Waterborne gravure ink additives must fit cylinder-cell transfer, doctoring, drying and downstream conversion. Substrate retraction, recirculation foam and dry-web blocking require different experiments. Lock pH, viscosity, cylinder, speed, treatment and dryer settings before changing an additive.
Confirm identity, then screen the 2100 wetting grade.
Screen 3062.
Gate 3501 by dose and protocol.
Define the gravure process
Record cylinder engraving, cell volume, doctor blade, impression, speed, ink temperature, pH, viscosity method, recirculation layout and dryer capacity. State substrate, treatment, print sequence, lamination or overprint and rewind conditions. Dirty cells or poor doctoring can resemble an additive failure.
Resolve the 2100 identity
Two live records conflict: CHLUMIAG® 2100 e CHLUMIWE® 2100. The public site does not establish one unambiguous current brand. Require exact commercial name, code, TDS and COA before using the published 0.1–1.0% range.
Compare supported routes
| Itinerario | Published evidence | First use | Boundary |
|---|---|---|---|
| 2100 wetting grade | Conflicting identities; both pages state 0.1–1.0%, all three system types and flexible addition | Retraction and uneven transfer after identity confirmation | Do not assume which record applies to the lot |
| 3062 | 100% active; printing-ink dose 0.1–0.5%; water/solvent/UV | Foam from mixing, pumping and recirculation | Solvent dilution requires stability and defoaming tests |
| 3501 | Printing, OPV and release/anti-sticking applications listed | Supplier-supported blocking/release study | No public dosage, active content or quantified block/rub result |
Use 2100 for measured wetting failure
After identity confirmation, start at the supplier-approved low dose. Hold treatment, pH, viscosity, cylinder, deposit and drying constant. Measure density, pinholes, skipped cells, tone, line quality and adhesion. Better spread does not prove better anchorage or lamination bond.
Use 3062 for process air
Locate air entry in the mix tank, pump, filters, chamber or return. Screen within 0.1–0.5% and measure wet density, foam height/decay and pinholes across a production-length circulation period. Reject crater, density, storage or resolubility failures.
Keep 3501 behind an evidence gate
First exclude retained water, inadequate dryer capacity, warm rewinding, excessive roll hardness and high storage temperature. Then obtain dose, active content, vehicle fit and a pressure/temperature/time block method. Do not create an equal-dose trial from an application listing.
Run a controlled matrix
| Trial | Change | Primary measure | Downstream gate |
|---|---|---|---|
| A | Control | Density, foam, wetting, dry and block | Adhesion/rub/lamination |
| B–D | Confirmed 2100 low/mid/high | Transfer and coverage | Adhesion and overprint |
| E–G | 3062 within 0.1–0.5% | Density, foam and pinholes | Print density and storage |
| H–J | 3501 after data approval | Defined block test | COF, rub and lamination |
Normalize density
ASTM D7305 describes reflection-density measurement for prints on paper, film or board. Match density before ranking rub, gloss or defects. It is not intended for metal or foil.
Measure rub and blocking separately
ASTM D5264 provides a comparative Sutherland rub practice. Fix receptor, load, cycles and conditioning. Blocking needs a separate rewind simulation. A grade can improve release while reducing rub or lamination bond.
Use vehicle testing as the framework
ASTM D6687 guides testing of printing-ink vehicles and components. Track pH/viscosity drift, resolubility, cell plugging and drying through the full run. Short drawdowns do not reveal every gravure failure.
Sample at start-up, steady state and the end of the press trial. Log fresh-ink additions, temperature and return-tank level so density or foam changes are not falsely attributed to the additive when the circulating ink has drifted.
Approve lamination and compliance
Apply the intended adhesive at production coat weight and cure schedule. Test bond, tunneling, odor and residuals as required. Public pages do not prove food-contact or low-migration suitability; obtain applicable declarations and validate the complete package.
Account for press aging
Return-loop temperature, water loss and pH drift change ink during a run. Sample beginning, middle and end, restore only through the approved control procedure and repeat density, foam and adhesion. An additive that works in fresh ink may fail after hours of recirculation.
Control cell emptying and doctoring
Inspect cylinder cells before and after the run and record blade material, angle, pressure and wear. Poor cell emptying, dried ink or blade chatter can cause density variation and streaks that look like wetting failure. Use the same cleaned cylinder and doctor setup for the control and additive trials.
Measure density across web width and through run time. Record misting, splash, deposits and filter pressure. A lower-foam ink is not acceptable if it reduces transfer, promotes cell plugging or increases blade lines.
Condition conversion samples
Use fixed time, temperature and humidity before rub, block and lamination tests. Measure residual water or solvent when required and reproduce actual rewind temperature and roll hardness. This separates additive effects from incomplete drying and makes the release decision relevant to production.
Decision rules
- Confirm 2100 identity before use.
- Use 3062 for measured process foam.
- Gate 3501 by dose and block evidence.
- Reject changes that harm transfer, drying, adhesion, rub, lamination or compliance.
Information to send
Provide resin, pigment, substrate/treatment, cylinder, speed, pH/viscosity history, pump/return, dryer, rewind, current additives, block/rub, lamination and photographs.
Ask Longchang for a controlled waterborne gravure ink study.