Modern Inks Formulae and Manufacturing Industries (Hand Book)

MODERN INKS FORMULAE AND MANUFACTURING INDUSTRIES

CHAPTER 1

Introduction

Elements of Ink

The nature of Printing Inks

Visual characteristics of inks

The colour of inks

The transparency and opacity of printing inks

The gloss of printing inks

Flexographic and Gravure Inks

Lithographic and letterpress inks

The Drying Characteristics

Absorption during

Oxidation drying

Evaporation drying

Chemical drying

The adhesive nature of printing inks

The resistance properties of printing inks

Light fastness

Heat resistance

Abrasion resistance

Product resistance

Radiation induced drying

CHAPTER 2

Colour Matching

Introduction

Practical Procedure in Colour Matching

The operation of printing

Ink

Paper

Printing Surface

Printing Conditions

Colour Pattern

The Pattern

Wet Ink Samples

Printed Pattern

Matching Procedure

Limitations

Tests on the pattern

Matching Details

Final Adjustments

CHAPTER 3

Raw Materials

Pigments

Yellow pigments

Diarylide Yellows

Ironoxide yellows

Tartrazine yellow lake

Chrome yellows

Cadmium yellows

Fluorescent yellow

Orange Pigments

DNA Orange

Pyrazolone orange

Diarylide orange

Fast Orange F2G

Benzimidazolone Orange HL

Ethyl Lake Red C

Red Pigments

Para Reds

Toluidine Red

Carmine F.B.

Naphthol Reds and Rubines

Permanent Red FRR

Bordeaux FRR

Rubine Reds

Lithol Reds

BON Red

Lithol Rubine 4B

BON Maroon

Rhodamine 6G

Lake Red C

BON Arylamide Red

Quinacridone Magentas

Copper Ferrocyanide Pink

Benzimidazolone Carmines and Reds

Azo Magenta G

Anthraquinone Scarlet

Madder Lakes

Pigment Blue

A Brief Introduction

Types Of Blue Pigments Available

Pigment Blue 15.0 (Alpha Blue)

Pigment Blue 15.1 (Alpha Blue)

Pigment Blue 15.2

Pigment Blue 15.3

Pigment Blue 15.4

Green Pigments

Phthalocyanine Greens

PMTA Greens

Violet pigment

Brown pigments

Diazo Brown

Benzimidazolone Brown HFR

Fluorescent Pigment Colors

Black Pigments

White Pigments and Extenders

White Pigments

Extender

Pearlescent Materials

Fluorescent Pigments

Dyestuffs

Acid Dyes

Basic Dye

Auramine

Diarylmethyaniline Yellow

Uses

Rhodamine 6G

Rhodamine B

Victoria Blue

Uses

Methyl Violet

Solvent Dyes

CI Solvent Yellow 19 No. 13900:1

Manufacturing Methods

Uses

Derivation

CI Solvent Orange 45 No. 11700: 1

Manufacturing Methods

Uses

Derivation

CI Solvent Red 8 No. 12715

Manufacturing Methods

Induline (spirit soluble)

Uses

Manufacturing Methods

Properties and Applications

Nigrosine (spirit soluble)

Properties

Manufacturing Methods

Properties and Applications

Uses

Nigrosine (free base)

Properties

Uses

Disperse Dyes

C1 Disperse Yellow 3 No. 11855

Properties

Uses

Structure

CI Disperse Red 4 No. 60755

Properties

Uses

Structure

CI Disperse Blue 3 No. 61505

Properties

Uses

Structure

CI Disperse Red 

No. 6075

Properties

Uses

Oils

Drying Vegetable Oils

Linseed oil

Tung oil (China wood oil)

Oiticica oil

Dehydrated castor oil

Other oils

Segregated oils

Marine oils

Semi-drying oils

Soya bean oil

Non-drying oils

Mineral oils

News ink oils

Non-drying vegetable oils

Natural Resins

Rosin

Natural Resin

Shellac

The formula of shelloic acid

Manila copal

Asphalts

Starch and dextrin

Gum Arabic

Synthetic Resin

Pure phenolic resins

Rosin-modified phenolic resins

Application & Uses

Pigment interactions

Hard resin interactions

Film-forming properties

Hydrocarbon resins

Polystyrene resins and copolymers

Terpene resins

Silicone resins

Alkylated urea formaldehyde resins

Alkylated melamine formaldehyde resins

Polyamide resins

Poly (amide imide) resins

Chlorinated rubber

Cyclised rubber (isomerised rubber) (Resiprene)

