SEMINARI

NOVE TEHNOLOGIJE U KORIŠĆENJU LEPKOVA U GRAFIČKOJ INDUSTRIJI


Seminar na temu lepkova u grafičkoj industriji održan je 03. marta 2007. godine u prostorijama štamparije Politika AD u Krnjači. Seminar je obuhvatio sledeće teme:
  1. uticaj različitih faktora na kvalitet poveza
  2. meki povez (Safe-T-Melt)
  3. poliuretanska lepila
  4. tvrdi povez (Dual Cure)
Predavači su bili gospoda Mario Eckers, Henkel Nemačka i Marcel Berzeki, Henkel CEE



Posle teoretskog organizovana je prezentacija i praktični deo na liniji za meki i na liniji za tvrdi povez. Više od 70 učesnika je veoma visoko ocenilo prvi seminar



Prezentaciju ćemo ovde predstaviti u originalnoj, ali nešto skraćenoj verziji. Prevod je po našem mišljenju nepotreban zbog autentičnosti izraza, podataka i fraza koje se koriste tokom samog seminara, a Henkel je sve to podržao pratećim grafikonima, fotografijama i veoma sažetim izlaganjem.
PERFECT BINDING

Soft-Cover Binding
Gluing off



Adhesive Choices to Suite the Application and Process
 

Requirement
Dispersion
Hot Melt EVA
Hot Melt PUR
 
 
 
 
Adhesion
+++
++
++++(+)
Cold resistance
+
+
++++(+)
Heat resistance
+++
+
++++(+)
Curing speed
+
++++
+++(+)
aging
++++
++
++++
Resistance to oils
+++
(+)
++++
trimming
+
+++
+++
roundability
+++
+++
+++(++)
processability
++++
+++
+++

 
 
Film strength characteristics
 

 
Dispersion adhesive
 
Hotmelt EVA based
Hotmelt PUR based
Elongation capacity
 
500%
350%
650%
Yield strength
 
3,5 N/mm²
3,4 N/mm²
9,6 N/mm²
Tensile strength
 
4,2 N/mm²
4,9 N/mm²
27,0 N/mm²

 
Typical Bookbinding Application
Spine Gluing
 
Technomelt 36-014
high quality solution, water white, no smell, perfect stability, best performance on all binders
 
Technomelt Q 3625
very flexible, white pigmented, good lay-flat properties, roundable
 
Safe-T-Melt Q 3131
pale yellow grade, good clamp effect, excellent adhesion range, economical, low temperature hotmelt, also possible as primer solution
 
Safe-T-Melt Q 3631
low temperature hotmelt (130°C), white pigmented, also suitable with 2-shot application
 
Adhesin A 3231 VL
PVAC primer for perfect binding, 13.000 mPas, elastic film properties
 
Adhesin A 3232 HL
PVAC top coat for perfect binding, 22.000 mPas, elastic film properties
 
Purmelt ME 3320
PUR spine glue with special performances (videti posebnu prezentaciju)
 
Purmelt DC 3111
PUR spine glue with special performances (videti posebnu prezentaciju)
 
Purmelt QR 3317 BR
Our PUR bestseller – highly catalyzed PUR spine glue, final strength within 6-12 hours available, suitable for roller and nozzle application, good pot life
 
Purmelt QR 3315
Same formulation as QR 3317, but higher initial tack


Technomelt
SAFE -T- MELT
 
 
Safe-T-Melt Q 3631 / Safe-T-Melt Q 3131
 
Type of adhesive hotmelt on synthetic basis
Field of application Bookbinding:
Safe-T-Melt is suitable for single shot binding on automatic Binding machines at high speeds and low application temperature (e.g. manufacture mail, order catalogues, telephone directories, timetables, magazines, etc.). Safe-T-Melt Q 3631 is also suitable for two-shot-binding. In the two-shot-binding process Safe-T-Melt Q3631 is used as a system of primer and top coat at different temperatures.
Product specification Safe-T-Melt Q 3631:
Viscosity 5.400–7.300 mPas at 130°C Brookfield Therm. spindle 27
Softening point 77-87°C R&B
Product specification Safe-T-Melt Q 3131:
Viscosity 4.200-5.700 mPas at 130°C Brookfield Therm. spindle 27
Properties Safe-T-Melt Q 3631:
Color white, Setting Time medium, Open Time medium
Properties Safe-T-Melt Q 3131:
Color yellow, Setting Time medium, Open Time medium
Processing:
Application Temp. one shot: 120-140°C
two shot Primer: 140-160°C
Top Coat: 120-140°C
Application by means of roller
 
BENEFIT

 
REDUCE COSTS
Energy costs reduction: as less power is needed for melting.
Safe-T-Melt adhesives have been developed to run at 130° instead of 180°, you can consequently reduce your energy costs by 33%! The exact saving will depend on your current operating conditions.
Due to the very high bonding performances less quantity is needed: up to 33% less
Comparative pilot tests with traditional HM, show that the spine film thickness can be reduced from 0,95 to 0,70 mm.
No oxidation into premelter/hose/glue pot; machine maintenance reduction; equipment longer life
 
