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a clean wipe of the anilox roll. The doctor blade system can either be an open single blade system or an enclosed dual blade system. The single blade system uses an open ink pan with a roller that is then sheared with one doctor blade to create a uniform layer of ink to be distributed. The remaining ink sheared from the anilox roll will collect in the ink pan to then be pumped back into the system. The cylinder plate, anilox, and doctor blade are independently controlled by hydraulic, pressure and/or pneumatic systems. This system is best used for low to mid quality print work - usually found in corrugated box printing. The dual blade system is an enclosed system that has one doctor blade for doctoring the ink and one containment blade that contains the ink in the chamber and allows ink from the anilox roll back in. Dual blade systems require 2 end seals and adequate chamber pressure in order to maintain the tight seal between the ink chamber and the anilox roll. This system is best used for high quality, intricate print designs, like those found in the label industry.
866:. A film negative is placed over the plate, which is exposed to ultra-violet light. The polymer hardens where light passes through the film. The remaining polymer has the consistency of chewed gum. It is washed away in a tank of either water or solvent. Brushes scrub the plate to facilitate the "washout" process. The process can differ depending on whether solid sheets of photopolymer or liquid photopolymer are used, but the principle is still the same. The plate to be washed out is fixed in the orbital washout unit on a sticky base plate. The plate is washed out in a mixture of water and 1% dishwasher soap, at a temperature of approximately 40 °C. The unit is equipped with a dual membrane filter. With this the environmental burdening is kept to an absolute minimum. The membrane unit separates photopolymer from the washout water. After addition of absorb gelatine for example, the photopolymer residue can be disposed of as standard solid waste together with household refuse. The recycled water is re-used without adding any detergent.
1193:. Measuring the physical properties of inks and understanding how these are affected by the choice of ingredients is a large part of ink technology. Formulation of inks requires a detailed knowledge of the physical and chemical properties of the raw materials composing the inks, and how these ingredients affect or react with each other as well as with the environment. Flexographic printing inks are primarily formulated to remain compatible with the wide variety of substrates used in the process. Each formulation component individually fulfills a special function and the proportion and composition will vary according to the substrate.
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1084:. The doctor blade removes excess ink from the anilox roller before inking the printing plate. The substrate is finally sandwiched between the plate and the impression cylinder to transfer the image. The sheet is then fed through a dryer, which allows the inks to dry before the surface is touched again. If a
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classified aniline dyes as unsuitable for food packaging and as a result, printing sales plummeted. Individual firms tried using new names for the process, such as "Lustro
Printing" and "Transglo Printing", but met with limited success. Even after the Food and Drug Administration approved the aniline
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system. The fountain roll or two-roll system has one roll spinning in an ink pan pressed against the anilox roll to transfer a layer of ink to then be applied to the printing plate. This system is best used for low quality print such as flood coats and block lettering due to its inability to produce
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The anilox roll is a unique characteristic of flexography. The anilox roller transfers a uniform thickness of ink to a flexible printing plate. The anilox roll has finely engraved cells with a particular ink capacity, viewable with a microscope. These rollers are responsible for transferring inks to
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roll (or meter roll) whose texture holds a specific amount of ink since it is covered with thousands of small wells or cups that enable it to meter ink to the printing plate in a uniform thickness evenly and quickly (the number of cells per linear inch can vary according to the type of print job and
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The same principle is applied for multiple plates across the sleeve and so either two cameras per plate are used or two cameras are used which move into the correct position driven by servo motors and camera setting software. To step plates around the sleeve to minimise risk of bounce is done either
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and containers, envelopes and wallpaper. In recent years there has also been a move towards laminates, where two or more materials are bonded together to produce new material with different properties than either of the originals. A number of newspapers now eschew the more common offset lithography
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Flexo has an advantage over lithography in that it can use a wider range of inks, water based rather than oil based inks, and is good at printing on a variety of different materials like plastic, foil, acetate film, brown paper, and other materials used in packaging. Typical products printed using
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The high magnification video cameras (positioned on a precision machined camera beam) are moved into the required position for the plate to be mounted, accurate measurement of this setting is critical. The plate is then adhered to the sleeve using a mounting tape (see item 5) and the complete unit
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The third method is to go through a molding process. The first step is to create a metal plate out of the negative of our initial image through an exposition process (followed by an acid bath). In the early days the metal used was zinc, leading to the name 'zincos'. Later, magnesium was used. This
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An optional doctor blade scrapes the anilox roll to ensure that the ink to be delivered to the flexible printing plate is only what is contained within the engraved cells. Doctor blades had predominantly been made of steel, but advanced doctor blades are now made of polymer materials with several
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Positioning is achieved by correctly lining up register marks that are common to each plate in the set. The skill is to plan carefully exactly where these marks should be. A variety of marks can be used, register crosses and micro dots. A good bond is achieved by means of special mounting tape.
