Advanced Technologies For Marabu Glass Decoration · 2007. 3. 27. · Marabu Marabuwerke GmbH & Co. KG Silan pre-treatment is a must and the preferred way of pre-treating of beverage

Marabu

Marabuwerke GmbH & Co. KG

Advanced

Technologies For

Glass Decoration

Author: Martin Hehl-HeinzProduct Manager GlassMarabu GmbH & Co. KG

Marabu

Marabuwerke GmbH & Co. KGMarabu Today… and

…History

found 1859 in Stuttgart / Germany Headquarter in Tamm near StuttgartFamily business with 450 employees worldwideRepresentations and Subsidiaries in more than 70 countriesScope of business in creative inks as industrial inks forscreen, pad, and digital printing.

In represented since 1990 by Servis Centrum

Marabu

Marabuwerke GmbH & Co. KGMarabu

Overview

• Surface characteristics of glass

• Decoration of Glass

• Pre-treatment

• UV Technology

• Cost comparison screen printing

Ceramic vs. UV

Marabu


Surface CharacteristicsContainer Glass

Hot-End-Coating

• Is standard practice with beverage bottles

• At approx. 550° - 600°C where a tin (IV)-chloride-film is

applied with a minimum of no less than 30 ctu

• Coating fuses with the glass surface.

Removal is not possible

micro cleft HE Layer

Glass Surface

without with

HE Coating

micro cleftmicro cleftmicro cleft HE LayerHE LayerHE LayerHE Layer

Glass Surface

without with

HE Coating

micro cleft HE LayerHE LayerHE LayerHE Layer

Glass Surface

without with

HE Coating

Marabu


Surface CharacteristicsContainer Glass

Cold-End-Coating• During labelling, varnishing, and printing, this coating acts like

a separating layer and often causes problems

• Type, thickness, and consistency vary

• The CE-coating provides a better slip for filling lines, protecting

against scratching

The film thickness

nearest the spray

nozzle is

extremely high.

The thickness and

density reduces

significantly the

further from the

nozzle.

Problem Zone for

Labelling

Conveyor Direction

Marabu


° There is a “fire side“,

° And a “bath“ or “tin side“

° Print onto the fire side! On the tin side flow problems

and bad adhesion are likely

Surface Characteristics Flat Glass

Marabu


Printing on Glass

Packaging glass� Beverage bottles

� Cosmetic flacons

� Conserve glass

Restaurant glass� Drinking glasses

� Ashtrays

� Cups

Marabu


Printing on Glass

Packaging glass requirements

• High scratch resistance (transport, filling line)

• Leach (base) resistance (NaOH)

• Humidity resistance (pasteurisation)

• Fill-product resistance (Alcohol, Perfume)

Restaurant glass requirements

• Dishwasher resistance

° Domestic dishwasher, 200 cycles

° Industrial dishwasher, 1200 cycles

• Scratch resistance , fingernail test

Marabu


Printing on Glass

Flat glass (indoor usage only)

� gambling machines

� furniture (tables, cupboards, showcases)

� mirrors

� tiles

� room and office dividers

� panels for light switches, communicators

Marabu


Printing on Glass

Flat glass requirements

• Exposed surface

° scratch / rub resistance

° resistance to glass cleaning agents

° short-term resistance to humidity

• Protected surface

° no mechanical requirements

° resistance to chrome-coating (mirrors)

° compatible with laminating agents (tiles, MLG)

° resistance to humidity (bathroom)

Marabu


Pre-treatment Flaming

The measure of surface wet-ability is the

surface tension (in mN/m). The higher the

surface tension, the better the wet-ability

Marabu


Pre-treatment Flaming

The exposure to heat with gas flame pre-

treatment breaks the molecule chain on the

substrate surface

Oxygen atoms from the flame bond to these

fissures

Inks adhere to the oxygen bridges

Marabu


The Pyrosil® or Silan method

° (pyro = flame; sil = Silan -> Silicate coating)

° Through dosage of the silicon based substance into the flame, a highly cross-linked silicone coating is created on the substrate surface

° This silicone coating is extremely beneficial for ink adhesion to glass

Pre-treatmentSilan

Marabu


The thickness of the densely cross-linked

silicone surface is very thin at between

20 and 40 nm

Figuratively spoken there is an invisibly

thin but enormous rough layer of glass

on the surface

Pre-treatmentSilan

Marabu


ISIMAT progressed the development of the Pyrosil

method for the decoration of glass with UV-inks

UVitro® -Technology (Patent is announced)

This procedure guarantees excellent long-term

adhesion of UV inks on glass

UVitro® -Technology is possible for all decorations

onto glass

Pre-treatmentUVitro®

Marabu


Pre-teatmentSilan / UVitro®

Positive Effects

• Increases surface area

• Better surface

wettability

• Increases surface tension

• Treatment in-line, no

additional time required

Influence

• Better mechanical

adhesion

• Better chemical

adhesion

• Better chemical

adhesion

• No additional time

wasting

Marabu


0

50

100

no pre-treatment flaming Pyrosil UVitro

no pre-treatment flaming Pyrosil UVitro

Comparison of pre-treatment processes regarding adhesion

Pre-treatment Comparison

Marabu


Silan pre-treatment is a must and the preferred way of pre-treating of beverage bottles and drinking tumblers before printing with UV inks.This way of pre-treatment offers the largest window in production safety.