MORE EFFICIENT
Fast setting, no trimming problems even during hot summer time
The spine glue cools much faster so no smearing effect on the knives and quality problems related to good curing of adhesives are greatly reduced
Lower production temperature reduce wrinkling on gross grain paper
As less moisture is produced by the contact between hot glue and paper, a standard humidity level is reached, so less chance of wrinkling.
Good paper penetration, no glue changes needed between different paper qualities
 
SAFETY
At low production temperature:
The amount of volatiles emitted is reduced , lower odor, lower risk of burn
 
 
Typical Bookbinding Application
Side Gluing
 
Technomelt Q 2416/Q 2415
Economical EVA side glue, pale yellow color, good adhesion properties, good for high speed machines due to its medium open time
 
Technomelt 53-241
Economical EVA side glue especially for high speed machines, short open time with a pale yellow color
 
Sanicare HM 6540/Technomelt 38-612
High quality solution , highest initial tack, has got a never ending open time, synthetic rubber
 
Adhesin A 7088
PVAC side glue, high initial tack and long open time
 
Adhesin A 7248
PVAC side glue, low viscosity, good cleaning properties
 
Purmelt QR 4777
PUR based side glue, excellent hot and initial tack, wide adhesion range due to PUR


Influencing factors
Open time / setting time

 
Setting time of dispersion adhesives with different substrates:
 
Paper/cardboard         0,04h
Paper/PE-film             0,1h
PE-film/PE-fil             100h
 

Thermal stress / time



Industry Standards
 
Hot Melt
Quality of bonding strength
 
 
0 – 4,5 N/cm
Insufficient
4,5 – 6,2 N/cm
Sufficient
6,2 – 7,2 N/cm
Good
7,2 N/cm
Excellent
 
 
PVAC/Purmelt
 
 
 
0 – 5,5 N/cm
Insufficient
5,5 – 6,5 N/cm
Sufficient
6,5 – 7,5 N/cm
Good
7,5 N/cm
Excellent



Bookbinding Adhesive Choices
 
PURMELT
Polyurethane based hot melt
Why PURMELT?
 
-         recycled papers result in shorter fibers which are difficult to bond
-         the amount of paper fibers are being reduced
-         multiple coatings to build paper thickness and improve print graphics are difficult to bond
-         residual print oils can attack traditional binding adhesives
-         printers want to print into the gutter for graphic transition, page to page
-         peace of mind for the trade binder
 
Benefits
 
-         excellent page pulls and flex values
-         bonds to coated and cross-grained stock
-         exceptional aging ability
-         impervious to print ink oil migration
-         high cold and heat resistance
-         excellent lay-flat performance with low glue film
 
Purmelt - Wheels & Slots
 
WHEELS
SLOTS
 
 
- Accepted technology
- Fully enclosed system
- Little adjustment, job-job
- Precise application control through metering pumps
- Open reservoir exposes adhesive
- Easy shut down
- More prone to viscosity increases
- Minimal clean up
- Longer clean up time
- Requires a binder with minimal clamp to clamp variation
 
 
Specifications and performance range of modern PURs
 
1st Generation
 
-         1989 Purmelt® QR 116
-         1990 Purmelt® QR 3310
-         1994 Purmelt® QR 3220
Properties: slow chemical reaction, 3-6 days; strong viscosity synthesis during the processing; low initial strength
 
2nd Generation
 
-         1999 Purmelt® QR 3366
-         1999 Purmelt® QR 3388
-         1999 Purmelt® QR 3344
Properties: faster chemical reaction, <3 days; strong viscosity synthesis during the processing; low initial strength
 
 
3rd Generation
 
-         2002 Purmelt® QR 3317 BR
Properties: accelerated reaction has been adapted to climatic zones with high air moisture
Temperature recommendations: Melting plate 100-110°C; Hose 110-120°C; Glue pot 120-130°C; Spinner 150°C
 
4th Generation
 
-         2004 Purmelt® ME 3320
Properties: fast chemical reaction, good viscosity stability during the processing, very high initial strength, high viscosity
 
 
 
PURevolution
MICRO EMISSION
 
Henkel is revolutionizing the processing of PUR hotmelt adhesives again
 
-         Micro Emission is PUR hotmelt adhesive innovation
-         ME™ products are not labeled as hazardous material
-         ME™ is a new PUR hotmelt adhesive product line
 
Benefits
Full adhesive performance; improvement of occupational safety; green production is a competitive advantage; less hazardous materials at work-less regulations; comply with substitution principle.
 