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Generally plates are mounted directly onto the print sleeve but for corrugated operations, plates are mounted onto a carrier sheet that is fixed to the print sleeve in the press when required, it is removed and kept in storage between print runs. You'll find out about carriers in the corrugated
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Precision mounting is critical for producing good quality print which is in the register and has a direct impact on minimizing waste. The mounting process needs to deliver the same accurate result each time a job is mounted, consistent accuracy is the target. For simplicity we'll refer to print
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exactly with the images transferred from the other colors. To ensure an accurate picture is made, mounting marks are made on the flexographic plates. These mounting marks can be microdots (down to 0.3 mm) and/or crosses. Special machinery is made for mounting these plates on the printing
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Once the plate is accurately aligned, it's pressed onto the strip of exposed mounting tape. The rest of the tape liner is then removed or a plate support table is moved so that the remainder of the plate can be laid onto the sleeve. This is done with each sleeve in turn so that all the plates
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material. Flexographic plates can be created with analog and digital platemaking processes. The image areas are raised above the non image areas on the rubber or polymer plate. The ink is transferred from the ink roll which is partially immersed in the ink tank. Then it transfers to the
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The most common form of mounting is register mark - also known as video mounting. When the print is run the register marks should print on top of each other indicating that the plates are correctly aligned. The register marks on the plate are lined up using magnifying cameras.
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The location of registration marks, whether crosses or microdots, is essential to the success of plate mounting. If they are incorrect, mounting can be difficult, time-consuming and inaccurate, so they need to be planned carefully. The marks should be positioned symmetrically
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Register crosses are more common in label and corrugated printing where waste and hidden folds are normal, the microdot is common in flexible packaging where waste is kept to a minimum and no un-required marks are to be seen on the packaging (example meat, dairy and hygiene).
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oil-based ink were developed. This led to the process being called "aniline printing". By the 1920s, most presses were made in
Germany, where the process was called "gummidruck", or rubber printing. In modern-day Germany, the process continues to be called "gummidruck".
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Always have a pair positioned in the middle of the plate in line with the sleeve axis. It is also recommended to have two more pairs, one at either end so a simple rotation and check under the cameras confirms the plate has not twisted when it was laid/stuck down.
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rolls along with chambered ink systems, have also played a part in the improvement of print quality. Full-color picture printing is now possible, and some of the finer presses available today, in combination with a skilled operator, allow quality that rivals the
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Micro dots as the name suggests are tiny dots on the plate, usually about a quarter of a millimeter across in labels and flexible packaging but 1mm diameter in corrugated. Since they are so small they don't have to be in waste areas as they are not easily seen.
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board or even glass or plastic, through a first molding process. Once cooled, this master mold will press the rubber or plastic compound (under both controlled temperature and pressure) through a second molding process to create the printing plate or cliche.
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For every colour to be printed, a plate is made and eventually put on a cylinder which is placed in the printing press. To make a complete picture, regardless of printing on flexible film or corrugated paper, the image transferred from each plate has to
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The next sleeve is loaded and the plate mounted in position by positioning the register marks on the plate based on the previously fixed camera positions. This ensures that every plate is mounted in the same position and thus the print is in register.
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process in 1949 using new, safe inks, sales continued to decline as some food manufacturers still refused to consider aniline printing. Worried about the image of the industry, packaging representatives decided the process needed to be renamed.
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Each plate is mounted on a double sided adhesive tape - there are many types of mounting tape and it is important to use the correct thickness and hardness. Adhesive type also needs to be correct for your mounting process (see Tape
Features)
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To counter this, automatic mounting provides up to 10x faster plate mounting than traditional plate mounting, no operator dependency and the highest possible accuracy and consistency down to 5 micron (0.0002 inch) per plate.
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The impression cylinder applies pressure to the plate cylinder where the image is transferred to the image-receiving substrate. This impression cylinder or "print anvil" is required to apply pressure to the plate cylinder.
