Transcript
xix
LIST OF TABLES
Table No
Title
Page
1.1
Increased levels of greenhouse gases since the start of industrial era 1750
7
1.2
Earth‟s water table calculation
8
1.3
Gases in Earth‟s atmosphere
8
3.1
India‟s print and allied items: market value, 2009 - 12 ($ millions)
35
3.2
India‟s print market value by end use, 2009-12 ($ million)
37
3.3
Offset Printing market value by process 2009-12 ($ million)
37
3.4
Offset printing machinery, market value 2009 – 12 ($ million)
39
3.5
India‟s print market value by Equip. & Consumables, 2009 -12 ($ million)
39
3.6
Magazines circulation by category, 2012
42
3.7
Books: Printing market value 2009-12 ($ million)
42
3.8.
Security Printing market value 2009-12 ($ million)
44
3.9.
Packaging Printing market value 2009-12 ($ million)
45
3. 10
India‟s print market value by process, 2009 -12 ($ million)
46
3.11
Print Market regional wise share
47
3.12
Printing market value by region 2009 -12 ( $ million)
47
4.1
Environmental Indicators of Heidelberg
62
4.2
Energy consumption table
64
4.3
Material breakdown of the Speedmaster XL 105
68
xx
4.4
Energy consumption data of dryers of sheetfed printing presses in kW
70
4.5
Input and proportional waste generated after processing
73
4.6
Material consumption during paper making a comparative study
74
5.1
Paper industry volume and values 2009 - 12
79
5.2
Indian Paper Industry Status (Company wise)
80
5.3
Print market demand volume 2009 – 12 („000 tones)
81
5.4
Paper and board printing market value by material 2009 – 12 ($ millions)
82
5.5
Dampening Unit setting from gripper to tail on OS, DS
89
5.6
Trapping percentage of different colour combinations
91
5.7
Mottling factor
92
5.8
Print contrast values
93
5.9
Dot gain values
94
5.1
Ink density at different ink zones of the press
95
5.11
CIE La*b* coordinate, gloss, ISO brightness, tolerance
97
5.12
La*b* value of [A] Sudarshan Classic paper
98
5.13
Slur or Doubling
99
5.14
Result showing performance of different papers
99
5.15
Visual analysis of the test papers.
100
5.16
Laboratory test report of papers
101
5.17
Ink drying on paper at different time period
109
5.18
Paper reaction with high tack ink and normal fountain.
109
5.19
Effect of fountain solution on paper during ink drying
110
5.20
Test paper parameters before and after improvement
118
5.21
Laboratory Test Result on 90 gsm and 130 Gsm Coated paper
119
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6.1
Printing Ink market volume („000 tons)
121
6.2
Printing ink market volume by end use 2009 – 12 („000 tons)
121
6.3
Printing ink market share by major manufacturers 2012
121
6.4
Comparative individual results and average values of ink test
141
6.5
Ink performance based on test evaluation
142
6.6
Details of Lab and ∆E values Hei Premium (Ink Code G) 142
6.7
Details of Gloss values of Hei Premium (Ink Code G)
144
6.8
Details of overall rating of Hei Premium (Ink Code G)
144
6.9
Ink D, Hei Utility deliver the highest yield
148
7. 1
VOC and HAP Emissions Factors
164
7.2
Comparison of the washing solvent‟s performance
165
7.3
Result of the washing solvent‟s performance
166
7.4
Industrial agreement for cleaning agent in the Printing
169
7.5
Factors influence the performance of the plate and press
176
8.1
Factors involved in the process of standardization
192
8.2
Calculation for packing thickness
201
8.3
Determining the IPA content
204
8.4
Proportionate Percentage of contents in dampening sol.