Application fields

Vinyl resins

Polyvinyl alcohol

Ketone resins

Acrylic resins

Epoxide resins

Polyurethane resin

Phenolic resin

Polyisocyanates and polyurethanes

Nitrocellulose, N/C (Cellulose nitrate CN)

Ethyl cellulose

Ethyl hydroxyethyl cellulose (EHEC)

Cellulose acetate propionate (CAP)

Cellulose acetate butyrate (CAB)

Sodium carboxymethyl cellulose (CMC)

Solvents

Types of Solvent

Hydrocarbon Solvents

Low boiling petroleum distillate-alipatic

White spirt

Uses of white spirit

Paraffin oil (kerosene)

Examples of Solvent

The Solution, Solubility and Solvation

Uses of Solvent

High boiling petroleum distillates-aliphatic

Hydrocarbon solvents-naphthenic

Aromatic hydrocarbons

Toluene (toluol)

Xylene (xylol)

High boiling aromatic solvents

Alcohols

Glycol Ethers

Ketones

Boiling Points and Solubility

Plasticisers

Waxes

Fully refined paraffin wax

Petrolatum or petroleum jelly

Microcrystalline waxes

Ceresin wax

Montan wax

Formulation and mechanisms of waxes in coatings

Drier

Paste Driers

Miscellaneous additives

Chelating Agents

Antioxidants

Surfactants

Anionic surfactants

Cationic surfactants

Non-ionic surfactants

Amphoteric surfactants

Deodorants and Reodorants

CHAPTER 4

Waxes and Additives

Introduction

Generic wax materials

Natural Waxes

Beeswax

Carnauba Wax

Lanolin

Miscellaneous Natural Waxes

Petroleum waxes

Micro-crystalline waxes

Mineral Waxes

Ceresin Wax

Ozokerite

Synthetic Waxes

Polyethylene Waxes

Polyethylene Glycols

Halogenated Hydrocarbon Waxes

CHAPTER 5

Typographic Inks

Harder-drying book and periodical inks, Jobbing inks

Platen Inks

Inks for cylinder machines

Jobbing Inks

Quick-setting Inks

Inks for process coated paper

Inks for banks, bonds, grease-proof papers, carton boards

Process Inks

Print down yellow

Transparent yellow

Magenta (Red)

Black

Cyan four-colour blue

Three-colour blue

CHAPTER 6

Printing Inks

General Requirements

Manufacturing Process

Mixing

Milling

Filtration

Ink Properties

Types of printing inks

Quick-Set Inks

Heatset inks

Moisture-Set Inks

Radiation-Curing Inks

High-Gloss Inks

Metallic Inks

Magnetic Inks

Fluorescent Inks

Scuff-Resistant Inks

Printing Requirements

Letterpress

Offset Lithography

Flexography

Gravure

Ink-Jet Printing

Copperplate and Die Stamping

Electrostatic Printing

Ink is manufactured in two stages

Step 1 - Varnish manufacture

Oleoresinous varnish manufacture

Non-oleoresinous varnish manufacture

Step 2 - Pigment dispersal

Three roll mills

Bead Mills

Cavitation Mixers

Composition of inks

Letterpress ink for newspaper

Lithographic ink for paper

U.V. curing lithographic ink for paper

The manufacture of oleo-resinous systems

Varnish manufacture

Flow pattern in practical terms

Deaeration and potting

The manufacture of polymer/solvent systems

Varnish manufacture

Cavitation mixer

Rotor/stator mixer

Storage and handling

Manufacture of additives

Liquid ink manufacture

Ball mills

Bead Mills

Chips

Pigment ‘chip’ manufacture

Pigment Production Technology

Manufacture of dye-based inks

Mixing Equipment

Butterfly mixers (Change pan)

Rotor and stator high speed mixers

High-speed impeller mixers

High Speed Mixers

The ‘star’ impeller type

The high-speed disperser

The fixed or on-line mixer

High-speed mixing

Typical uses and applications

Milling Equipment

Three-roll mills

Construction

Development of single cast rollers

Bead mills or stirred ball mills

Ball Mill

Vertical Bead Mill

Pin Type Bead Mill

Turbo Bead Mill

Disc Type Bead Mill

Open sieve mill

Closed sieve mill (Dupont and Draiswerke)

Developed by Herr Durr and Herr Engels of Draiswerke GmbH, this major

John mill (Netzsch GmbH)

Tex mill (Draiswerke GmbH) (see Fig. 12.23)

Dyno mill (Willy A Bachofen Ag)

STS mill (Draiswerke GmbH)

Boa 500 mill (Buhler Brothers Ltd)