 
Purmelt Sideglue
Polyurethane based hot melt for side gluing
 
In graphic arts, Purmelt is very well accepted due to its unique properties for perfect binding and spine gluing of sewn books. Frequently the hot melt side glue is the weak point of a Purmelt bound brochure. Mineral oils derived from the printing ink affect the adhesion of the hot melt and may cause staining inside brochure and/or on the cover, resulting in a claim.
Purmelt as side glue, is resistant against the attack of mineral oils. If during perfect binding, Purmelt is applied onto the cover via a slot nozzle, the spine glue acts also as a side glue. All companies using a wheel as Purmelt applicator, are potentially interested in a separate Purmelt side glue.
Application profile for side gluing: good adhesion, high viscosity, stable viscosity, long open time, very good hot tack, suitable for nozzle application
 
Purmelt QR 4777
Viscosity /130°C                      8000 mPas
Visc. Stability 8h/130°C           80%
Open time PUR methode          230 sec, surface tacky        
Hot tack                                   better than Q 2415/ Q2416
EDITION BINDING
Hard-cover binding
 
End sheet attachment/wheel or nozzle
 
Adhesin A 7248
Good for coated papers and PP materials
 
Adhesin A 7277-21
Economical version of A 7248, very good cleaning properties
 
Technomelt Q 3101
EVA based product for hotmelt application units
 
Purmelt QR 4777
Excellent adhesion properties and high initial tack on difficult surfaces
 
End capping
 
Lessoflex 1680
Protein glue for back lining, highest tack, good process ability, good cleaning properties
 
Casing in
 
Adhesin A 7248 / Adhesin A 7232 / Adhesin A 7314
Universal product for casing-in of standard quality book covers, good cleaning properties, good adhesion range, no wetting
 
Adhesin A 7277
Economical PVAC adhesive for casing-in, best cleaning properties, wide adhesion range, no wetting
 
Adhesin A7045
Solvent based PVAC adhesive especially for soft PVC covers and difficult substrates.
 
Advantages: excellent adhesion and cohesion; very high heat resistance; very good cold resistance; resistant to mineral oils from printing inks; very good suitability for recycling
 
Limits: rounding only possible after hours/days (time frame too narrow and vague); limited mechanical stress possible; no quality control “on the job” possible
 
 
Adhesive Choices to Suite the Application and Process
 
requirement
Standard PUR
PURMELT
3. generation
PURMELT
4. generation
 
 
 
 
Adhesion
++++(+)
+++++
+++++
Cold resistance
+++++
+++++
+++++
Heat resistance
++++(+)
+++++
+++++
Curing speed
++
++++(+)
+++++
Aging
+++++
+++++
+++++
Resistance to oils
+++++
+++++
+++++
Trimming
+++
+++++
++++(+)
Roundability
+
+++
+++++
Processablity
+
+++
+++++
Initial strength
+
+++
+++++
Quality control
+
+++
+++++
 


The Ideal Hard-Cover-Book
Necessities:

Purmelt - Spine Preparation
4 th Generation UV dual cure
 
1. In line production               2. Hard cover production       3. PUR rounded books
 
 Purmelt DC 3111-21 elongation versus time 
Technical preconditions:
Installation of a UV lamp: microwave or electrode; additional air connection to cooling for some systems/or water cooling; outgoing air: Ozone-sanitation; shielding from UV radiation; optimum backspin preparation 
 
Inline rounded book-blocks




UV-Coatings
 
Ultra Violet (UV) coatings are 100% solids liquids that cure instantaneously when exposed to a specific wavelength of condensed light or electrons. This reaction takes place in milliseconds and at high speeds. 

Possibilities for UV Coatings:
Magazine Covers; Annual Report Covers; Magazine Inserts; Post Cards, Credit Cards, Trading Cards; Point of Purchase Displays; Folding Cartons; Tapes & Labels; CD Inserts; Bags & Sacks.






THE NEW DIMENSION IN PRINTING EFFECTS



-         Utilizing highly reflective micro thin aluminum plates
-         100% solid and UV curable
-         Substitutes metallure printing inks, foil stamping & foil lamination
 
Benefits:
 
Create beautiful metallic colors; achieve high opacity with single print; excellent press stability and easily applied; applied with screen and flexo printing/coating techniques; eliminates off-line lamination or foil stamping; apply metallic areas selectively; eliminate curling issues that often occur while printing light weight foil laminates; reduce converting steps due to its “foil on demand” capability.
 
3 months shelf life; over printable and over coatable (in-line); can be applied for paper, foils, boards, plastic; apply at print speed; eliminate the needs for primer and special inks; environmentally friendly and recyclable.
 
- Folding cartons for cosmetics, golf balls, alcohol, oral care, entertainment (DVD/VHS)
- Graphic arts: paperback books, travel tags, covers
- Tape, Labels and Coatings: container/pharma labels
- In-line finishing: promotional pieces
- Envelopes
 
    
nazad