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Registration crosses are commonly used but need to be positioned in waste areas as they are easily seen on the print, they can also be used as a guide for aligning the print to a bag or box structure if this is required.
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the quality required). To avoid getting a final product with a smudgy or lumpy look, it must be ensured that the amount of ink on the printing plate is not excessive. This is achieved by using a scraper, called a
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The tape is applied to the sleeve being careful to lay it on without trapping air underneath it (must be flat to sleeve). A small strip of the tape liner is removed to leave the adhesive exposed initially.
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flexography include brown corrugated boxes, flexible packaging including retail and shopping bags, food and hygiene bags and sacks, milk and beverage cartons, flexible plastics, self-adhesive labels,
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The plate cylinder holds the printing plate, which is made from a soft flexible rubber-like material. Tape, magnets, tension straps and/or ratchets hold the printing plate against the plate cylinder.
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industry for printing plastic materials for packaging and other end uses. For maximum efficiency, the flexo presses produce large rolls of material that are then slit down to their finished size on
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The fountain roller transfers ink located in an ink pan to a second roller, an anilox roller. In modern flexographic printing, the anilox roll is referred to as a type of meter or metering roller.
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The cameras provide an enlarged visual display indicating whether or not the register marks are correctly positioned in line with crosshair targets. If necessary the plate position is adjusted.
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cylinders to maintain registration. Earle L. Harley invented and patent the Opti-Chek
Mounting and Proofing machine enabling the operator to check the registration before going to the press.
1341:"Printing Process Descriptions: Environment and Printing: The Printers' National Environmental Assistance Center: PNEAC: The Environmental Information Website for the Printing Industry"
788:'s Printed Packaging Committee narrowed the selection to three possibilities: "permatone process", "rotopake process", and "flexographic process". Postal ballots from readers of
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Printing press speeds of up to 750 meters per minute (2000 feet per minute) are achievable now with modern technology high-end printers. Flexo printing is widely used in the
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process until recently. Since 1990, great advances have been made to the quality of flexographic printing presses, printing plates, ink systems and printing inks.
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to eliminate air bubble inclusions, tape application options, plate and tape cutting options and moving cameras, replacing multiple camera mounting systems.
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In recent years higher quality demands from customers, shorter and more frequent job runs result in an increasing relative cost of the prepress department.
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On most mounting machines the dots or crosses on the plates are lined up using magnifying cameras, the higher the magnification the greater the accuracy.
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process. One ongoing improvement has been the increasing ability to reproduce highlight tonal values, thereby providing a workaround for the very high
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To align the plates accurately a mounting system using video cameras is required. Each print sleeve is transferred to the mounting system in turn.
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During the early part of the 20th century, the technique was used extensively in food packaging in the United States. However, in the 1940s, the
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The ink is controlled in the flexographic printing process by the ink system. The ink system contains an ink pump, anilox roll and either a
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Originally, flexographic printing was rudimentary in quality. Labels requiring high quality have generally been printed using the
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Accurate positioning is essential or the images of each colour will not be superimposed correctly, they will be out of register.
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Johansson, Lundberg & Ryberg (2003) "A guide to graphic print production", John Wiley & Sons Inc., Hoboken, New Jersey.
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The plate is carefully positioned over tape, usually by hand so that the register marks are seen directly below the cameras.
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In 1951 Franklin Moss, then the president of the
Mosstype Corporation, conducted a poll among the readers of his journal
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893:, Polymount, Screen and SPGPrints from The Netherlands are market leaders in manufacturing this type of equipment.
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have pioneered the latest technologies, with advances in fast washout and the latest screening technology.
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Each sleeve is fixed in the mounter by a clamping system and mounting tape is then applied to the sleeve.
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Precision mounting of flexo plates on tape with the aid of laser pointers on automatic mounting machine
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The second method uses a computer-guided laser to etch the image onto the printing plate. Such a direct
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to submit new names for the printing process. Over 200 names were submitted, and a subcommittee of the
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sleeves throughout this module but you can substitute cylinders if these are used in your operation.
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Diagram of a typical flexographic printing apparatus, illustrating the general operating principle.
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printing plates, including improvements to the plate material and the method of plate creation.
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may contain an excessive amount of intricate detail that may interest only a particular audience
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A flexographic print is made by creating a positive mirrored master of the required image as a
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mechanically using an index disc or by use of stepper motors to drive and lock it in position.
