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Customer Manual

Content

1. Product Introduction

1.1 Huaguang Processless Thermal CTP Plate TD-G PLUS

1.2 Product Features

1.3 Plate Structures

1.4 Plate-making Procedure

1.5 Plate Technical Indexes

1.6 Application

1.7 Transportation and Storage

1.8 Use Safety and Protection

2. Parameter Settings for Plate-making

2.1 Precautions for the First Use

2.2 Parameter Settings for Plate-making

2.3 Precautions for Taking and Using Plates

2.4 Precautions of Platesetter Handling

2.5 Storage Requirements after Plate-making

3. The Adjustment of Tone Reproduction Curves

4. The Press’ Debugging

4.1 The Program of Start-up Press

4.1.1 The Program of Start-up Press for Processless Thermal CTP Plate TD-G PLUS

4.1 2 The Removal Process for the Non-imaging area of Processless Thermal CTP Plate TD-G PLUS

4.2 The Operation of the Left Plates after Pressing

4.3 The Use of the Fountain Solution

4.4 The Use of the Plate Cleaner

4.5 The Use of the Washing Water

5. Troubleshooting

5.1The Plates Unable to Be Punched nor Loaded into Platesetters

5.2 Printed sheets have areas of artifacts/scratch marks

5.3 Scumming at start up

5.4 Image blinding

5.5 Plate non-image wear

5.6 Plate image wear

5.7 The Damaged Plates

 

1. Product Introduction

1.1 Huaguang Processless Thermal CTP Plate TD-G PLUS

 

Huaguang Processless Thermal CTP Plate TD-G PLUS is a new kind of environment-friendly printing product as well as a special plate suitable for thermal CTP platesetters. After exposure, it can be put on press directly without processing.

1.2 Product Features

  High-quality aluminum substrate and unique-grain processing technology. The substrate grain is uniform fine, which ensures the exact dot reproduction and excellent printing adaptability of the printing plate.

   The professional formula design with infrared laser sensitive phase- change layer ensures that the plate can be put on press directly after exposure.

   High sensitivity , wide tolerance, screen dots with margin sharpness

   Excellent printability, fast-inking balance, suitable for high-grade commercial and packaging printing.

   Compatible with various dominant thermal platesetters in the market, suitable for manual and automatic loading system.

   Bright room operation in which people can operate safely under fluorescent lamp.

   Stable quality.

  A variety of the plates provided with thickness from 0.15mm to 0.40mm.

1.3   Plate Structure

1.4   Plate-making Procedure

1.5 Plate Technical Indexes

Type

Non-ablation thermal negative-type

Substrate

Electrolyte graining and anodized Al substrate

Thickness

0.15mm/0.27mm/0.30mm/0.40mm

Spectrum scope

800-850nm

Platesetter

Various dominant thermal platesetters in the market

Low-energy imaging

140mJ/cm2

The period of latent image stabilization

≤7days

Resolution

1%~99@200lpi

Screen method

AM/FM and mixture

The paper number of start-up

<50 sheets

Safety light

1 hour under fluorescent lampno direct irradiation

with natural light), 4 hours under yellow light

Processing

Without processing, directly on press

Run length

100,000 impressions, actual run length depends on printing conditions

Baking

No recommended

Note:

1.   After imaging exposure, the longest time which plate can be placed for without affecting the printing quality is the laten-image stabilization.

2.   The paper number of start-up is the paper number at loss from the first paper to providing completely clean background.

1.6 Application

Suitable for sheet-fed offset press or high speed rotary offset press

  Run length: 100,000 impressions

  Suitable for different types of traditional inks and fountain solutions, including alcohol’s substitutes as fountain solutions.

  Unsuitable to improve run length by baking plates.

1.7 Transportation and Storage

Packed in seal and stored by means of preventing from light/moisture proof, over heat and high humidity. Recommended conditions: 18°24°C30% 50% RH.

 

1.8 Use Safety and Protection

The chemicals used in the progress of plate-making for Huaguang Processless Thermal CTP Plate TD-G PLUSs are basically nontoxic, but its use and handling must comply with Regulations on the Safety Administration of Hazardous Chemicals (the State Council released on February 17, 1987).The Implementing Regulations on Safety Administration of Hazardous Chemicals (No. 677, [1992] by the Ministry of Labor) and Regulations on Workplace Safe Use of Chemicals (No. 423, [1996] by Ministry of Labor) are strictly followed. Read the following protection instructions carefully before operation in order to protect the environment and your personal safety.