205
8.5
Comparative study on the difference in Auto and manual
207
8.6
FOGRA dot gain values
220
8.7
Shows the density, dot area and corresponding dot gain
224
8.8
Additive compatibility with (Varn Protector) Inference and conclusion
232
8.9
Additive compatibility with (Akron Gold) Inference and conclusion
233
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8.1
Additive compatibility with (Huber Hydro) Inference and conclusion
234
8.11
Additive compatibility with (Total Care) Inference and conclusion
235
8.12
Additive compatibility with (DSC Stabilat) Inference and 236 conclusion
8.13
Additive compatibility with (Saphira FS 13) Inference and conclusion
237
8.14
Blanket compatibility with (Perfect Dot) Test Inference and conclusion
238
8.15
Blanket compatibility test (Day 3000) Test Inference and conclusion
239
8.16
Blanket compatibility test (Conti Air) Test Inference and conclusion
240
8.17
Summary of Compatibility Test
241
8.18
CO2 Factor for typical consumables in printing presses
243
8.19
Input Material Attributes before optimising
244
8. 20
Calculating the CO2 release
246
8. 21
Input Material Attributes after optimising
247
8. 22
Calculating the CO2 release
249
xxiii
LIST OF FIGURES
Fig. No
Page
Title
1.1
Ice glaziers melting (1950 – 2002)
2
1.2
Annual Green House Gas emission by sector
5
1.3
Green house effect
6
1.4
Flow diagram showing Research methodology in Eco Printing
14
3.1
Environmental impact of a sheet fed offset printing machine
53
4.1
Sheet fed printing press – amalgamation of technologies 68
4.2
LCA of a Printing Press shows the Impact of the use phase
69
4.3
Environmental impacts of input on the printing process
72
4.4
Energy utilization in a sheetfed offset printing machine
75
5.1
Sequence in paper making from Wood or Bagasse.
83
5.2
FSC logo and procedure for accreditation
86
5.3
SM 74 – 4 – P + L at PMA, Heidelberg India
88
5.4
Back trapping of previous image on the blanket
90
5.5
Paper fiber being picked on the blanket surface
91
5.6
CIE La*b* system
97
5.7
Paper pile for the performance evaluation test
100
5.8
Colour patches having different spectral colour measurement
102
5.9
Test image for optimizing the reverse printing time
104
5.1
Impression cylinder before printing. (1st Phase)
105
5.11
Impression cylinder at 3000th copy (1st Phase)
106 st
5.12
Impression cylinder condition at the end of printing (1 Phase)
106
5.13
Impression cylinder at 3000th copy (2nd Phase)
107
5.14
TNPL Radiant Print Platinum STD grade paper
108
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5.15.
Impression cylinder at 4000th copy after having the ink
111
5.16
Quality evidence Test form 4-259 for paper opacity
113
5.17
Checking the pH of paper with pH tester
116
5.18
Checking the Rh of paper with Sword hygrometer
116
5.19
TW side transfer the image to BW side due to poor opacity
117
5.20
No transfer of ink from TW side to BW side
117
6.1
Inks lined up for the performance test
125
6.2
Quality Evidence Test form
127
6.3
Plate‟s copy curve for all the print tests.
128
6.4
Dot gain curve for black component
128
6.5
Ink density variations due to dampening solution
129
6.6
Print-out quality in screen background
129
6.7
Samples of two scuff tests
131
6.8
Scuff resistance of process inks
132
6.9
Ink set off between sheets in the pile
133
6.10
Proof strips with increasing ink film thickness
134
6.11
Color intensity curves of yellow ink
135
6.12
Color intensity curves of magenta ink
136
6.13
Color intensity curves of cyan ink
136
6.14
Color intensity curves of black ink
137
6.15
ΔE comparison of yellow ink
138
6.16
ΔE comparison of magenta ink
138
6.17
ΔE comparison of cyan ink
139
6.18
ΔE comparison of black ink
139
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6.19
Gloss values for the ink series
140
6.20
YMC and B Dot gain curves for Hei Premium
143
6.21
Yellow ink with varying pigmentation
145
6.22
Contaminated Yellow ink
145
6.23
Oxidized top layer of ink in the used tin
146
6.24
Ink mileage test on SM 74
147
6.25
Density measurement displayed on SM 74
148
6.26
Solvent recovery plant
149
7.1
Starch based powder crystals (enlarged 400 times)
153
7.2
Calcium carbonate based powder crystals (enlarged 100 times)
153
7.3
Sugar based powder crystals (enlarged 400 times)
154
7.4
Left: Hydrophilic (Uncoated) Right: Hydrophobic (Coated)
154
7.5
Power dust travelling route which penetrate the lungs of operator
