According to KBA, the use of hybrid inks, with subsequent all-over UV varnishing, achieves higher gloss values than are possible from a double-coating process. The gloss attained is said to be on a par with that of most offline alternatives.
KBA says that its evaluations of long-term hybrid tests have also indicated significantly reduced draw-back effects after 72 hours compared to the currently prevalent technologies. KBA and its partners have worked intensively and successfully on means to minimise draw-back over the past five years. Even though other inline coating possibilities are today able to offer similar gloss results, the high production speeds of a hybrid press still represent an important advantage.
KBA says the process stability of the hybrid technology is not an issue provided the inks and auxiliary media recommended by KBA and its partners are used.
A typical standard hybrid configuration comprises a five-colour press with coating tower, UV interdeck dryer, a delivery extension accommodating infrared and hot-air dryers, and UV final drying. For certain applications, a second UV interdeck dryer may be expedient. The investment outlay for a 3B press is thus approx. 20 per cent less than that for a double-coating configuration, power consumption and work centre costs are significantly reduced and the hybrid press is characterised moreover by a notably enhanced flexibility. KBA supplies hybrid presses across the whole product range from the half-format Rapida 74 to the super-large-format Rapida 205.
At the same time, the deliberate combination of two differing ink systems, ie. hybrid and oil-based inks, permits spot finishes with interesting matt-gloss effects, but without requiring the otherwise indispensable photopolymer plates. With this technology, KBA says it is possible to control such matt-gloss effects and to realise spot finishes with extremely fine structures in offset-quality register.
The company says that even gentle gloss gradations can be produced with ultimate process reliability. Through careful selection of suitable material combinations (hybrid and conventional inks, oil-based varnish and UV varnish), a broad diversity of gloss levels and effects (e.g. matt satin, pearlescent, soft-touch or relief effects) can be achieved.
At drupa 2004, KBA and its partners will be presenting the latest in its hybrid technology. KBA believes that one breakthrough certain to cause a stir is the further development of hybrid inks with low-odour and odourless properties, which opens up additional fields of application in packaging printing.
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