●Wearing yarn gloves when taking the plates

Wearing yarn gloves can protect the skin from scratching by the aluminum plate. Once the skin is scratched by aluminum plates, the person requires taking the hemostatic bandage measures immediately and consulting medical personnels.

●Safety measures for exposure operation

In the exposure operation, in order to prevent the occurrence of safety accidents, the operator should wear suitable clothes with the hair bundled up, tighten the cuffs and wear safety shoes. Prohibit operating with wet hands and with the cuffs opening, ties or necklaces exposed, extra things in pockets, wearing the trousers with long skirt and slippers, sandals and so on.

 

2. Parameter Settings for the Plate-making

2.1 Precautions for the First

The testing process of Huaguang Processless Thermal CTP Plate TD-G PLUS for the first use (consulting platesetter suppliers if necessary) must be noticed.

TD-G PLUS plate has a debugging process before plate-making, including the focus according to the thickness of the plate, the exposure energy according to the sensitivity and so on, and finally a set of best data to work with can be determined. 

 First check the plate’s type, size, thickness, make sure whether the platesetter, the workflow are a in standby mode or not; whether the working environment of the platesetter is clean without foreign materials inside the drum and the rollers or not; Set the plate-making parameters of Huaguang Processless Thermal CTP Plate TD-G PLUS and measure the tone reproduction curves adjusted, and then do the plate-making operation.

 

2.2 Parameter settings for Plate-making

After setting the plate’s thickness, type and name, first set the laser energy and the drum speed according to the values recommended by Huaguang, ??then make the focal length test, the zoom test, make the focal length test, the energy test and the plate reflectivity test, etc. once again, at last set the tested parameters as application parameters of Huaguang Processless Thermal CTP Plate TD-G PLUS.

Specifications of dominant platesetters recommended as the following table:

    制版机

参数

TRENDSETTER

Q800

MAGNUS Q800

SCREEN

8600SL

SUPERSETTER

VLF

Laser power

15-17W

19.5-21.5W

90-95%

120-150mW

Drum speed

250-300rpm

400-450rpm

800-900rpm

320-380rpm

Resolution

根据

要求设定

根据

要求设定

根据

要求设定

根据

要求设定

需设定参数

Focus

Zoom

Focus

Zoom

Focus

Zoom

Focus

Zoom

2.3 Precautions for Taking and Using Plates

●Take out the plate with the slip sheet when taking plates, and the slip sheet should cover the emulsion side.

Before putting the plate into the platesetter, don’t remove the slip sheet  and there’s no relative sliding between the slip sheet and the surface in the  taking process.

When removing the slip sheet, you should be careful. A quick or a sharp pull isn’t advisable. Before the plate entering the platesetter, you should check whether there are any apparent defects on the surface.

●As the coating of Huaguang Processless Thermal CTP Plate TD-G PLUS is a hydrophilic coating, you should avoid saliva, water stains, water mist and other aqueous solution contaminating the surface in the process of taking and making plates so as to avoid damage of coating which influences the graphic quality.

When the plate exposure is completed, taking the plate to the press in a careful movement, because the aluminum plate is easily broken, you should avoid the problem, such as the broken plates’ occurrence.

If the plates cannot be used up after unpacking right away, the rest should be put into the original package, then seal it to prevent from moisture.

 

2.4 Precautions of Platesetter Handling

Before starting the platesetter, ensure that the plate-making room’s environment temperature, humidity, hygiene and health achieve requirements on platesetter.

●Before the plate-making, ensure that the compressed air volume reaches the specified range.

●Ensure the used exposure parameters corresponding with the plate.

●If the color code and work requirements can’t be seen clearly after the plate-making, you can make simple annotations behind each plate with a suitable pen when making plates.

●If the cross line can’t be seen when register punching, graze slightly  near plate’s four corners with a sponge dipped in fountain solution, then use the sponge dipped in ink to graze slightly in the  the position of  the cross line image, which is clearly visible. You can also directly punch on the punch machine according to a fixed location without cross line.

 

2.5 Storage Requirements after the Plate-making

●If there’s need for short-term storage (1-2 days) after the plate-making, please put the photosensitive layer of the plate exposed opposite to each other with slip sheet interval in pairs into a suitable packing box and store them according to the storage conditions recommended.

It isn’t recommended that the plate is stored for a long time (more than 2 days) after the plate-making. Although a long-time placement will not affect the printing quality, the visibility of the image will be reduced, affecting the color code and the graphic observation. If you do need a long -time storage, please put the photosensitive layer of the plate exposed opposite to each other with slip sheet interval in pairs into a suitable packing box and store them strictly according to the storage conditions recommended.

