM THICKNESS CONTROLS
    
     
Determining a desirable film thickness
requires understanding of how a wet film reacts at various thicknesses.
Viscosity, surface tension and other physical properties that affect the
final result must be understood before establishing what thickness will be
accepted for a particular production. UV Process Supply offers many
different tools for helping you determine these characteristics.
8
PATH SCRAPER DRAWDOWN
This
chrome applicator features 8 precision channels ranging
from 1 mil to 8 mils. A small quantity of the material to
be checked is placed on the inside of the selected channel
and drawn down over a paper chart or other smooth flat
surface providing a uniform thickness of film for
observation and testing.
BLADE
APPLICATOR PROOFER
The
Blade Applicator Gauge combines the accuracy of a
"bird" type applicator with the ease of
thumbscrew adjustability. It is specially designed to
provide precise test samples of inks, paints, coatings and
adhesives. The shape of the applicator blade is not a
sharp knife edge, but a flat area. Through a shearing
action only half the liquid is deposited on the test
sample. The applicator lays down a wet film thickness
which is nominally one-half the gap clearance.
To operate, loosen each knob, slide the calibrated plate
to the desired gap setting, and retighten the knobs.
Drawing the applicator across a pool of coating liquid
allows the precise gap at the blade to produce a wet film
of the required thickness.
DRAWDOWN
BARS / RODS - WIREWOUND RODS
These
rods give users the ability to fine-tune coating thickness
quickly and easily, without altering the chemistry of
their coating material, and without time-consuming and
expensive changeovers.
For users that require a coating path of up to 12",
use the standard Laboratory Drawdown Rods (N008-005 choose
1/4", 3/8", or 1/2") . With an overall
length of 16", these rods are longer than the Jr.
variety.
The
Accu-Lab Jr. Laboratory Drawdown Rods (N008-026,
N008-026A) are designed for users producing test samples
up to 8½" wide. These stainless steel rods are
4" shorter than conventional lab rods and offer an
additional savings.
Wet
coating thickness can be accurately predicted within one
tenth of a mil (.0001"). Rod selection tables allow
coaters to consider coat weight and percent of solids in
choosing the proper rod size for each production run.
Bottom-line profits have encouraged many coaters to modify
existing machines, in order to take advantage of the
flexibility, the ease of use and the dollar savings
associated with rod coating.
The market for wire-wound rods has grown rapidly during
the past few decades, because they provide predictable,
accurate coatings time after time, at a minimal cost.
Although the technology goes back almost a century,
today's high quality materials, multi-wire designs and
special wire surfaces have made this system more popular
than ever before.
Wire-wound rods were first used in coating machines built
by Charles Mayer in the 1900's to manufacture waxed paper
and carbon paper. They are still called "Mayer
Bars" by many coaters.
Standard Lab Rods (N008-056, 057 & 058) are less
expensive due to a different manufacturing process and all
of these are 16" long with a centered wound length of
12".
ROD SIZE NOTES:
To determine approximate wet film thickness in Mils for a
specific rod number from the table below, multiply the rod
number by 0.10. For example, the number 3 rod would be 3 x
0.10 = 0.30 Mils. The number 20 rod would be 20 x 0.10 =
2.0 Mils.
For Microns, multiply rod number by 2.54. For example the
number 3 rod would be 3 x 2.54 = 7.62 Microns.
AVAILABLE DRAWDOWN ROD WIRE SIZES
82-90:
Standard Lab Rods Only (Accu-Lab Jr. Rods only go to 80)
>62: Standard Lab Rods with a Rod
diameter of 1/4" is not recommended above 62
HANDHELD
DRAWDOWN FOR LABORATORY USE
The
CON-TROL-CURE™ Handheld Drawdown is a low cost precision
drawdown tool for testing inks, paints, emulsions,
adhesives and chemicals in the laboratory, on the plant
floor or in the field. The heavy-duty stainless steel
construction will not rust or corrode and can be
completely submersed in solvent for easy clean-up. Quick
one hand operation provides a full 5" wide drawdown
path of controlled coating thickness. Easy to change
Drawdown Rods are available to produce coatings from .25
mils (.00025") using the number 2.5 rod to 9 mils
(.009") thick using the number 90 rod. Includes 1
drawdown rod of your choice in that range.