Co-ball mill (Fryma Ag)

Manufacture of Newspaper Inks

Oil handling

Production method

Handling and Storage of Inks

Ink Cartridge Handling Precautions

Handling precautions for replacing ink cartridges

Consumption of ink

CHAPTER 7

Formulations

Considerations governing Choice of Pigments

Choice of Pigments

The Role of Water

Ink Vehicles

Linseed Oil based Black Offset Litho

Soap Carbon Printing Yellow Offset Litho

General Purpose Hard Drying Red Offset Litho

Summary of general consideration

Damping Water and the Ink

Ink Consistency

Ink Drying

Drier Absorption

Letterpress Ink Formulation

Platen ink for absorbent papers

Cylinder press ink for uncoated papers

Quick-set inks for coated paper

Letterpress ink drying by oxidation

Water-reducible inks

Process inks

Process magenta letterpress

Newspaper coloured inks

Rotary black inks for newspapers

Formula A: General-purpose low mist black

Formula B: Ink rail

Formula C: Page-Pak

Formula D: Keyless inking (indirect flexo)

Formula E: Flat-bed rotary

Formula F

Use of refined oils

CHAPTER 8

Publication Inks, Cork tipping Inks, Carton Inks and their Formulations

Paper in publication printing

Gloss and absorbency

Formulation requirements

Easily dispersible pigments for publication gravure inks

Inks for catalogue printing

Typical formulation of a catalogue ink

Packaging inks for paper and board Labels

Typical fast-drying formula for labels

Typical formula of a chip-based non-curl label ink

Typical co-solvent polyamide ink

Metallic label inks Formula

Bronze ink

Paper wrapper inks

Inks for cork tipping

Carton Inks

Heat-resistant carton ink Formulation

Heat seal resistant varnish Formulation

Metallic bronze gravure ink for cartons

Foil inks

Virgin foil

Formulation for lightweight aluminium foil

Foil laminates

Foil board laminates

Inks for polyethylene film

Ink based on co-solvent polyamide resin

Ink based on alcohol-soluble polyamide resin:

Inks for treated polypropylene films

White ink for treated side of co-extruded polypropylene:

Red ink for pearlisedopp

Coated polypropylene films

Yellow ink for printing on coated polypropylene film

Cellulose films

Main application

White ink for surface printing on N/C coated films

Polyester films

Red ink for reverse print and lamination on uncoated polyester film

Nylon films

Vinyl films

Metallised films

Wall coverings

Inks for paper

Typical formula for a gravure wallpaper ink

Vinyl coated wallcoverings

Typical formula of a vinyl wallcovering gravure ink

Typical gravure/flexo wall-covering ink

Expanded polyethylene

Decorative wall panels

CHAPTER 9

Photogravure Inks for Three and Four colour Reproduction

Introduction

Black Inks

Coloured and Extender Inks

Metallic Gravure Inks

Gravure Overprint Varnishes

CHAPTER 10

Screen Process Inks

Introduction

Poster Inks

Gloss Poster Inks

CHAPTER 11

Ball-Point Pen Inks

Ink Components

Innovations in Ink

Additive Assistants

Raw Materials

The Manufacturing Process

Making the ink

Stamping and forming

Molding the housing

Ink filling and assembly

Final assembly, packaging and shipping

CHAPTER 12

Testing of Finished Inks

Short Term Tests

Longer Term Tests

Short Term Tests

Consistency (Letterpress and Litho Inks)

Dispersion

Scale Comparisons of Grinding Gauges

Hue and Strength

Short Term Tests on Other Types of Inks

Liquid Inks

News Inks

Silk Screen and Die-stamping Inks

Longer Term Tests

Drying Time

Automatic Drying Time Testers

Skinning time

Setting Time

Strength (Concentration of pigment)

