Screen printing manufacturers and screen printing companies have completely different quality requirements. The former always pursues the standardization and continuous upgrading of the production process. Successful manufacturers do not let themselves lose any opportunity to improve their quality. They will purchase raw materials from reliable suppliers, and as production improves, they will also measure and improve every detail. Once they have optimized production, they will record the work flow and insist on checking every production step. Here we take a look at what factors will affect the production process of the screen template and how to regulate these factors.
Environmental conditions
Most live jobs do not require a clean indoor environment, but all printing companies can benefit from daily dusting and humidification work because it helps them reduce airborne dust and batting. The temperature and relative humidity of the press room also need to be controlled because they directly affect the exposure time, dimensional stability, register conditions, and the performance of the ink on the press.
Stretching
High-quality screen templates are determined by several important factors. Strictly speaking, these factors have nothing to do with the plate making process. For example, we need to select the number of meshes and meshes based on the customer's requirements for the thickness of the ink film and the details of the image, and also reasonably stretch it on the stencil holder.
The tension of the stencil will affect its off-plate distance and dimensional stability, and thus affect the registration of the plate. Mesh manufacturers will provide the best tension parameters for each type of mesh they produce. Users only need to consult. If it is too tight or too loose, it will have a certain impact on production, so it is better to measure the tension of the mesh with a tensiometer.
Darkest point density, brightest spot density, and contour plots
Since most screen printing plants do not currently use CTS-computertoscreen technology, they must use photocopying artwork. This image must have sufficient density - the darkest dot density is preferably 4.0 - to block the light in the image area, enough sharpness (lowest bright spot density) - so that the light through the template material costs Image area and sharp edge definition between the two.
If the non-image area of ​​the original document is not sufficiently clear - semi-transparent and not transparent - and its density is low, the effect it prints and the quality of the template will inevitably be compromised. If the edges of the image are not clear enough, even with high-quality stencil materials, it is difficult to achieve the desired results. In actual production, we can get ink jet images with a density between 2.8-3.5, but its quality is still lost. The key problem is that the quality of the photographic template cannot be better than the original, and the quality of the printed product cannot be better than the template.
Vacuum contact exposure and light
Contacting platesetters must have a vacuum range of at least 0 to 20 cm Hg, otherwise Newton rings may appear. In addition, the vacuum blanket must be black, and the contact glass must also be cleaned regularly. The exposing unit of the plate-making machine must use a high-quality specific light source to match the sensitivity curve of the stencil material. All in all, regardless of the point from which light hits the stencil, try to keep its vertical injection.
If the contact distance of the stencil is movable, its distance during exposure is at least 1.5 times the diagonal of the image area. This ensures that hot and underexposed areas do not appear on the plate. In addition, the operator should also use a spectrophotometer to measure the spectral output of the device. Of course, this method is not suitable for printing companies using digital direct exposure equipment because the latter does not need to use photocopying at all.
Imaging characteristics
In addition to mesh fibers, manuscripts, and light sources, the first step in standardizing templates is to select a suitable stencil system based on your skill level, number of prints, and imaging characteristics. Then see if this particular platemaking system can meet the job requirements for ink and cleaning agent compatibility, exposure speed, throughput, and imaging characteristics.
The so-called imaging characteristics refer to the two parameters of the image transferred to the substrate through the template: sharpness (usually referred to as edge sharpness) and resolution (detailed accuracy). The higher the resolution of the job, the closer the relationship between these two parameters, but in most cases they are two separate parameters. For example, when we use stencil printing, it is possible to obtain high sharpness and low resolution images.
In the same way, we can get high-resolution and low-sharpness images in some cases. The lower image sharpness may be caused by the poor quality of the stencil emulsion layer (low solids content) or larger filler particles. If necessary, you can measure the resolution and sharpness of the image yourself.