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Automatic Flexo Plate
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ink is used, the sheet does not have to be dried, but the ink is cured by UV rays instead.
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overwhelmingly chose the last of these, and "flexographic process" was chosen.
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systems have seen a good improvement in the industry recently. Companies like
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any relevant information, and removing excessive detail that may be against
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to lay the plate on to make maneuvering the plate into position simpler,
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These are various types of mark used for aligning the plates correctly:
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The greatest advances in flexographic printing have been in the area of
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process in favour of flexo. Flexographic inks, like those used in
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the flexible printing plates mounted on the plate cylinders.
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Handbook of print media: technologies and production methods
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and unlike those used in lithography, generally have a low
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The first method of plate development uses light-sensitive
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30:"Flexo" redirects here. For the Futurama character, see
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International Paper - Knowledge center - Flexography:
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reactions) - although these are uncommon at the moment
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1318:(Illustrated ed.). Springer. pp. 976–979.
1397:"Automatic Flexo Plate Mounting Machine | SAMM 2.0"
760:In 1890 the first such patented press was built in
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481:Learn how and when to remove these messages
443:PCMC's Fusion C Flexographic Printing Press
1460:European Flexographic Industry Association
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462:This article has multiple issues.
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1373:from the original on 2013-09-08
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1031:options to increase efficiency.
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41:A flexographic printing plate.
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1223:Water based flexo inks with
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681:Knowledge's inclusion policy
1039:lay down (pressure) rollers
946:Types of registration marks
873:Flexographic printing press
620:the claims made and adding
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1367:"AV Flexologic: Cosmoline"
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1179:Flexographic printing inks
1156:3. Doctor blade (optional)
1116:Outfeed and rewind section
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1098:Unwind and infeed section
374:Thermal-transfer printing
1312:Kipphan, Helmut (2001).
1092:Basic parts of the press
936:effective plate mounting
931:section of this module.
249:Photostat and rectigraph
27:Form of printing process
1171:5. Impression cylinder
48:Part of a series on the
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837:Laser-etched ceramic
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1455:what is Flexographic
1364:AV Flexologic B.V.:
1128:Operational overview
1026:register correctly.
512:improve this article
239:Daisy wheel printing
786:Packaging Institute
279:Dot matrix printing
54:History of printing
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1404:. Retrieved
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1375:. Retrieved
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1349:. Retrieved
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1252:Applications
1245:doctor blade
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1235:Ink controls
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1214:polyurethane
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510:Please help
505:verification
502:
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464:Please help
461:
189:Rotary press
89:Movable type
18:Flexographic
1052:3. Printing
906:2. Mounting
746:letterpress
730:Flexography
384:3D printing
357: 1972
169:Lithography
132: 1515
117: 1440
1474:Categories
1406:2019-05-07
1377:2015-08-05
1351:2009-01-29
1285:References
1281:machines.
1275:converting
1243:system or
1217:isocyanate
689:March 2021
677:relocating
630:March 2021
614:improve it
568:March 2021
538:newspapers
467:improve it
289:Xerography
229:Mimeograph
199:Hectograph
71:Techniques
1480:Packaging
1268:viscosity
1123:Operation
1086:UV-curing
796:Evolution
762:Liverpool
618:verifying
473:talk page
139:Mezzotint
1371:Archived
1345:Archived
1279:slitting
1229:deinking
912:register
899:bakelite
848:dot gain
814:Digital
738:printing
159:Aquatint
1264:gravure
1077:ceramic
1068:polymer
864:polymer
766:aniline
756:History
612:Please
552:scholar
124:Etching
1322:
1073:anilox
1064:rubber
1060:relief
1035:tables
839:anilox
830:, and
820:DuPont
802:offset
742:relief
554:
547:
540:
533:
525:
1062:in a
891:Kodak
824:Kodak
734:flexo
559:JSTOR
545:books
1320:ISBN
887:Esko
832:Esko
828:XSYS
531:news
398:1991
388:1986
378:1981
368:1972
343:1969
333:1957
323:1950
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293:1938
283:1925
273:1923
263:1911
253:1907
243:1889
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193:1843
183:1837
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143:1642
103:1430
93:1040
1075:or
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675:or
616:by
514:by
83:200
1476::
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1386:^
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1057:3D
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