In the soft packaging printing process, achieving a high-quality print depends on the ink's saturation and color intensity. Based on our experience in production, we have encountered issues with poor ink saturation and have analyzed these problems to share insights with fellow professionals.

Ink saturation refers to the ability of ink to fully cover the substrate, producing a smooth and even appearance. When saturation is low, the printed image appears dull, with uneven ink distribution and rough textures. Microscopically, this may indicate poor dispersion of the ink, where pigments and resins separate, leading to ink dots forming abnormally.

Poor saturation is commonly seen in colors like green, pink, and purple. These colors are more sensitive to ink formulation and printing conditions. To understand why such issues occur, it's essential to trace them back to their root causes. Here’s an analysis of the main factors that affect ink saturation during the printing process.

Key Factors Affecting Ink Saturation:

1. Ink Viscosity: The viscosity of the ink must be carefully controlled. It should match the speed of the press and the solvent evaporation rate. High-speed printing requires lower viscosity to ensure proper ink transfer. For example, at 150 meters per minute, the ideal viscosity for spot colors is between 16–18 seconds. If the viscosity is too high, it can cause ink mottling or uneven coverage.

2. Impression Roller: Choosing the right impression roller is crucial. A softer roller (around 60–65 Shore A) with appropriate pressure (0.18–0.2 MPa) ensures better ink transfer. Harder rollers may not allow the ink to spread evenly across the plate, reducing transfer efficiency. Keeping the roller clean is also important to avoid contamination.

3. Ink Quality: Using old ink can lead to poor performance due to oxidation, solvent loss, and pigment separation. Mixing old and new ink in a 7:3 ratio, after thorough stirring and filtering, can help maintain consistency. Adding a small amount of white ink can improve leveling without drastically affecting color tone.

4. Solvent Composition: The solvent balance is critical, especially in high-speed printing. A fast-drying solvent can cause issues like drying on the plate or blocking. Using a slow-drying solvent like n-propyl ester, along with co-solvents like butyl ester or isopropyl alcohol, helps maintain stability. Always add solvents gradually and stir thoroughly before use.

5. Scraper Angle: The scraper angle should be set between 45–50 degrees. A flatter or steeper angle can lead to ink buildup or dry plate issues. This setting helps control ink flow and prevents excessive drying on the plate.

6. Printing Environment: High humidity can cause moisture to mix with the ink, affecting its performance. Ideally, the workshop should maintain a relative humidity of around 50%. Excessive moisture can reduce ink solubility and cause mottling. Dust and foreign particles can also interfere with the printing process.

7. Plate Roll Condition: A deep mesh or poorly etched plate roll can reduce ink transfer efficiency. Clogged plates can further hinder ink flow. Cleaning the lower plate roll before printing and pre-polishing with 600-grit sandpaper helps ensure even ink distribution. It's recommended to use a screen angle of 40–45 degrees for optimal results.

8. Raw Material Preparation: Before printing, check the corona treatment level of the film. Low corona strength can prevent proper ink adhesion, leading to poor transfer and color issues. Ensuring the material has sufficient surface tension allows the ink to adhere effectively, resulting in a more vibrant and consistent print.

In summary, achieving good ink saturation involves careful control of multiple variables—ink formulation, printing speed, environmental conditions, and equipment setup. By understanding and addressing these factors, printers can significantly improve the quality and consistency of their output.

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