Pressroom Chemicals Adapt to CTP, Stochastic

Makers of pressroom chemicals are honing their products to enhance production efficiencies, reduce materials costs and consumption, minimize ecological impact, and leverage the benefits of new technologies like computer-to-plate (CTP) imaging and stochastic screening.

Fountain solutions, press washes, plate cleaners, and a host of other products are all being adapted for maximum performance in a constantly evolving graphic arts production system.

"We constantly strive to provide products that enhance productivity and profitability for our end users," says Chuck Pascarelli, vice president and general manager of Fuji Hunt Graphics Products, Allendale, N.J.

Adds Jeff Pieper, business director of Day International's Chemical Products Division, Addison, Ill., maker of the Varn product line, "We develop and create products that optimize performance areas that have the best financial impact for the printer. Our mission is not how we can sell chemistry for 25 cents less per gallon, but how we can generate dollars of value for the customer," says Pieper.

For example, he says, Day's new Pantheon brand of sheetfed fountain solutions mix at lower dosages and offer a bigger operating window, which allows a printer to be more productive.

Chemical manufacturers report that product development these days is evolutionary, not revolutionary.

"There was a time when pressroom chemistry had a place on technical discussion panels in the industry, but conferences today include a lot less talk about the topic," observes David Gerson, vice president of research and technology for Prisco (Printers' Service), Newark, N.J. He speculates that chemical makers have done their jobs well, and that the big problems that beset the industry a decade ago are no longer critical.

Today's key issues, Gerson says, have to do with keeping product costs down and complying with government regulations concerning health, safety, and the environment.

At the same time, vendors report, pressroom chemical prices are expected to increase in the coming months as petroleum prices continue to climb and a pending shortage of gum arabic, a key ingredient in fountain solutions, looms. By some estimates, prices could climb by 10% to 15%.

Fountain solutions remain a central focus of pressroom chemicals. Here, manufacturers are developing products that are not environmentally abrasive and are concentrated to run at lower dosages.

"The industry is pretty much alcohol free today, but the next level has to happen," says Rick Sures, president of Allied Pressroom Chemistry, Hollywood, Fla. "Alcohol replacements contain a lot of strong solvents, which can affect print quality."

Following two years of trials, Sures reports, Allied launched a product called All Star, a one-step fountain solution that runs at a dosage of three ounces per gallon to replace two-step products that require six to eight ounces. He says the product runs on a variety of plates, including CTP versions.

D.A.A. International (originally known as Domenic Argenio Associates), West Paterson, N.J., specializes in environmentally friendly products. The company offers a full line of water-based chemical cleaners, fountain solutions, and blanket/roller washes.

"Environmental products are somewhat more expensive per gallon, but because the dosage is lower, they're less expensive on a total cost basis," reports Walter Rozanski, D.A.A.'s general manager.

Adds Pascarelli of Fuji Hunt, "All of us have to become even more green; doing so continues to be an opportunity and a challenge for each of us."

Given the many variables of the print production system, chemical makers report that more and more they are tweaking and customizing core products to fit customers' individual requirements.

"Technically we're a chemical supplier, but I view us more as a customized blender because of the numerous variables that occur on press," notes Pascarelli. "We continually work with customers to supply them with a product that is unique to their uniqueness."

Gerson adds that Prisco and other suppliers do a great deal of custom formulating of blanket washes, fountain solutions, and fountain chemistries.

For its part, Milwaukee-based RBP Chemical opted to put the power of formulating in the customer's hands with its Concept 21 product, which it introduced to the web offset market two years ago. Next target: the sheetfed market.

"Our fountain solution product allows customers to make adjustments on site," reports Jeff Berhens, product development manager for RBP Chemical. "The product is made up of base concentrates and a blending proportioning pump."

"For us the exciting new things in press chemistry revolve around working on solutions that maximize ink and water balance," says William Glass, vice president and general manager of Vivitek, Fort Lee, N.J. "We are focused on providing total solutions."

Because the company is a part of ink making giant Sun Chemical, Glass says Vivitek is in a unique position to develop a combination of inks and fountain solutions that maximize performance. Add to that is the fact that Sun Chemical just purchased the Rycoline Incorporated Group of Companies, which includes a complete line of fountain solutions, blanket and roller washes, silicone and silicone replacement products, overprint coatings, printing blankets, and miscellaneous products from aerosols to anti-static products.

