Understanding the Problem: Ink Foaming in Flexo Printing
Ink foaming is a silent but significant challenge in water-based flexographic printing. The presence of foam in the ink delivery system can lead to print inconsistencies, increased waste, and higher production costs. Traditional hexagonal cell-based anilox engravings contribute to micro foaming, which negatively impacts ink transfer, coat weight, and print quality.
How Apex International Solves Ink Foaming
Apex International has taken a proactive approach to resolving this issue with its GTT Open Channel Anilox Engraving technology. This breakthrough innovation significantly reduces ink foaming, resulting in:
Higher print quality- Smoother, more compact laydown
- Less downtime
- Cost savings for printers
What Causes Ink Foaming in Flexo Printing?
Ink, in its natural state, does not foam. However, as it moves through the ink delivery system, multiple factors contribute to foaming, including:
- Pump Type and Operation: Diaphragm pumps introduce air into the system, leading to micro foaming, whereas peristaltic pumps are a better option.
- Leaky or Poorly Designed Piping: Even minor leaks create turbulence and can aerate the ink.
- Return Line Positioning: If the return line is too high, ink splashes back into the reservoir, adding air into the system.
- Cell-Based Anilox Engravings & Doctor Blade Chamber Interaction: Traditional hexagonal cell engravings combined with the doctor blade chamber create a micro-pump effect, constantly pulling air into the ink.
The Impact of Ink Foaming on Print Quality
Excessive foaming leads to numerous print defects, including:
- Ink Density Drop: Reduced color consistency and vibrancy at high speeds.
- Pinholes in Print: Small air pockets create a dull, uneven print surface.
- Increased Waste: More rejected prints due to inconsistencies and defects.
- Higher Production Costs: The need for chemical anti-foam additives increases ink costs and creates an uncontrolled manual adjustment environment.
How GTT Technology Eliminates Ink Foaming
Apex International developed the GTT Anilox Rolls as a superior alternative to traditional cell-based engravings. Unlike conventional hexagonal anilox rolls, the GTT design features a wave/channel structure that improves ink flow and eliminates aeration.
Key Benefits of GTT Technology:
✔ Reduced Ink Foaming: Test results show significantly lower foam formation compared to traditional engravings.
✔ Improved Ink & Coating Transfer: Consistent, even, and compact ink/coating laydown.
✔ Elimination of Anti-Foam Additives: Reduces waste and cost by eliminating unnecessary chemical agents.
✔ Enhanced Print Quality & Gloss Level: Sharper, more vibrant prints with reduced pinholes.
✔ Sustainability Benefits: Lower chemical waste, reduced environmental impact, and improved ink press returns that can be reused.
Scientific Testing Confirms GTT’s Effectiveness
To validate the effectiveness of GTT anilox rolls, Apex commissioned Technology Coaching BVBA to conduct independent tests using an MPS EF430 web printing machine. The methodology included measuring ink density before, during, and after printing sessions.
Key Findings:
- Ink samples from traditional cell-based engravings contained microbubbles, making the ink weight (mass) lighter after production. In contrast, GTT-engraved ink remained consistent in weight.
- After 24 hours of rest, ink foaming significantly reduced in traditional engravings, confirming aeration effects during production.
- The GTT roll eliminated the need for chemical anti-foam agents, leading to cost savings and improved ink press returns that can be reused.
Why Printers Should Switch to GTT Technology
Switching to GTT Open Channel Anilox Engraving provides printers with:
✅ Higher print quality with consistent ink laydown
✅ Reduced downtime and increased production efficiency
✅ Lower ink costs by eliminating excessive anti-foam additives
✅ Sustainability benefits through reduced chemical waste
✅ Higher profitability due to improved efficiency and reduced material waste
Experience the Apex Difference
Apex International continues to revolutionize flexo printing with GTT 2.0 Anilox Rolls. If you're experiencing ink foaming issues or looking to improve your print quality, explore how GTT technology can transform your production process.
Ready to eliminate ink foaming?
Contact Apex International today to learn how GTT technology can enhance your flexo printing and reduce costs!