155
7.6
Checking the powder concentration
156
7.7
Data showing variation in powder concentration
157
7.8
Scanned diagram of powder brand Nikka AS 160
157
7.9
Scanned diagram of powder brand Nikka CD20
158
7.10
Scanned diagram of powder brand Nikka VP-XXX
158
7.11
Powder particles seen on the entire delivery section of the press
159
7.12
Comparison of different particle size - 5000 sheets with 30μm
160
7.13
Powder distributions - even and uneven
160
7.14
Pile influenced by uneven powder distribution
161
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7.15
Sampler for taking the dust sampling
163
7.16
Dust Sampler at press delivery
163
7.17
Non-breathing zone VOC sampling
164
7.18
Use of bear hands can cause skin irritation
167
7.19
Use of hand gloves can protect the hands
167
7.20
Flash point of Wash-up solvents
168
7. 21
Ink misting at the rear frame of a printing press
168
7.22
Catch plate
172
7.23
Image setter (CtP) with online plate processor
175
7.24
The evaluation of laser power on the plate
179
7.25
The power difference between diodes
180
7.26
Test image for Laser focus test
180
7.27
Matching field test on Plate
181
7.28
Test plate for accuracy of exposure time
181
7.29
Plate test strip to check the exposure accuracy
182
7. 30
Test image to find the developing time of plate
182
7.31
Image to check the consistency of developing and exposure
183
7. 32
Checking the processor roller pressure
184
7.33
Test to check the dwell time setting
184
7.34
Saphira 830 C and Technova Thermostar TN Plate
185
7.35
Power and Focus plate test strip
186
7.36
Test page linearization (calibrated and uncalibrated)
187
7.37
Gradient tests on plate
188
7.38
Differentiating Linear and Process calibrated out put
188
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7.39
CtP Test Chart
189
8.1
Feeder setting with bowers, suckers and pile height governors
197
8.2
Cross section of an offset printing blanket
198
8.3
Tightening the blanket with a torque wrench
199
8.4
Packing height requirement on blanket achieve printing pressure
200
8.5
Checking the blanket pressure using 3 dial gauge
201
8.6
Squeeze pressure of 0.01 mm and with optimum pressure of 0.100mm
202
8.7
Test strip to check the water hardness.
203
8.8
Areometer for checking the IPA percentage
204
8.9
Unusable dampening solution due to foggy effect.
205
8.10
Fresh dampening solution
205
8.11
Questionable dampening solution and unusable dampening
206
8.12
Inking and dampening unit setting (mm)
207
8.13
Roller setting through strip method.
207
8.14
Flooding due to wrong setting and correct setting rollers
210
8.15
Comparison of Glazed roller surface and good roller surface
211
8. 16
Checking the shore hardness of roller
211
8. 17
Checking the surface of roller quality
212
8. 18
Printed paper jogged and land in delivery pile.
213
8. 19
Registration grid test chart.
214
8.20
PAN4C analysis print test form
215
8.21
99%, 97% and 93% patches
215
8.22
Line scumming area of 50%
216
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8.23
Measuring areas of 43, 45, 47 and 49 patch
216
8.24
Reference values for dampening
217
8.25
Showing bad ink splitting in Cyan and Black
218
8.26
Scum start variation at OS and DS
218
8.27
Print Contrast Test chart
221
8.28
Test form for cecking the dot gain and ghosting
223
8. 29
PAN 4C Mixed test form 45 for print characteristics
225
8.30
Emulsification process
227
8.31
Ink splitting technique
227
8.32
Magenta showing density variation due to excess of dampening
228
8.33
One mm yellow ink strip indicates optimum ink water balance
228
8.34
Minimum oscillations to keep the color density stable
229
8.35
YMCK Gradation test form
230
8.36
Effect of Dot gain on Grey balance solid patch
231
8.37
Test form to adjust the Ink Presetting
242
8.38
Print taken before optimizing the press
245
8. 39
Ink trapping percentage (M+Y 72%, C+Y 80%, C+M 63%)
245
8.40
Graphical representation of the print
245
8.41
Print taken after optimizing the press
248
8.42
CP 2000 reading on SM 74
248
8.43
Graphical representation of the print
248
8.44
Ink trapping percentage (M+Y 73%, C+Y 87%, C+M 64%)
250
9.1
Measuring typical emissions at work place of a printing press
254
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9.2
Sinusoidal encoder main drive motor
255
9.3
Two-stage water filtration systems
256
9.4
Economic life of a machine
257
9.5
VLFM process
259