Glass says Vivitek introduced a non-silicone web conditioner, marketed under the product name MagniTek MicroSurf, that doesn't require mixing and features doses applied at lower rates. He says, "The product, which comes in a single solution concentrate, is eliminating some of the issues associated with silicone conditioners, such as white streaking, watermarks, or build-up on the nose cone."

Varn also markets a non-silicone web conditioner called Apollo 900.

Another important trend influencing pressroom chemistry is the rising popularity of stochastic screening, adds Glass.

"As more printers adopt stochastic screening, there will be a higher demand for inks and fountain solutions to work better together," he says. "We're developing a solution that answers the need for getting the emulsion right so you don't have dot gain, and ensuring a good release from the plate to the blanket so you don't get piling."

Adds Pieper, "At Day International, where we also manufacture press blankets, we think we're uniquely positioned to resolve the piling issue, given that we can attack from both a blanket and chemical perspective. We work with a lot of customers to create a system that helps them print stochastic much more efficiently."

Prisco's Gerson holds an alternative view on the need for specialized fountain solutions for stochastic applications, saying, "A first-class fountain solution will run a stochastically generated screen as well as an AM screen. Granted, you're dealing with small dot sizes, but that's not a significant limiting factor in our ability as fountain solution manufacturers to make that process work."

He says adjustments may need to be made for ancillary problems, such as piling, but these don't require radical product redesigns.

Computer-to-plate is another focus area for chemical makers, in terms of fountain solutions and washes.

"The single biggest trend in the pressroom chemical market now is the compatibility of the chemistry to CTP plates and CTP media because these plates are more chemically sensitive than conventional plates," says Rick Principato, president of Tower Products, Inc., Palmer, Pa.

As a result, he says, CTP plate vendors have initiated a program to approve chemical products.

Rycoline developed a one-step fountain solution for use with CTP. "CTP plates carry water differently, so we developed a fountain solution to address that need," explains Mark DeSandre, Rycoline's vice president of sales and marketing.

But DeSandre says the Rycoline product works on conventional plates as well. "The benefit of a one-step fountain solution is that because no mixing is required, it's easier to use and allows for fewer mistakes."

Yet another area affecting fountain solution formations is paper.

Explains Berhens of RBP Chemical, "As the calcium carbonate in paper stocks continues to increase, they become more difficult to run on press. In response, we've incorporated sequestering agents for calcium in the fountain solution so precipitate does not form."

The increased popularity of energy-curable or hybrid printing inks and coatings is also exerting influence on press chemical formulations.

"We have some washes specially designed to clean these types of inks efficiently, and some firms market a special fountain solution for hybrid inks," reports Principato. He says his company's Millennium SF fountain solution will work in such applications.

Plate cleaners are another chemical area transformed by CTP. "Plate cleaners for CTP must perform effectively and keep the plate clean and wet, but not degrade the image," says Sures of Allied Pressroom Chemistry. "We designed a product specifically for CTP plates that can be applied on the fly with spray bottles."

Prisco recently announced full availability of Prisco Velocity Plate Cleaner, a heavy-duty cleaner/scratch remover containing cleaners, desensitizers, and a mild abrasive. The product offers deep cleaning action, which assures complete ink removal while providing safety for even the most sensitive CTP plate emulsions. Plates are ready for storage after an application.

"A lot of the older plate cleaners won't work with CTP plates because the image is more susceptible to chemistry attack," explains Berhens. "As a result, printers need to know that a given plate cleaner may be reducing plate life." Thus, plate manufacturers have begun to certify the products that work on their plates.

Tower Products introduced an acid non-emulsion plate cleaner called Great Plate Digital, designed for CTP plates, which, Principato says, is approved by Fuji and Kodak Polychrome Graphics.

Finally, press washes can influence CTP plate performance, too. "In response," reports Berhens of RBP Chemical, "press manufacturers have standards and approvals for washes used in their automated systems." He reports that Fogra Graphic Technology Research Association in Germany offers guidelines and standards for certifying washes.