To test the efficiency of the temperature control, 55 kW (OP-TC-B), under real conditions, we conducted a field trial in collaboration with a customer on a CERUTTI 4-color gravure press. We integrated the cooling system at printing unit 2 in the return from the viscosity measurement station (bypass) to the ink tank. 75,000 meters were printed with and without the cooling system. The initial ink was prepared and supplied identically for both productions. Temperature regulation was carried out using the existing Fasnacht viscosity control system S4.
Results
Without cooling system
- Initial temperature: 22.5°C
- Temperature of the refilled ink: 18°C
- Final temperature: 23.3°C
- Ink consumption: 135 kg
- Solvent consumption: 63.8 liters
With cooling system
- Initial temperature: 22.5°C
- Temperature of the refilled ink: 18°C
- Final temperature: 18.0°C
- Ink consumption: 120 kg
- Solvent consumption: 59.8 liters
Discussion of Results
The test results illustrate that ink temperature not only significantly affects viscosity control and ink consumption but also brings additional benefits. The use of the cooling system at printing unit 2 led to a saving of 15 kg of ink, which represents 11% of the total consumption and in this case translates to a monetary value of approximately €300.00.
Furthermore, optimal ink temperature not only enhances efficiency but also significantly improves the final product quality. Printing results are more consistent, color deviations are minimized, and the overall quality of the printed materials is enhanced.
Requirements and Test Setup
Printing Job
- Product: Cigarette filters
- Ink: Gray
- Meterage: 150,000
- Substrate: Paper
- Machine Speed: 450 meters per minute
- Print Width: 1.2 meters
- Number of operational printing units: 3
- Viscosity: 13 seconds
Used Instruments
- Flow Sensor: KEYENCE FD-X, consumption display in dl
- Temperature Sensor: Sensostar E, cooling system installation water-side
- Viscosity Control System: Fasnacht S4, falling body principle
- Additionally: Thermometer for manual temperature measurement
Environmental Conditions
- Outside: Rain, 15°C
- Inside: Air-conditioned, 24°C
- Cooling Water: Inlet 7.2°C / Return 8.8°C"
Related Files
- Product sheet «OP-TC-EN» (1 MB)