Ink Automation for Flexographic Printers

Software advances and internet-driven machine-to-machine connectivity have brought opportunities for speeding up processes, cost savings, stock control and forecasting.

These advances have enabled a new era of “smart manufacturing”—a term for digital technologies that ensure transparent, integrated and intelligent production processes.

Examples of these technologies are “work-on-screen” applications that replace paper with digital information—product tracking and enterprise resource planning (ERP), management information systems, press controls, etc.

For managing inks, printers working with spot colors have struggled to reap the benefits of digitalization, and thus automation, because of the complex workflow route taken by those inks.

Existing ERP systems are specifically designed for tracking raw materials that follow a “linear” route through the workflow, without being returned to inventory after production. Inks for making spot colors take a more convoluted passage: base inks are blended to form special colors and, often, leftovers are returned in small quantities from the press after printing, for reuse in yet new colors.

For spot color printers, therefore, a dedicated software for managing ink in the workflow, with the capability to connect with other corporate software platforms, such as for color formulation or resource planning, is necessary.

A new generation of modular ink software packages is meeting that need. They offer greater connectivity, the capability to store, share and analyze more data, and functionalities that enable greater waste reduction, ingredient traceability, faster decision-making and strategic planning. Spot color printers can choose the combination of packages to suit their needs, for a host of functions.

Here are some software innovation highlights at various steps in the workflow.

Inventory Control

Ink inventory control provides a simplified and informed solution for the purchasing stage, and record-keeping of stock movements as they pass into the warehouse, and on to the inkroom where they are gradually dispensed into new color blends.

Monitoring every logistics event, the software gives real-time information about stock availability, helping the user make timely purchasing decisions in accordance with production demands. Its logging of dispensing events also enables traceability.

The software’s purchasing function enables the user to raise a purchase order that can be sent directly to the supplier, or internally to those responsible for corporate procurement. It acts as a flexible vendor management system. There are data-entry requirements when setting up—ink supplier profiles, existing ink stocks, desired minimum and maximum stock levels, and ink prices—but once in the system, this data provides long-term efficiencies.

For instance, when raising a purchase order, the software helps the user make buying decisions that match consumption by recommending order quantities for each ink stocked. Other inputs simplify job costing and stock-taking exercises as well.

When new inks arrive from the supplier, the user books them in, by logging each barrel’s batch code, expiration date and intended warehouse location, in the database. The software then generates a unique barrel identification number, and the user puts the barrel into stock.

Finally, when barrels are exchanged at the ink dispenser, the software guides the operator through the correct barrel connection/disconnection procedures. Entering or scanning the barrel ID number and updating the barrel’s location status is enough for the system to automatically update the stock levels in both the inkroom and the warehouse. Its record-keeping provides:

• A historical log of all ink barrels connected to the dispenser
• The ability to trace ink ingredients forward to each job and backward to the supplier
• Current stock levels (in weight) of each connected barrel

Color Recipe

The ability to add new colors and modify color formulas is essential for packaging printers. A brand extension, a market trial and even a change of substrate for the same brand color can require a new ink formula. A dedicated software module can import new and corrected ink formulas—normally generated by ink formulation software—without the need to re-enter data.

Six steps for creating and correcting colors follow:

1. Measure the sample of the color you intend to print with the spectrophotometer
2. The color formulation software calculates the ink formula with components and their precise quantities
3. Import the new formula directly into the ink management software simply by clicking the import icon in the software’s dispense window
4. Once the formula is imported, activate the dispensing process. The new color is dispensed into a container
5. Print a proof of the sample, ideally offline, with a tabletop proofer to save press time and material waste
6. After proofing, measure the color again with the spectrophotometer

If the result is within the specification, proceed with printing the job on press.

Color Correction

If the result is outside the specification, then a color correction is needed. That of course extends the six essential steps to 12. The specific additional actions required list out like this:

1. The color formulation software calculates what is missing, and suggests a change to the formula
2. Import the modified components into the ink management software in the “adjust container” window
3. Dispense the additions
4. Print a proof and measure results according to the procedure above. The color is verified to be within specification
5. The adjusted formula is stored in the ink management software
6. Proceed to the press to print the job

By interfacing color formulation and ink management software, the package printer can adapt swiftly to changing customer demands, assuring repeatable quality, without losing time or incurring startup waste.

Clustering Returns

The standard way to reuse press returns is to store the leftover ink from each printing station in a dedicated container—normally a bucket—until it is recalled for the next suitable job.

Converters consuming large ink volumes can save space, handling and administration by “clustering” their returns. “Clustering” is when leftover inks with a similar color are collected together in one large barrel. The barrel is then connected to the ink dispenser and treated as a base ingredient in new ink recipes.

Batch Traceability

An ink traceability software module helps the converter generate traceability reports instantly. They comply with the most stringent quality standards used for food, pharmaceutical and cosmetics packaging, like GMP.

Monitoring barrels connected to the dispenser and the ingredients of each dispensing job, the software links all vital data for tracing ink ingredients from the raw materials supplier to the customer order. Whenever requested, the software can generate traceability reports instantly, linking batches with jobs and vice-versa.

In the event of a safety concern, any affected packages or labels can be identified and remedial action can be taken swiftly, limiting costs.

Transferring Data

An interface connects the ink management software to other management information systems such as ERP software. This allows importing of data such as a job’s graphic design details, like printed surfaces, and order quantity requirements, to calculate required ink quantities for production. It also enables the exporting of inventory changes, such as the arrival of new stock or the booking-in of press returns.

Integrating software packages within the printing house speeds many processes, from color preparation to order management, avoiding administration.

Fast Response Cuts Costs

Modules are available in bespoke combinations with the latest ink management software suites. Your ink logistics provider can advise the most suitable package, depending on the end-user markets served.

Handling ink was once a slow process that involved lots of administration and cumbersome data entry. Thanks to the latest ink management software developments, these processes are automated and accelerated. This brings faster response times, reduced administration costs, improved decision making and lower risk of error. Staff can focus on higher-value tasks.

About the Author

Maarten Hummelen is co-owner of GSE Dispensing, a world leader in ink management solutions for packaging printers. His management expertise is the result of more than 25 years in business-to-business sales, marketing and operations. Prior to the management buy-out of the ink dispensing activities from Stork Prints (SPGPrints) in 2006, he held a number of marketing, sales and purchasing positions within the Stork Group.

GSE delivers robust, fast and smart dispensing equipment, software and services to minimize ink-related waste in the printing workflow. With more than 45 years’ experience in the industry, it has an installed base of 2,100 systems worldwide. The company is based in Brummen, the Netherlands. For more information, visit gsedispensing.com.