AVAILABLE HANDHELD DRAWDOWN ROD
WIRE SIZES
For
a film thickness greater than 9 mils, custom double a
triple wound rods are available at an additional cost.
Please contact us for a custom quotation.
LENETA
CARDS OPACITY TESTING
Printing
ink drawdown sheets provide a variety of substrates for
testing ink qualities. They are also useful for testing
coatings because of their range in absorbency and texture.
Sheet Size: 5" x 7-5/8"; Paper: Non-fluorescent/Unwatermarked;
Ink: Jet Black/Non-bleeding; Packaging: Sold per box (10
pads/box - 100 sheets/pad for a total of 1000 sheets)
PERFECT
PROOFER : AUTOMATIC FLEXO PROOFER
The
Perfect Proofer™
The Perfect Proofer is an air driven device used to mimic
Flexographic presses. It systematically controls speed and
pressure until it matches your particular press. Once that
speed and pressure is identified those settings become the
press “signature”.
As with the system’s earlier proofing head designs, the
Perfect Proofer’s new Print Head has
micrometer-calibrated nip controls. But on this new design
the anilox nip affects contact with a plate – not with a
rubber transfer roller. The other significant difference
is that the new Print Head employs a second set of
micrometer adjustments which calibrate plate-to-stock
contact. Though this new capability is significant, the
fundamental concept of a Perfect Proofing System remains
unchanged. With it, plants can determine a set of specific
system settings that represent accurate fingerprints of
individual press stations. By recalling those settings and
a few other basic pieces of information (stock, anilox
specs, etc.) from an archive, ink technicians can
reprogram the system to emulate the press station where an
ink will be used.
Benefits
Accurate: Faithful reproduction of proof samples with
consistent Delta E variances in the range of 0.5 – 0.8
Fast: Consistently produce accurate proofing samples the
first time, greatly reducing the time spent generating
samples with hand proofers
Time Saving: Once correlated to the presses, users report
savings of 3 to 4 hours per day. By having the ability to
mimic your press(s), you will save an average of 10
minutes per color (setup) and a 10% material savings. For
a three-press company this translates to an average
savings of over $200,000 timesaving per year. In a typical
operation, users report a full payback of unit cost in
less than one year.
Quick Cleanup: Designed to clean quickly and easily
between sample proofs
The Perfect Proofer is easy to use, and no press
experience is required.
1. Place the hand proofer into the clamp base.
2. Insert the sample paper from the left, under the hand
proofer.
3. Ink the hand proofer
4. Press and hold the red button to perform the draw down.
Releasing the button will immediately raise the hand
proofer and end paper travel.
5. Travel speed is adjusted by turning the upper left knob
on the front of the Perfect Proofer. Clockwise for slower,
counterclockwise for faster.
6. Roller pressure is adjusted by turning the lower left
knob. Clockwise for higher pressure and counterclockwise
for lower pressure. Roller pressure is indicated on the
gauge to the right of the knob.
Reproducing faithful color is one of the most critical
elements in print quality and continues to be a major
challenge for most print shops. The availability of low
cost spectrophotometers has greatly impacted the industry
by providing more precise color measurements, making it
more feasible to achieve that goal. The color of the ink,
and the manufacturer’s ability to reproduce the exact
colors that were prepared in the laboratory with standard
inks, is the next vital component in the color equation.
This is typically done by comparing the color of proof
samples prepared in a laboratory with those of the
accepted standard ink. It has long been suspected that the
weakest link in the color measurement chain has been the
laboratory proof samples.
In a test conducted by the NPIRI Task Force on Color
Proofing, they found significant differences in color, not
due to the ink, but rather to variations in substrate used
and the method used to apply the ink. They found that
color variations can be minimized by using mechanical ink
applicators, the same paper substrate, and averaging the
results of several replicate samples.
Test Findings – The NPIRI Task Force took great care to
prepare prints having the same density, and to assure that
each proof was measured by the same calibrated equipment.
The test was conducted in several different labs. By
controlling paper stock and ink, the test isolated the
effect the method used to apply the ink has on results. It
clearly demonstrated that commonly used hand-held anilox
proofers inherently have higher Delta E variances (0.3 to
1.49) than were experienced with mechanical proofers (0.2
to 0.83). The hand-held proofers also had much higher
variability between drawdowns.