3. The Adjustment of Tone Reproduction Curves

1. Be ready for the digital signal and the press.

2. Use the current plates of customers on press after the normal imaging, and then measure the dot of the printing.

3. Use Huaguang Processless Thermal CTP Plate TD-G PLUS on press after the normal imaging, and then measure the dot of the printing.

4. Compare the dot of Huaguang Processless Thermal CTP Plate TD-G PLUS with the dot of the current plates of customers.

5. Correct the dot appropriately according to the plate-making dot of the current plate.

 

4. The Press’ Debugging

4.1 The Program of Start-up Press

4.1.1The program of start-up press for Huaguang Processless Thermal CTP Plate TD-G PLUS

   For the use of Processless Thermal CTP Plate TD-G PLUS, first, the damping roller needs to run for 30 seconds to 60 seconds at the normal speed, and then the inking roller runs for 30 seconds to 60 seconds, at last, the paper is provided to press.

4.1.2 The removal process for the Non-imaging area of Processless Thermal CTP Plate TD-G PLUS

 

 

As can be seen from the above process, the excess coating of Processless Thermal CTP Plate TD-G PLUS is taken away by the paper of the start-up, which won’t pollute the fountain solution and the ink.

4.2 The Operation of Plate Storage after printing

4.2.1 At the end of the press run, sheet the plates down/off to remove the bulk of the ink from the plates.

4.2.2 After removal from the press, lay the plates flat on a table, ensuring they are away from any objects that may cause damage to the plate.

4.2.3 Apply a generous amount of Huaguang HGC-1 cleaner to one side of a sponge dampened with water.

4.2.4 Using a circular motion, apply the Huaguang HGC-1 cleaner to the entire plate surface, removing all the residual ink. Note: ensure the entire plate surface is covered.

4.2.5 Apply a generous amount of Storage Gum to one side of a sponge dampened with water.

4.2.6 Using a circular motion, apply Storage Gum to the entire plate surface. Note: ensure the entire plate surface is covered.

4.2.7 Reverse the sponge and using a circular motion lightly buff the entire the plate to smooth out any areas of excess Storage Gum.

4.2.8 Repeat the above steps for each plate, ensuring that the sponge is cleaned for each plate. Using a clean lint free cloth to buff plates dry.

4.2.9 The plates are now ready for storage. For best results, store the plates face to face with a slip sheet between the plates. 

4.3 The Use of the Fountain Solution

Different fountain solutions have great influence on the performance of thermal plates; the fountain solution can make plates keep the water -ink balance good in the printing process, which ensures the quality of printing, reduces the plate temperature, promotes the ink’s good running and quickly reaches the ink balance. In order to ensure the performance of the printing plate, the standardized use of the fountain solution should be strictly controlled.

Keep the fountain solution clean

Keep the fountain solution’s conductivity, temperature, pH, alcohol concentration appropriate in the range.

Specification parameters of the fountain solution

Temperature:  8-10  

PH:  4.8-5.2

Alcohol concentration:  6-10%

Conductivity:  1000-1400 µS/cm

●The content of the isopropyl fountain solution, isopropyl alcohol is 8-10% , as is recommended.

 

4.4 The Use of the Plate Cleaner

Huaguang HGC-1 cleaner is recommended. If you use the other brands of cleaners, please do a matching test of the cleaner and the coating plate. Coat the cleaner to the image surface for about 5 minutes. After washing, check whether the coating is damaged or not. If damaged, it shows that the cleaner doesn’t match the plates.

4.5 The Use of the Ink Cleaner (Cleaning water)

The Processless Thermal CTP Plate TD-G PLUS can adapt to the great majorities of the ink cleaner types. If you find that the ink cleaner has damaged the coated plate, please change another brand of ink cleaner. To determine whether an ink cleaner match with the TDG-coating, you can use the ink cleaner to flush the surface of the imaged plate for about 5minutes. Check the coated layer after washing. If damaged, it shows that the ink cleaner doesn’t match the plate.

5. Troubleshooting

5.1 The Plates Unable to Be Punched or Loaded into Platesetters 

Problems

Causes

Solutions

Plates can’t be Punched or Loaded into Platesetters

1. Plates are bent or kinked due to mishandling.

Use correct storage, handling and loading. Check unused plates in the pack for damage.

2. Adjust Platesetters.

Contact  Platesetter Engineers

 

5.2 Printed sheets have areas of artifacts/scratch marks

Problems

Causes

Solutions

Blank Spots / Scratches on the Print

1. This is an area of plate that has become out of focus during imaging due to a dent or a kink in the plate, or debris on the surface of the drum

Use correct procedures of storage, handling and loading.