Hue: Instrumental Measurements

Gloss

Density and Specific Gravity

CHAPTER 13

Flexography

Ink Fountain

Printing Unit

Plates

Rubber Plates

Outfeed Section

Inks and Substrates

Paper and Paperboard

Non-Paper Substrates

Press Configurations

Sheetfed Flexography

Hybrid Flexographic Presses

Flexo Gravure

Offset Flexo

Advantages

Disadvantages

Designing for Flexography

The Flexo-printing Process

Platemaking

Printing

Understanding the key flexographic label printing press components

Feed & Unwind Station

Printing station

Drying Station

Die Cutting & Converting

Outfeed and Rewind

Types of flexographic label press

In-Line Press

Central Impression Press

Stack Press

CHAPTER 14

Lithographic Inks

Nature of the process

Formulation of Lithographic ink

Characteristics of Litho Inks

Film thickness considerations

Drying Mechanisms

Restrictions of the process

Penetration

Oxidation

Quickset mechanism

Physical Properties

Viscosity

Solvents

Formula

Formulating Principles

Formula for lithographic offset printing ink

Lithographic Inks

Violets

Greens

White

Extenders

Typical inks and varnishes

Inks and varnishes for sheet-fed paper printing

Sheet-fed label inks

Metallic inks

Small-offset

Inks and varnishes for sheet-fed carton board printing

Ink for sheet-fed impervious substrate printing

Formulation

Inks for web-offset paper printing

Coldset

Heatset

Ink-related problems and their possible solutions

Step-by-Step Troubleshooting Guide:

Check for Physical Damage

Clean the Pump:

Verify Ink Levels

Inspect Tubing

Address Unusual Noises

Tighten Connections

Address Leaks

Perform Test Prints

Consult Technical Documentation

Seek Professional Help

High Dot Gain

Piling

Setoff

Poor Ink Mileage

Litho problems

Rheology problems

Tack problems

Setting and drying problems

Appearance problems

Dot reproduction

Poor Lay

Problem

Problem

Problem

Problem

Problem

Recent and future trends

3D Printing Will Penetrate Into Different Sectors

Expertise In IT Will Be Key

Sheet Fed Digital Printing

Print Security Spending Will Be Fuelled by IoT

Cost Effective Printing Is Of Prime Demand

Security Printing

Cloud Printing

The Role of Automation and Artificial Intelligence

The Personalisation and Customisation Trend

CHAPTER 15

Melamine Laminate Inks, Fluorescent Inks, Textile Inks, Water-based Inks, Non-Impact Printing, Electrostatic Imaging, Inks for jet Print-ing, Speciality Screen Inks

Stamps

Speciality systems

Metallic inks

Colors and Types

Metallic Ink Screenprinting

The Benefits

Bronze inks for film

Aluminium-based inks

Typical formula - vinyl wallcovering simulated gold

Pearlescent inks

Typical formula of pearlescent ink for wall covering

Fluorescent inks

Textile Inks

Reactive Ink

Disperse Ink

Water-based Inks

Acid Inks

Sublimation Inks

Pigment Inks

Non-Impact Printing

Electrostatic imaging

Inks for jet printing

Water-based continllous jet ink

Drop-an-demand (impulse) system

Speciality Screen Inks

Encapsulated perfume inks

Thermochromic inks

Phosphorescent inks

CHAPTER 16

Inks for the Electronics Industry

Printed circuit products

Alkali-soluble rich resist

Two-pack epoxy solder resist

UV solder resist

Thermal-curing notation ink

Membrane switches

Inks for laminated plastics

Inks for wallcoverings

Water-based flexowallcovering ink

H/C free flexolgravure vinyl wallcovering ink

Textile transfer inks

Flexo water-based heat transfer ink

Sterilisation Inks

One-pack steam sterilisation ink

Other colour change and security inks

Security Ink Technologies

Biometric Taggants

Erasable Ink

Coin Reactive Ink

Bleeding Ink

UV Invisible Fluorescent Ink

Thermochromic Ink

Fugitive Ink

Chemical Reactive Inks

Optically Variable Ink

Magnetic Ink

Penetrating or Indelible Ink

Pen Reactive Ink

Secondary Fluorescing Ink

Photochromic Ink

Visible Infrared Ink

Adhesion Promotion Varnish

Security Ink Applications

Bank Notes

Textiles

Packaging

Official Documents

Labels

Pharmaceuticals

Handbags and Cosmetics

Concert, Sports and Lottery Tickets

CHAPTER 17

Offset Printing Inks

Product Introduction of Colour Printing Ink

Properties and Characteristics

B.I.S. Specification

Principles of ink formulation

Offset printing inks (coloured)

Formulae

Blue Plate Inks

Flexographic Inks

Gravure Ink

Automatic Press Red

Manufacture of Offset Printing Inks

Steps to Formulate Offset Printing Inks

Inspect Incoming Ink

Agree on a Specification

Define the Target Color

Measure the Print Substrate

Define the Ink Film Thickness or Anilox Roller

Formulate of Recipe

Create a Drawdown

Measure the Drawdown

Save the Recipe

Evaluate Results

Resolve On-Press Issues

Special offset printing inks

Thermochromic inks

Metallic inks

Mirror inks

Pearlescent inks

Watermark imitation inks

Scented inks

Scratch-off inks

Magnetic inks

Luminescent inks

CHAPTER 18

Stamp Pad Inks

Introduction

B.I.S. specification of ink, stamp pad

Process of manufacture

Glycerine based

Purpal colour (Oil Based)