EOM and Rz values
The emulsion thickness (EOM) on the mesh also affects the Rz value of the template (roughness of the stencil surface) and the deposition thickness of the ink. Lower Rz values ​​help seal the ink and prevent drying of the ink on the screen. One can use the surface finish measuring instrument in the production document to measure the Rz value of the template.
Environmental conditions
Most live jobs do not require a clean indoor environment, but all printing companies can benefit from daily dusting and humidification work because it helps them reduce airborne dust and batting. The temperature and relative humidity of the press room also need to be controlled because they directly affect the exposure time, dimensional stability, register conditions, and the performance of the ink on the press.
Stretching
High-quality screen templates are determined by several important factors. Strictly speaking, these factors have nothing to do with the plate making process. For example, we need to select the number of meshes and meshes based on the customer's requirements for the thickness of the ink film and the details of the image, and also reasonably stretch it on the stencil holder.
The tension of the stencil will affect its off-plate distance and dimensional stability, and thus affect the registration of the plate. Mesh manufacturers will provide the best tension parameters for each type of mesh they produce. Users only need to consult. If it is too tight or too loose, it will have a certain impact on production, so it is better to measure the tension of the mesh with a tensiometer.
Darkest point density, brightest spot density, and contour plots
Since most screen printing plants do not currently use CTS-computertoscreen technology, they must use photocopying artwork. This image must have sufficient density - the darkest dot density is preferably 4.0 - to block the light in the image area, enough sharpness (lowest bright spot density) - so that the light through the template material costs Image area and sharp edge definition between the two.
If the non-image area of ​​the original document is not sufficiently clear - semi-transparent and not transparent - and its density is low, the effect it prints and the quality of the template will inevitably be compromised. If the edges of the image are not clear enough, even with high-quality stencil materials, it is difficult to achieve the desired results. In actual production, we can get ink jet images with a density between 2.8-3.5, but its quality is still lost. The key problem is that the quality of the photographic template cannot be better than the original, and the quality of the printed product cannot be better than the template.
Vacuum contact exposure and light
Contacting platesetters must have a vacuum range of at least 0 to 20 cm Hg, otherwise Newton rings may appear. In addition, the vacuum blanket must be black, and the contact glass must also be cleaned regularly. The exposing unit of the plate-making machine must use a high-quality specific light source to match the sensitivity curve of the stencil material. All in all, regardless of the point from which light hits the stencil, try to keep its vertical injection.
If the contact distance of the stencil is movable, its distance during exposure is at least 1.5 times the diagonal of the image area. This ensures that hot and underexposed areas do not appear on the plate. In addition, the operator should also use a spectrophotometer to measure the spectral output of the device. Of course, this method is not suitable for printing companies using digital direct exposure equipment because the latter does not need to use photocopying at all.
Imaging characteristics
In addition to mesh fibers, manuscripts, and light sources, the first step in standardizing templates is to select a suitable stencil system based on your skill level, number of prints, and imaging characteristics. Then see if this particular platemaking system can meet the job requirements for ink and cleaning agent compatibility, exposure speed, throughput, and imaging characteristics.
The so-called imaging characteristics refer to the two parameters of the image transferred to the substrate through the template: sharpness (usually referred to as edge sharpness) and resolution (detailed accuracy). The higher the resolution of the job, the closer the relationship between these two parameters, but in most cases they are two separate parameters. For example, when we use stencil printing, it is possible to obtain high sharpness and low resolution images.
In the same way, we can get high-resolution and low-sharpness images in some cases. The lower image sharpness may be caused by the poor quality of the stencil emulsion layer (low solids content) or larger filler particles. If necessary, you can measure the resolution and sharpness of the image yourself.
EOM and Rz values
The emulsion thickness (EOM) on the mesh also affects the Rz value of the template (roughness of the stencil surface) and the deposition thickness of the ink. Lower Rz values ​​help seal the ink and prevent drying of the ink on the screen. One can use the surface finish measuring instrument in the production document to measure the Rz value of the template.
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