Increased importance of measuring devices in gravure cylinder production

Quality control is a very important factor in the production of gravure cylinders. The following points play a major role in this:

• Process control of each step during cylinder production (copper plating, chrome plating, grinding process, engraving, etc.)
• Repeatability of gravure cylinders
• Avoidance of problems during engraving (broken stylus, etc.) and during printing (chrome wear, color change, etc.)
• The gravure cylinder is very important for the quality of the printed product and plays a particularly important role in high-quality printed products (brand names).

In addition, the issue of sustainability is becoming increasingly important. The last few years of crisis have also left their mark on gravure printing. Rising raw material and energy prices are not making the business any more lucrative and present manufacturers and buyers of gravure cylinders with difficult decisions. Here, too, quality control plays an important role. In order to ensure efficient use of resources, it is essential, for example, to measure the layer thickness of the galvanically deposited metals (copper, chromium) non-destructively in order to avoid unnecessary waste of materials. The copper layer is determined using the Minitest layer thickness measuring device (see Figure 1) with a magnetic-inductive probe. The chrome layer, on the other hand, is measured with a special probe using the eddy current method.

Other important measurement methods are:

• Copper hardness test using the UCI method: important for optimal engraving (Figure 2: Hardness tester SD-H3)

• Measurement of the surface roughness: optimal surface roughness ensures trouble-free printing and increases the service life of the cylinder (Figure 3: Roughness tester PS10)

• Circumference measurement of the cylinder: the correct cylinder circumference plays a major role in determining the required web tension in the printing press (Figure 4: D.Mess circumference measuring device)

• Measurement of the engraved cells using the CheckMaster II measuring microscope: determination of deviations from the ideal shape of the engraved cells (Figure 5: CheckMaster II)

The quality of the printing form and the printed product can only be optimized through precise process control of the gravure cylinders produced. Ultimately, no materials are wasted and resources are conserved. In addition, waste and thus the unnecessary consumption of ink and printing material is avoided in the printing process. In summary, the following can be said:

Poor gravure cylinder quality costs time and money and wastes resources!