SubscribeZeller + Gmelin, together with its subsidiaries Intercolor (UK), Zeller+Gmelin Corp. (USA), Zeller+Gmelin Sarl (France), Zeller+Gmelin B.V. (Netherlands) and Zeller+Gmelin A/S (Denmark) is a global manufacturer of high quality inks and coatings for the specialist print and packaging industries.
They have led the field in producing inks for many exciting new developments in print – including UV flexo for label printing, cartons and flexible packaging, high-lustre metallic ink systems and a brand new range of speciality inks which include unique thermochromic, pearlescents, fragrance coatings and UV-invisible inks.
One important development has been a unique range of UV curing shrink sleeve inks for narrow web printers. This market has been traditionally dominated by solvent-based gravure printers; however the costs of cylinder engraving, solvent reclamation units and the initial investment in the press itself translate into an expensive process. Cationic UV inks as an alternative have been available for some time. Unfortunately, high wattage lamps are required to fully cure these systems. Consequently more IR heat is generated - particularly undesirable when printing shrink films. Cationic systems also have limitations with graphic quality and speed and are therefore not considered viable alternatives to gravure.
Zeller & Gmelin’s recent developments in free-radical flexo technology have shown enhancements over solvent-based gravure printing in graphic quality, opaque whites, environmental constraints, shrink and slide traits and most importantly production speeds. The free-radical inks offer low ink film shrinkage and high flexibility gradients. The system has proved to be a successful cationic alternative, not only in shrink applications but also on untreated metallised films, difficult plastics and thermoforming applications, where previously cationics or solvent based inks were the only options.
Fast cure and high adhesion allows the operator to print with light impression and low lamp wattage this translates into fast press-speed and a comparative productivity to gravure. The adhesion is high enough to bond with many forms of untreated metallised surfaces. Small amounts of acrylate shrinkage create a degree of stress in the ink film itself without suffering from crumple problems. This memory in the ink itself is similar to how shrink films are manufactured. Solvent –base gravure inks can inhibit shrinkage at higher weights. Slide traits of the new system are lower than solvent gravure allowing better conversion properties and smoother transfer of sleeves on tight-fitting applications.
With the gravure process there is no ink-film split from anilox to plate to substrate, effectively doubling the amount of ink transferred. Greater ink weight and lower viscosity mean that solvent gravure dot gains are higher. Zeller & Gmelin’s system has been developed particularly for high line YAG technology that can reach up to 1800LPI. Thin vibrant ink films and instant cure of the ink dot achieve better quality print and pigmentation is more transparent than gravure, offering cleaner images. Opaque whites have higher opacity, cleanness and are useable in combination printing with solvent and waterbased flexographic inks.
The lower environmental impact and potential savings with UV flexo – with cheaper presses, lamps and plates - are significant and production is swift to press and to changeover for short runs. Inks are more expensive than solvent-based – however pigmentation is around twice as high and therefore mileage is better.
The shrink sleeve industry is a challenging yet profitable application for UV presses. The opportunity for narrow web printers to bid on existing gravure work alone can transform the market fairly quickly. Cheaper and higher performance alternatives in free-radical UV technology can act as a catalyst for this advancing market.
Zeller & Gmelin, and their UK subsidiary Intercolor, are names synonymous within the industry for quality, consistency, service, support, performance and reliability. Forged through more than 130 years of experience in research and technology, Zeller+Gmelin is a dedicated UV ink specialist. Working closely and cooperatively with partners, customers, machine manufacturers, parallel suppliers and vendors, they strive to continuously develop systems and solutions to meet or exceed new product and market requirements. The commitment and focus on UV development, technology, training, manufacturing, quality, environment and its processes has been ongoing since 1970. Based in Eislingen, Germany, Zeller & Gmelin has continued to expand its presence throughout the global market. The company has manufacturing and strong support facilities in the UK, America and in the Benelux countries and Denmark. A global distribution network for all products is supported by international agents and subsidiaries.