Procedure

Blue Ink

Procedure

Red Inks

Procedure

Method of manufacture for stamp pad ink

Formula

Flowchart

CHAPTER 19

Rotogravure Printing Ink

Formulations

Flexographic inks

Formulation-1

Formulation-2

Formulation-3 (Bright blue ink)

Formulation-4 (Green ink)

Formulation-5 [Flexographic (Nitro cellulose base) Ink]

Formulation-6 (For Paper, Carton Board, Foil, Cellophone, Cellulose Acetate Film and Other Plastic Films)

Manufacturing process of flexographic ink

Gravure Inks Formulation

Manufacturing process of gravure printing ink

Manufacturing process of vehicle

Dispersion of Pigments

CHAPTER 20

Printing Inks (Flexographic Ink)

Introduction

Formulations

Flexographic Inks

Formulation 1

Formulation-2

Formulation-3 (Bright blue ink)

Manufacturing process of flexographic ink

Gravure Inks Formulation

CHAPTER 21

Duplicating Ink

Introduction

Uses and Application

Properties

Raw Materials

Formulations

Formulation-1

Formulation-2

Formulation-3

Manufacturing Process

CHAPTER 22

Ball Pen Refill Ink

Ball pen inks formulations and processes

formulation - Cold Climate Ball Pen Ink

Temperature Climate Ball Pen Ink Formulation

Tropical Climate Ball Pen Ink Formulation

CHAPTER 23

Plastic Ink (Flexographic & Rotogravure Ink) and Golden Silver Paste

Introduction

Flexography

Gravure

Flexographic Inks

Gravure Inks

Uses and Application

BIS Specification

Formulations

Flexographic Inks

Formulation-1

Formulation-2

Formulation-3 (Bright blue ink)

Formulation-4 (Green ink)

Formulation-5 (Flexographic (Nitro cellulose base) ink]

Formulation-6 (For Paper, Carton Board, Foil, Cellophone, Cellulose Acetate Film and Other Plastic Films)

Formulation-7 (For Plastic Packaging Film)

Flexographic Ink Formulation

Process

Flexographic Ink

Flexographic Ink

Process of Manufacture

Manufacturing process of flexographic ink

Gravure Inks Formulation

Manufacturing process of gravure printing ink

Manufacturing process of vehicle

CHAPTER 24

Printing Machine Roller

Detailed description of the preferred embodiments

Working principle of three roll mill

How to choose a three roll mill

The quality of the roller

Roller size

Feeding method

Influence of parameter setting on grinding effect

Pressure

Temperature

Blade

Tips for finding the best device

CHAPTER 25

Testing of Printing Inks

The Importance of Ink Testing

Methods of Ink Testing for Commercial Printing

Specific Gravity

The Effect of temperature on Viscosity

The effect of ink viscosity on quality

Viscosity Measurement

Viscosity

Penetration

Refraction

Evaporation

Acid Number

Ink Absorbency

Various tests can determine the ink absorbency of a paper

Tung Oil

Detection of Resin

Detection of Rosins

Testing of Pigments

Do organic pigments contain chlorinated aromatics?

Can pigments be a source of cyanide?

Can certain pigments produce aromatic amines?

Solid Prints/Side-by-Side comparisons of Batches

Pigment Strength & Transfer (Wedge Prints)

Dry Rub Resistance

% Volatiles

% Trap

Water Pickup & Contamination

Brookfield Viscosity

Duke Viscosity

Fineness of Grind

Ink Mileage

CHAPTER 26

Printing Inks and Allied Products Standards List

CHAPTER 27

Plant Economics of Ball Point Pen, Refills & Ink

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

CHAPTER 28

Plant Economics of Digital Inks

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

CHAPTER 29

Plant Economics of Industrial Paint and Inks (Various Types)

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

CHAPTER 30

Plant Economics of Offset Printing Inks (Coloured)

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

CHAPTER 31

Plant Economics of Printing Inks (Flexo Graphic)

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

CHAPTER 32

Plant Economics of Printing Inks (Flexo, Roto, Offset and Screen)

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

CHAPTER 33

Plant Economics of Printing Inks on HDPE Laminated or Unlaminated Bags

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

CHAPTER 34

Plant Economics of Rotogravure Printing (For Flexible Packaging)

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

CHAPTER 35

Plant Economics of Screen Printing Inks

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum