Production Increase And Savings With Nickel Screen

German label converter, Rako Etiketten of Witzhave has increased productivity and generated cost savings since it started using Stork Prints' re-usable nickel Rotaplate screen on its presses.

German label converter, Rako Etiketten of Witzhave has increased productivity and generated cost savings since it started using Stork Prints' re-usable nickel Rotaplate screen on its presses.

Rako Etiketten switched from stainless steel woven meshes to the new Rotaplate screen from Stork Prints early last year.

The company has been able to boost printing speeds for rotary screen printing jobs on its new Gallus presses by as much as 20 per cent, achieving bout 50 metres per minute.

Furthermore, it has reported an increased lifespan, with most screens having no problem in running more than 50,000 web-metres.

The Rotaplate screen is based on Stork's concept of a pure nickel, electro-formed mesh, with hexagonal holes.

It is a single, non-woven piece of material and that structure is claimed to give it optimum strength and stability to cope with handling and the rigours of printing.

Rako has a fleet of 33 Nilpeter and two Gallus presses.

On the Stork RSI unit within the Nilpeter presses, Rako uses Stork's Rotamesh screens, which can also be re-engraved with different screen images.

Stefan Behrens, Rako Etiketten's pre-press manager, said: "The new screen is helping reduce production costs greatly.

It's extremely strong, reliable material that never breaks when being removed or re-inserted on to the press, or when being rinsed after printing.

As a result we have no problem re-using the Rotaplate screen - often as many as five times." He added: "Following on from this, we no longer need to make a back-up screen because the chances of a mishap during production are virtually nil.

We're also able to print faster because the screen's single-piece construction makes it more resistant to web impurities, such as dust or splices." The new Rotaplate screen was said to be easier to inspect, too, thanks to its green emulsion, which gave a clearer contrast under the light.

The screen itself requires a small amount of preparation by the customer, said Stork Prints, which added that after arriving as a flat, coated mesh from the supplier, it is then cut to the required format by the customer.

Following that, the mesh is then exposed and rinsed out, then made in to a cylinder with a strong adhesive.

The end rings are attached and the screen is ready for the press.

Rako said it has faced a great increase in demand for rotary screen printed designs from customers and to remain competitive, the company needed to watch the costs of the process more closely.

In the last year, Rako used 2500 Rotaplate screens and as a prominent player in markets such as cosmetics, food and beverage, as well as security printing, the company uses the rotary screen process extensively, said Stork Prints.

The company added that the process can be used to great creative effect because it can print very thick deposits of ink in a single pass.

Screen is popular for opaques with extra richness of colour and the no-label look, but there is increased interest in screen-printed varnishes as well.

They result in raised images that make the underlying graphics stand out.

Rako is actively promoting that effect under the High and Clear varnish brand.

Behrens added: "With customers wanting partial deliveries more frequently, we find ourselves dealing with smaller production runs.

We're often coming back to the same job many times, therefore, we need screen cylinders that are sturdy enough to withstand all the handling that goes with job changing.

The Rotaplate screen meets these challenges admirably.".

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