1

Quad/Graphics Presents

An Introduction toGravure Imaging

2007

Gravure Imaging

2

Cylinder Engraving

Gravure is an intaglioprinting process.

That means, theimage is cut or etchedbelow the surface.

3

Copper Cylinders

• Copper is used to cover cylindersbecause it’s soft and pliable, making iteasy to engrave.

• Each cylinder weighs approximately2,500 pounds – about the same weightas a VW Beetle.

• Cylinders last for tens of millions ofimpressions, so gravure is usedfor long press runs. The gravure image carrier is a

re-usable steel-based cylindercovered with a layer of copper

=

Gravure Workflow

4

Cylinder Preparation

• The gravure imaging processbegins with the cylinder comingoff press.

• Gravure cylinders come invarious circumferences.

• The cylinder size is determined by:

– Final size of the page

– Number of pages in the form

– Repeat of the design

Stripping Station –RemovingBallard Shell

• After the cylinder is cleaned,the top layer of copper andchrome is removed fromthe cylinder.

• This is called the Ballardshell, which allows thecylinder to be reusedmany times.

5

Copper Plating

• After the cylinder is cleaned, it’s movedto a copper plating tank, and the steelcylinder is electroplated with a thinlayer of copper.

• The cylinder is stored in racks to usefor future jobs.

• The copper is only 80 microns thick –about the thickness of a human hair.

• Later, the copper will be removed fromthe cylinder and replaced, so thecylinder can be used over and over.

Play clip

Copper Polish

• To prepare for engraving,the copper surface isautomatically polished.

• Polishing removes anyimperfections and smoothesout the cylinder.

• Polishing also adds aroughness to the surfaceso it can retain the ink that willlubricate the cylinder.

6

Helio Form Station

• A press imposition formneeds to be created beforewe engrave the cylinder

• The form positions andaligns pages accordingto the book layout.

• Forms are digitallytransferred to theengraving station.

Cylinder Engraving

• Now the cylinder is ready to beengraved (after impositionform stage).

• Digital data for text and imagesfeed these engraving heads,that images the copper cylinder.

• The printed image consists ofhoneycomb shaped cells that areengraved into the copper cylinderusing a diamond-tippedengraving head.

• The un-etched areas of thecylinder represent the non-image(unprinted) areas.

100 % 50 % 5 %

Electromechanical Engraving

Cross Section of Cells

7

• Engraving the image onto the cylinderis a high-speed, fully automatedprocess.

• Diamond tips engrave hundreds ofthousands of individual cells into thesurface of the cylinder.

• The depth and size of the cells controlthe amount of ink that gets transferredto the paper.

• The size and shape of the cells alsodepend on the color of the ink and thetype of paper it will be printed on.

K6 Fully AutomatedEngraving Technology

K-6 Advantages

• Fully automated cylinder engraving

– HelioSprintHigh speed electro-mechanical engrave heads

– CellGuardPre-engrave & post-engrave verification of cells

– GipsyNTHigh speed processor of digital page information

• Enhanced productivity(shorter setup times; reducing client cycle time)

• 40-44 cylinders engraved per 24 hrs.(2 engravers)

• Consistent quality(automated ribbon balance verification)

8

Pre-ChromePolisher

• After engraving, the cylinderis polished for a consistentsurface, and removesburrs (imperfections).

Play clip

Cylinder is submergedinto degreasing tank

Cylinder isDegreased

• The cylinder is electronicallycleaned to remove all greaseand oil from the surface.

9

Chrome Plating

• Once the cylinder is engraved, it’s cleaned andcoated with a final layer of chromium.

• Chromium:

• Provides a hard surface layer that helps preventthe doctor blade from wearing outduring printing.

• What is a doctor blade?

– Device that removes excess ink from thenon- engraved portions of the cylinder.

– Allows cylinders to be used for press runsof over one million

Play clip

Chrome Polisher

• Chrome polisher looks similarto the pre-polisher.

• The chrome-plated cylinder ispolished once again to “roughup” the surface, making theink act as a lubricant.

• After the final chromiumsurface is polished, thecylinder is inspected.

• If it’s okay, it’s ready to goto press.

10

Cylinder Handling& Storage

• The cylinder is stored in racks to use for future jobs.

• Lomira stores up to 2,000 cylinders

• Cylinders are automaticallytransported from one step tothe next – from imaging tothe press room and backto storage.

• During makeready, thepress operator carefullyloads the printing cylindersinto the press.

Cylinder Handling& Storage

11

Cylinder Goesto Press

One of Quad/Graphics’ Gravure Plants

12

What Type of CustomerFits Gravure?• Gravure prints high-quality

images with intense, rich colorwith one pass through the press.

• That’s why it’s often used forhigh-volume printing such asadvertising pieces like inserts,magazines and catalogs.

Thank you,questions?

13

K6 Installations

Helio Location Start-up Date

Helio 12 OKC June 2004

Helio 13 OKC June 2004

Helio 14 Lomira March 2006

Helio 15 Lomira March 2006

Helio 16 Martinsburg April 2006

Helio 17 Lomira April 2006

87% Improvement - Reduction in Press Correction Downtime

Thank you