For pre-treatment of cosmetic bottles and flat glass flame treatment increase adhesion but is not required. However we would always recommend it.

Pre-treatment Summary

Marabu


UV-technology

Advantages by UV-inks

•unlimited mesh opening

•absence of solvents

• fast drying (curing)

•high production speed

•chemical resistance

and high gloss

•heavy metal free

Marabu


UV-technology

Advantages by UV-inks

•easy handling of the inks

• increased printing quality

• intermixable basic shades – variety of colour

shades

•no shade deviation with long print runs

• less space for dryer needed

• time savings

Marabu


UV-technology

Requirements for UV-printing

•UV-dryer unit

•suitable UV-inks

•100 % curing

•adapted mesh and stencil practise

•Tight control of ink deposit

•constant control of sufficient adhesion

•exhaustion of ozone

•careful use of UV-inks

Marabu


Printing principle on multi-colourmachine

pretreatment 1. print station 2. print station posttreatmentUV-curing UV-curing

Marabu


Characteristics

° No oven baking is necessary

° Wide colour range. Nearly all Pantone and

HKS colours are possible

° Very fine pigments admit the use of fine

mesh. In due of this printing of very fine

details is possible.

° Very good adhesion and scratch resistance

without baking

° Excellent printability

Printing onto GlassUV Inks

Marabu


Applications

° Pre-treated, cold-end-coated container glass

such as beverage bottles (only disposable)

° pre- and un-treated cosmetic bottles

° pre- treated restaurant glass such as drinking

glasses, ashtrays, bowls

° pre- and un-treated flat glass for indoor use,

such as mirrors, gambling machines, furniture


Marabu


Resistances° Only disposable bottles with the print in the

labelling field

° Alkali resistance: 2.3 % of NaOH/80°C/40 Minutes

° Pasteurisation: 90°C � 60°C/40 minutes

° Dishwasher resistance domestic dishwasher: min. 500 cycles (65°C/130 minutes)Winterhalter dishwasher: min. 3500 cycles (80°C/3 minutes)


Marabu


Cost Comparison Ceramic - UVMesh Cost/ m²

17

,00

€

28

,60

€

25

,50

€

32

,00

€

18

,60

€

21

,80

€

37

,40

€

78

,25

€

24

,80

€3

1,5

0 €

0,00 €

15,00 €

30,00 €

45,00 €

60,00 €

75,00 €

120 -

34

140 -

31

150 -

31

165 -

27

165 m

esh

200 m

esh

325 m

esh

400 m

esh

on

avera

ge

PolyesterPolyesterPolyesterPolyester MetalMetalMetalMetal

Marabu


Cost Comparison Ceramic - UVMesh Cost/ m² + Durability

MetalMetalMetalMetal PolyesterPolyesterPolyesterPolyester

costs in %0000

20202020

40404040

60606060

80808080

100100100100

Approximately 40% Cost SavingsEnergy costs to heat screens not taken into account

Marabu


Cost Comparison Ceramic - UV Ink Consumption /kg

Ink mileage in m²

15,515,515,515,5

25252525

70707070

0 20 40 60 80

Pb/Cd

Pb/Cd Free

UV

Marabu


Cost Comparison Ceramic - UV Ink Consumption

100%100%100%100%

53%53%53%53%

0%

20%

40%

60%

80%

100%

ceramic UV

Marabu


Cost Comparison Ceramic - UV Curing/Drying

48 m³/h, Gemco lehr gas

consumption

Running 24 hours

61.44 €/h

9.00 €/h

70.44 €/h

Gas cost lehr

Electricity

TOTAL CERAMIC

360 €/lamp

1500 h operating life

Running only when printing

1.45 €/h

10.50 €/h

11.95 €/h

UV lamps/6 colours

UV Electricity

TOTAL UV

Marabu


Cost Comparison Ceramic - UV Curing/Drying in %

100%100%100%100%

35%35%35%35%

0%

20%

40%

60%

80%

100%

ceramic UV

Not taking real running time into consideration– lehr runs 24 hours

Marabu


Cost Comparison Ceramic - UV Printing Cost Analysis in %

6055

35

0

20

40

60

80

100

mes

hin

k

ener

gie

ceramic

UV ink

Marabu


• EU Guide line 94/62

° limits heavy metal concentration for packaging (100

ppm)

° Up to now no penalties known.

• US - Proposition 65

° Californian law with extensive regulations in connection

to glass and ceramics concerning contact with food.

There are first penalties against PEPSI and COCA COLA

in double digit millions. Dr. Pepper also.

Through this we realised a noticeable increase in

requests for UV-inks and this will become stronger in the

future

° Already having influence to European decorators, too

Printing onto Glass Guidelines

Marabu


Summary

• Enormous potential

• Cost savings and environment friendly

• Tendency more & more to UV

• UV colours are in a strong position

• This is the time changing over to

decoration with UV inks

Marabu

Marabuwerke GmbH & Co. KG

Thank You For Your Attention!

Documents

Advanced Technologies For Marabu Glass Decoration · 2007. 3. 27. · Marabu Marabuwerke GmbH & Co. KG Silan pre-treatment is a must and the preferred way of pre-treating of beverage