Check unused plates in the pack for damage.

Platesetter / drum may require cleaning by a qualified engineer.

 

2.Platesetter adjustment/cleaning

required

Contact platesetter engineers

 

5.3 Scumming at start up

Problems

Causes

Solutions

Scumming at start up

1. Incomplete removal of the non-imaged coating on press.

1. Ensure safelight tolerance without excess.

2. Ensure product within the expiration date.

3. Ensure the start-up method for TD-G PLUS  is strictly followed.

2. Dampening system contaminated with ink and/or wash up chemicals

 

1. Wash the dampening roller sleeves regularly. With older conventional dampening systems, the roller sleeves require replacing more often than with newer systems.

2. Clean rollers with solvent cleaner and desensitise chrome rollers.

3. Check fountain solution dosage

3. Too much ink being run

Readjust ink/water balance for minimum ink and fountain solution feed.

4.Insufficient  fountain solution

1. Ensure sufficient alcohol or alcohol replacement is being used for he type of dampening system used.

2.Ensure that the fount etch and alcohol replacements are being mixed to the manufactures recommendations.

5. Excessive roller and/or plate to

blanket pressures.

 

1. Reset the rollers to the correct roller stripe width.

2. Correct the plate and/or blanket packing to the minimum needed for good ink transfer.

2. A clean start-up but smudged several thousand impressions

1. Fountain solution is too weak.

1.Increase the fountain solution etch concentration, but do not exceed the manufacturers recommended amount.

2.Contact fountain solution supplier to ensure etch is compatible with inks and dampening system.

2. Fountain solution is too warm.

Check that fountain solution chillers are maintain a correct and constant temperature of the fountain solution during pressing.

3.Insufficient amount of alcohol in fountain solution

1. Replenish alcohol to maintain a constant level during pressing.

2. Ensure that the alcohol-replenshing system is set correctly.

4. The non-imaging area of the plate is worn excessively.

1.To prevent excessive nonimage wear, wash blankets more often during the print run.

2.Check plates, blanket and form roller pressures

5. Fountain solution contaminated from

ink and/or paper feedback, resulting

in too high a Ph with unbuffered fountain solution.

1. Drain fountain solution and replace with a fresh batch.

2. To reduce excessive contamination, change fountain solution more frequently.

3. Use a solution with better buffering.

 

5.4 Image blinding

Problems

Causes

Solutions

1.The image blinding at the start-up

1.Plate improperly imaged

Verify platesetter settings for focus, power and drum speed .Contact HuaGuang technicians.

2. Plate cleaners have dried on the plate.

1.Thoroughly rinse the plate with water. Sometimes a plate can be revived by wiping over the plate with the same cleaner used initially, following rinsing immediately with  water. Never allow the plate cleaner dried on the imaging areas.

2.The image can be lost at the start of a re-run if an unsuitable plate cleaner has been used to wash the plate at the end of the previous run.

3.The preferred solution is to use the plate cleaner recommended by HuaGuang. Alkaline cleaners must not be used. Use only acid based cleaners.

3. Glazed rollers or blanket.

1.Clean and deglaze or replace roller and the blanket.

2.Replace the rollers and the blanket

4. Ink is too short and/or too high in tack.

Consult the ink manufacturer.

5.Fountain solution contaminated with paper paste / calcium.

Drain the fountain solution with a fresh batch and replace it. If problem persists, consult the paper manufacturer.

2. The image blinding after several thousand impressions

1. Ink, fountain solution, paper, plate

incompatibility.

Chemicals from inks and paper can react with the fountain

solution and the plate surface to form insoluble, water receptive

compounds on plate image and non-image areas. Consult consumable manufacturers.

2.Alcohol-free

concentrates and / or alcohol replacements are incorrectly mixed.

When excess amount of alcohol replacements are used, the ink will lose tack and also lose its ability to be transferred in the ink train. Consult with the fountain solution manufacturer.

 

5.5 Plate non-image wear

Problems

Causes

Solutions

Scummed or the dot gain after several thousand impressions

1. Paper coating, fibres, or fillers pile in

the non-image areas of the blanket.

1. Reduce water feed if possible.

2.Change to a blanket with less tack (quick release)

3.Change to a more moisture resistant paper.

4.Wash blanket more frequently.

5.Consult paper manufacturer.

2. Ink takes up fountain solution too fast.(Metal polish following an image area).

1. Try a different type of fountain solution.

2.If the problem persists, consult the ink and fountain solution manufacturers.

