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Effects of Alkaline Internal Sizing on Rotogravure Print Quality Using Waterbased Inks

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Effects of Alkaline Internal Sizing on Rotogravure Print Quality Using Waterbased Inks Western Michigan University ScholarWorks at WMU Master's Theses Graduate College 6-1994 Effects of Alkaline Internal Sizing on Rotogravure Print Quality Using Waterbased Inks Michael L. Busche Follow this and additional works at: https://scholarworks.wmich.edu/masters_theses Part of the Wood Science and Pulp, Paper Technology Commons Recommended Citation Busche, Michael L., "Effects of Alkaline Internal Sizing on Rotogravure Print Quality Using Waterbased Inks" (1994). Master's Theses. 4913. https://scholarworks.wmich.edu/masters_theses/4913 This Masters Thesis-Open Access is brought to you for free and open access by the Graduate College at ScholarWorks at WMU. It has been accepted for inclusion in Master's Theses by an authorized administrator of ScholarWorks at WMU. For more information, please contact [email protected]. EFFECTS OF ALKALINE INTERNAL SIZING ON ROTOGRAVURE PRINT QUALITY USING WATERBASED INKS by Michael L. Busche A Thesis Submitted to the Faculty of The Graduate College in partial fulfillment of the requirements for the Degree of Master of Science Department of Paper and Printing Science and Engineering Western Michigan University Kalamazoo, Michigan June 1994 EFFECTS OF ALKALINE INTERNAL SIZING ON ROTOGRAVURE PRINT QUALITY USING WATERBASED INKS Michael L. Busche, M.S. Western Michigan University, 1994 The effect of alkaline internal sizing in improving paper smoothness and ink gloss in waterbased rotogravure printing was investigated. Papers were internally sized with alkyl ketene dimer (AKD) under alkaline conditions from slack-sized to hard-sized. Papers were printed with waterbased inks on a web gravure press. A major problem with waterbased inks is increased surface roughening of paper and a low ink gloss. Temporal surface roughening was reduced by increased AKD internal sizing with a concomitant significant increase of up to 400% in ink gloss. Surface properties were correlated with print quality. The print quality improved with increased hydrophobicity of the papers. TABLE OF CONTENTS LIST OF TABLES. .. .. .. .. .. .. .. .. .. .. .. .. vi LIST OF FIGURES. .. .. .. .. .. .. .. .. .. vii CHAPTER I. INTRODUCTION. .. .. .. .. .. .. .. .. 1 II. LITERATURE REVIEW.. .. .. .. .. .. .. .. .. 6 Environmental Regulations............. ....... 6 Recovery Systems.. .. .. .. .. .. .. .. .. 8 A Review of Common Printing Methods .......... 10 Control of Compressibility and Ink Transfer on a Rotogravure Printing Press............................... 13 Definition of Printability, Print Quality and Gloss ...................... 18 Critical Rotogravure Printing Press Conditions That Determine Print- ability/Print Quality........................ 19 An Overview of the Correlation of Sizing With Print Quality and Printability............................. 29 Factors Affecting Print Quality and the Measurement of Print Quality ................................ 31 The Relationship of Surface Smoothnes of Paper With Print Quality............. 32 Print Gloss as an Indicator of Fiber Rising and Surface Roughening. .. .. .. .. .. .. .. .. 3 4 The Importance of Surface Compressabil- ity Along With Surface Smoothness........ 35 ii Table of Contents--Continued CHAPTER The Effects of Sizing and Absorption Rates on Surface and Ink Film Properties .......................... 3 7 Sizing Effects on Surface Roughness. .. .. .. .. .. .. .. 38 Review of the Methods of Sizing, Internal and Surface Sizing ............. 38 The Effects of Sizing on Ink Film Transfer and Gloss ............ 39 Dependence of Furnish on the Effectiveness of Sizing and Control of Ink Gloss................ 42 The Importance of Ink Density Relative to Ink Gloss and Surface Smoothness of Paper ......... 42 Effects of Water Absorption and Penetration Into Paper .......... 42 III. PROBLEM STATEMENT AND OBJECTIVES ................. 47 IV. EXPERIMENTAL DESIGN.. .. .. .. .. .. .. .. .. .. 49 Overview...................... ............... 49 Outline................................ • ..... 49 V. EXPERIMENTAL METHODOLOGY ......................... 51 Preparation of Papers ........................ 51 Printing Procedures .......................... 55 Determination of Delta Gloss ................. 56 Statistical Analyses ......................... 56 Determination of Print Quality ............... 57 List of Equipment. .. .. .. .. .. .. .. .. .. 59 iii Table of Contents--Continued CHAPTER VI. RESULTS AND DISCUSSION.......................... 60 Overview.. .. .. .. .. .. .. .. .. 60 Paper and Ink Film Properties Related to Print Quality.................... 61 Paper Surface Smoothness ............... 61 Ink Film Smoothness .................... 