The implications are clear…mechanical proofers provide a
higher degree of accuracy and reliability. The Perfect
Proofer provides the greatest range of precise speed and
pressure control available in the industry. This unique
precision makes it possible to correlate the proofer and
your presses, virtually eliminating inconsistencies
between your presses and the ink room.
FEATURE:
- Precision motor with digital speed control, giving speed
accuracy to within ± 1% at 100 fpm
- Precision commercial grade pressure regulator provides
accurate pressure to within ± 2%
- High-strength, brushed aluminum case
- Variable speed and pressure control
• Speed - 50 fpm to 250 fpm
• Pressure - 10 psi to 60 psi
- Precision ground impression drum with lifetime bearings
- Floating, self-compensating proofer mounting bracket
- Locking rings on pressure and speed controls
- Precision speed and pressure gauges
- Compact and portable
- Automatic lubrication system; lifetime seals
- Two year warranty
- Optional substrate roll feed stand
BENEFITS:
- Comes up to speed nearly instantaneously, providing a
longer, usable proof sample that is more accurate
- Provides the ability to precisely match the pressures in
your flexo-presses with digital accuracy
- Strong case protects proofer; wipes clean quickly and
easily without absorbing or staining
- Precise speed and pressure controls allow you to
correlate your flexo-presses to the proofer for improved
proofing accuracy and consistency
- Impression drum is non-absorbent and easy to clean;
heavy duty bearings assure a lifetime of performance
accuracy
- Assures correct and accurate alignment of the proofer
and substrate for improved color accuracy; reduces
probability of human error
- Locking the desired settings in place assures that speed
and pressure will be maintained throughout the proofing
cycle
- Provides finely calibrated adjustment accuracy to
correlate your presses’ speed and pressure parameters
with those of the Perfect Proofer
- Weighing only 35 lbs., the Perfect Proofer is easy to
move and takes very little shelf space
- Lubricates internal parts to provide long-term,
consistent test results
- Provides added value and confidence that you are
purchasing a high-quality mechanical proofer
- Removes the requirement to stop the substrate before it
goes through the impression drum to avoid cleaning
UV
FLEXO INK HAND PROOFER
Precision
Tools for Matching Color and Coatings
Finally, a
quick and precise way to reliably match PMS and custom
colors for UV Flexo, and Primographic inks off-press.
After relentless hours of research and much time testing
the ultimate way to match color, we finally found what we
believe is the ultimate precision color matching tool.
Each of the below hand proofers is sold with 1 anilox roll
of your choosing (see the table at bottom.) If more rolls
are needed please contact us.
With these UV Flexo Hand Proofers, you can go to press
with an anilox/ink combination that delivers the precise
color you need. Commercially compatible color proofing for
both customer color approval, and spectraphotometer
readings.
These industry leading units are compatible with solvent
based systems, ensuring a minimal clean-up. The easy take
down design allows for quick and easy changing of the
engraved anilox rolls. The anilox rolls are platinum laser
engraved. The Doctor Blade loads the celIs of the anilox
rolls and meters the ink to a repeatable ink film
thickness.
The Traditional
Echocel Junior is a Flexographic hand proofing system
incorporating Platinum® laser engraved ceramic anilox
technology, steel doctor blade and solvent resistant
rubber roll. This system has benefited from years of
successful exposure in the field. Designed specifically
for water based and solvent inks, this lightweight unit is
the standard in the field. Ink path width is 2.75 inch
(70mm) Traditional Rolls are engraved at a 60º Hex.
Our newest
model, the Phantom Proofer, is the ultimate proofer
to increase pressroom efficiency! Manufactured with many
of the same quality components and high standards as the
Echocel Junior, this unit improves upon that design. Its
quick change anilox roll mechanism and doctor blade allow
for easier clean up, increasing efficiency. The ultra
lightweight design features less replacement parts and
built-in bearings. Ink path width is 2.75 inch (70mm)
Echocel
Jr. Plus THIS ITEM HAS BEEN DISCONTINUED BY THE
MANUFACTURER. HOWEVER - SPARE PARTS AND ANILOX ROLLERS ARE
STILL AVAILABLE. THE JUNIOR PLUS IS A WIDER PROOFER (5
inch path instead of 2.75 inch)
AUTODRAW
III LABORATORY DRAWDOWN MACHINE
AUTO-DRAW™
III is a motorized drawdown machine that is affordable for
even the smallest coatings laboratory. It was designed to
eliminate human variables and to create laboratory
precision samples. This simple instrument is the latest
addition to our line of drawdown sampling devices and
allows the scientist to produce accurate, repeatable
drawdowns time after time at an economical price!