3. An abrasive ink(usually the black)

prints back onto the blanket of the text printing unit, polishing non-image area.Polished areas show the images of prior plate.

1. Use a more absorbent paper, a faster setting ink, a shorter ink or reduce ink feed to the prior unit if possible.

2.Wash blanket more frequently.

4. Polishing of non-image area

Check plates, blankets and form roller settings

5.6  Plate image wear

Problems

Causes

Solutions

  Plate image wear,

 

short run-length

1. Improper exposure

Verify platesetter settings for the focus, the power and the drum speed .

Contact HuaGuang technicians.

2. Abrasive ink and /or paper

1. Use less abrasive ink.

2. Don’t use the mixture of white ink  with opaque ink.

3. Paper coating, fibres, or fillers piling on image areas of blanket.

Change to a paper with better pick

 resistance, change to an ink

with less tack, reduce press speed or wash blanket more frequently during the run.

4. Plate and/or blanket packed too

high.

Reduce packing to a minimum pressure needed for sufficient ink transfer. Refer to press manufacturer specifications.

5. Rollers set too tightly to the plate.

(Wear is more pronounced on the

lead edge of the plate).

Reset rollers to manufacturers specifications

6. Insufficient bearer pressure (Wear  is  evenly spaced,  streaks

parallel with the plate cylinder.)

1.Increase bearer pressure so that the cylinders are not riding on the gears. 2.Refer to press manufacturer specifications.

7. Press chemicals cause blanket or rollers to swell.

1.Use chemicals that are compatible with the blanket or rollers.

2.Consult blanket and roller manufacturers for recommendations

8. Press chemicals are not compatible with the plate coating

1.Test the chemicals by placing on a solid image area for approximately 5 minutes.

2.Wash off with water and check for

damage to the coating.

3. A print test should be done to confirm the result.

9. The fountain solution is too acidic or alkaline

Check pH of the fountain solution. If the pH is 3.5 or lower and the least minimum concentration recommended by the manufacturer, which shows it not suitable with the water used. Consult with the fountain solution manufacturer for alternatives

10.Ink starvation(Image wear takes place in an area where there is an ink

ghost).

1.The thinner ink film causes plate wear in the ghost areas before the rest of the image area.

2.Run more ink if possible or use ink

  with less pigment loading.

3.An oscillating ink roller may reduce ghosting, but if pigment content of the ink is too high, the entire plate may wear early.

11. Sharpening of image, particularly

highlight dots during the press run

1. Check press chemicals, fount concentration and temperature.

2. Check alcohol percentage. Alcohol at concentrations above 10% can induce image breakdown during the press run.

3. Check ink quality and oleophilic feeding properties, try other inks.

5.7  The Damaged Plates

Problems

Causes

Solutions

1.The Plate is cracking

1. Not tight on the cylinder.

Check for fit after mounting the plate

 

 

2. Short plates, or not aligned correctly.

1. Check the length of the plate.

2. Make sure the plate clip cannot move during pressing.

3. Carefully align the plate clip with the plate at the initial time of mounting.

3.The plate bender doesn’t aligned with the plate correctly

1. Check the bender alignment.

2. Measure the plate for squareness.

4.Incorrect plate thickness

Check the thickness of plates for correct specifications.

5.Dirty in the cylinder gap

Clean the cylinder gap

6. The cylinder edge has burrs or dried ink.

Clean and de-burr the cylinder edge

7. The lead or the tail of the plate isn’t properly bent.

Check that the plate bends properly in the cylinder gaps.

8. Excessive pressure of ink / dampening rollers causes the lead edge of plates to flex.

Reset rollers for the plates’ contact recommended.

2. Scratching

1.Improper plates’ handling

Handle the plate with care. CTP plates are more sensitive to improper handling than conventional plates.

2. Punch the plate

Inspect the cleanliness and ensure the smooth operation

3.Plates auto-loaded system

Inspect its cleanliness and ensure the smooth operation

4. The roller contamination with hard particles.

1. Locate and eliminate the source of the contamination and remove the particles if possible or scrub the rollers.

2. Replace the rollers if the problem persists

3.Gouging mark in the plate

1.Improper plate handling

Handle the plate with care. CTP plates are more sensitive to improper handling than conventional plate.

2. Punched plates

Inspect its cleanliness and ensure the smooth operation

3.Plate auto-load system

Inspect its cleanliness and ensure the smooth operation

4. Roller contamination with hard particles.

1. Locate and eliminate the source of the contamination and remove the particles if possible or scrub the rollers.

2. Replace the rollers if the problem persists.

 

 

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