68 Surface Compressibility of the Paper Substrate.................... 81 A Comparative Measurement of Ink Transfer by Ink Optical Density............. 86 The Relationship of Ink Gloss With Internal Sizing and Fiber Swelling.......... 90 Gloss Analysis of Printed Papers............ 91 Kraft Versus Groundwood..................... 97 VII. CONCLUSIONS..................................... 103 VIII. RECOMMENDATIONS . 104 APPENDICES A. Test Data of "USA WEEKEND" ...................... 105 B. GAA Roto News Classifications ................... 107 C. An Explanation of the Statistical Analysis of Experimental Data................... 109 D. Analyses of Variance for HST Groups ............. 118 E. Analyses of Variance for the Delta Gloss of Magenta.. .. .. .. .. .. .. 122 F. Analyses of Variance for the Delta Gloss of Trap.. .. .. .. .. .. .. .. 127 iv Table of Contents---Continued APPENDICES G. Analyses of Variance for the Optical Density ofMagenta .............................. 132 H. Analyses of Variance for the Optical Density of Cyan............... •.................. 138 I. �-Test to Analyze, for Each Paper Group, the Ink Optical Density of the Solid Printed Blocks ..................... 143 J. Identification of Tested Areas .................. 147 K. Analyses of Variance for Smoothness, Parker Print Surf of 10 Kg Force ................ 1{9.. L. Analyses of Variance for Compressibility, Difference of 10 and 20 Kg Forces ............... 154 M. Analyses of Variance for Paper Surface Smoothness Compared to Printed Areas.. .. .. .. .. .. .. .. .. .. .. 159 N. Analyses of Variance for Smoothness of Un- printed Areas Compared to Printed Areas. .. 163 0. Moisture Content of the Paper Immediately Following Production on the PaperMachine Reel .............................. 171 REFERENCES .. .. .. .. .. .. .. .. .. 173 V LIST OF TABLES 1. Examples of Clean Air Act Nonattainment Areas.... .. .. .. .. .. .. .. 7 2. Properties of Toluene and Wate�................... 23 3. Solvent Evaporation Rates Compared to Water ................................. 24 4. Comparison of Sheet Thickness and Roughness From Skowrinski et al .................... 33 5. A Comparison of the Effectiveness of Sizing on Preventing Surface Roughening.............. .................. 39 6. Wet Ink Film Thickness Values....... .............. 41 7. The Volume of Water Absorbed Relative to Time and Level of Sizing....................... 45 8. Internal Sizing Dosage Levels of AKD.............. 52 9. Smoothness Comparisons of Nonprinted Areas With Magenta Blocks.................. ....... 62 10. Effect of Sizing Level on Smoothness of Magenta Block and Delta Gloss of Trap...................... ............... 66 11. Smoothness Comparison of Printed and Nonprinted Areas .............................. 69 12. Paper Compressibility Compared to Gloss and Smoothness..................... ............... 81 13. Ink Optical Density ............................... 88 14. Hercules Sizing Test Results and Color Coding Scheme. .. .. .. .. .. .. .. .. 89 15. Delta Gloss of Printed Solid Magenta Block........ 94 16. Delta Gloss of Printed Two-Color Trap............. 95 vi LIST OF FIGURES 1. Areas Violating the Clean Air Act-Ozone........... 7 2. Carbon Adsorption Solvent Recovery System................ • . .. .. .. .. 8 3. Emissions Comparison of Waterbased Ink Versus Solvent Recovery System................ 9 4. Different Printing Application Surfaces .......................................... 11 5. Rotogravure Printing .............................. 12 6. Rotogravure Impression Roller Systems............. 14 7. Rotogravure Impression Width Calculation ................................. 15 8. Impression Cylinder Nip Compression............... 16 9. Rotogravure Ink Application System................ 17 10. Rotogravure Press Register Marks.................. 21 11. Two-Zone Rotogravure Dryer........................ 25 12. Dryer Air Flow in One Zone. .. .. .. .. .. .. .. 26 13. Air Flow in Two-Zone Dryer........................ 28 14. Comparison of Sizing Levels with Surface Smoothness. .. .. .. .. .. .. 64 15. Hercules Sizing Test Results...................... 65 16. Magenta Block Smoothness Compared to Delta Gloss of Trap............................ 67 17. Sizing Level 1: Comparison of Smoothness Values of Unprinted and Printed Areas............. 73 18. Sizing Level 2: Comparison of Smoothness Values of Unprinted and Printed Areas............. 74 vii List of Figures---Continued 19. Sizing Level 3: Comparison of Smoothness Values of Unprinted and Printed Areas............. 75 20. Sizing Level 4: Comparison of Smoothness Values of Unprinted and Printed Areas............. 76 21. Sizing Level 5: Comparison of Smoothnesst I Values of Unprinted and Printed· Areas............. 77 22. Sizing Level 6: Comparison of Smoothness Values of Unprinted and Printed Areas............. 78 23. Sizing Level 7: Comparison of Smoothness
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