FEATURES:
• Eliminates all human variables - speed, direction and
rod pressure.
• Easy 1-switch control knob
• Uses Accu-Lab™ Jr. rods
• Compact - requires only 11" x 22" (28cm x
56cm) of bench-top space.
SPECIFICATIONS:
• Maximum sample size: 8.5" x 13" (21.5cm x
33cm)
• Power: 110V AC, 60 Hz
CLEAN
MACHINE FOR CLEANING HAND PROOFERS
Any
hand proofing tool can be cleaned automatically in just a
few seconds with the newest generation of Clean Machine.
Originally developed as a companion product to the
company’s Perfect Proofer, the Clean Machine now has a
universal adapter that accepts any Harper, Pamarco or
other common hand proofing device. Once a tool is mounted,
the Clean Machine’s drive cylinder spins its moving
parts while a stream of solvent washes over the inked
surfaces. After this 10-second “bath”, a technician
just removes the tool and blow-dries it with the unit’s
integrated air nozzle. When earlier generations of this
unit were used with hand drawdown tools, applications were
limited
to water-based inks. However, this new design is suitable
for both water- and solvent-based plus UV inks.
No electrical connections are required. The entire system
runs on shop air and uses a diluted solution of any common
ink solvent.
According to the manufacturer; “Toolcleaning eats up at
least 4 hours of labor each day in most ink labs. With the
Clean Machine, virtually all that time can be redirected
to other, much more productive activities.”
APPLICATOR
ROD STORAGE RACK
Horizontally
holds up to 12 drawdown rods 8.375" (22 mm) in length
and longer. Sturdy polyethylene support measures 9.5 x
7" wide (241 mm x 178 mm) and 11.5" high (292
mm). There is 8.375" (213 mm) between plates with a
0.75" (19 mm) diameter carrying bar at the top. Rods
not included.
LABORATORY
DRAWDOWN MACHINE
For
accurate, repeatable applications of test coatings, the
precision CON-TROL-CURE™ Laboratory Drawdown is an
economical solution to many of the problems associated
with manual drawdowns. The unit controls the load on the
drawdown rod with a simple, weighted assembly and holds
the rod securely during the drawdown stroke. This
operation eliminates human-related differences in rod
pressure and direction of stroke. Accurately make samples
up to 12"W x 13"L (30.5 cm x 33 cm). The system
is constructed with heavy-duty ball bearing slides for
reliable, long-lasting use. The Laboratory Drawdown uses a
standard 1/2" (1.27 cm) diameter stainless steel bar
that is tightly wound with stainless steel wire. The
diameter of the wire, in the wound form, regulates the
thickness of the coating. The bars are available in 45
different wire diameters from .0025"-.090" (wet
film thicknesses from .25-.9 mils). Bars are sold
separately.
MINI-LABORATORY
DRAWDOWN MACHINE
The
Con-Trol-Cure™ Mini Laboratory Drawdown offers a
low-cost, economical and precise method of measuring film
thickness, for samples up to 8-1/2" (21.6 cm) wide.
Easy to use handheld precision stainless steel Mini
Drawdown Bars assure "no rocking" application.
With a shorter bar, applying liquid samples in a
straighter path is easily achieved. Its precision drawn
wire is accurate to within .0001". The bars have an
overall length of 12" and are 3/8" diameter
(30.5 mm x 0.95 mm). Mini Drawdown Bars are not included.
Each bar is sold separately.
INK
PROOFER QUICK PEEK - OFFSET PROOFER
Industry-standard
"Quick Peek" Offset Lab Proofing Kit is designed
for color matching and UV cure testing. Use to evaluate
offset ink characteristics. This complete lab proofing kit
features a 2" (50.8 mm) hand proofer, 1/4" x
3/4" x 4" (6.35 mm x 19 mm x 101.6 mm) nickel
plate ink gauge, hexagon handle ink plunger, polished
stainless steel inking surface, ink knife, and ink hole
cleaners.
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