6 major effects! Functional display and usage scenarios of Conventional Offset And UV Offset Ink Demulsifier
Publish Time: 2025-05-19
In the printing process, ink emulsification is one of the core issues affecting printing quality and efficiency. Conventional Offset and UV offset printing have different requirements for ink stability due to process differences, but demulsifiers can solve the emulsification problem through targeted effects. The following combines the six core effects to elaborate on its key application scenarios in actual production.1. Efficient demulsification and restoration of ink performanceOffset printing production in high humidity environmentDuring the rainy season or coastal areas, the humidity in the printing workshop often exceeds 70%, resulting in excessive emulsification of ink and fountain solution. For example, when a packaging printing factory was printing food packaging boxes, the density of the solid part was insufficient and the dot expansion rate exceeded the standard due to ink emulsification. After adding the demulsifier, the ink emulsification value dropped from 40% to 15%, the solid density was restored to 1.5 (original standard requirement), and the dot restoration degree was increased to more than 95%, avoiding delivery delays due to rework.Ink stratification problem in UV offset printingUV offset ink has a fast curing speed, and after emulsification, it is easy to have stratification caused by incomplete oil-water separation. When a cosmetic packaging printing factory was printing metallic labels, the ink stratification caused "orange peel texture" on the surface of the printed product. After using demulsifier, the ink uniformity was significantly improved, and the surface gloss after curing increased from 60GU to 85GU, meeting the needs of high-end customers.2. Improve ink fluidity and improve printing efficiencyThe problem of plate blocking in high-speed rotary offset pressIn book and magazine printing, the speed of rotary offset press is as high as 15,000 sheets/hour, and insufficient ink fluidity can easily cause plate blocking. When a large book and magazine printing factory was printing textbooks, the number of plate blockings per hour due to ink emulsification reached 5 times, and the cumulative downtime for cleaning exceeded 1 hour. After adding demulsifier, the ink viscosity was reduced by 15%, the number of plate blockings was reduced to less than 1 time per month, and the daily production capacity was increased by 20%.Thin ink layer transfer in UV offset printingUV offset printing requires high-precision printing through a thin ink layer, but the ink transfer rate decreases after emulsification. When printing QR codes, an electronic label printing factory had a scanning failure rate of up to 5% due to uneven ink transfer. After using a demulsifier, the uniformity of the ink layer thickness was improved to ±0.5μm, and the scanning success rate reached 99.9%, reducing customer complaints.3. Prevent ink skinning and extend the service life of inkInk waste after long-term shutdownWhen changing orders or equipment maintenance, the printing press is shut down for more than 2 hours, and the ink is prone to skinning in the ink fountain. A packaging printing factory wastes about 5 kilograms of ink every day due to ink skinning, with an annual cost of more than 100,000 yuan. After adding a demulsifier, the ink anti-skinning time is extended to 8 hours, the skinning thickness is reduced by 80%, and the annual ink cost is saved by 80,000 yuan.Ink roller stickiness in UV offset printingUV ink is easy to remain on the surface of the ink roller after curing, resulting in "ghosting" in subsequent printed products. During continuous printing, a cigarette packaging printing factory had a defective rate of 3% due to dirty ink rollers. After using demulsifiers, the ink roller cleaning cycle was extended from 2 hours to 8 hours, and the defective rate dropped to less than 0.5%.4. Reduce printing failure rate and improve the quality of printed productsRegistration deviation in multi-color overprintingIn four-color printing, the inconsistent ink drying speed caused by emulsification can easily cause registration deviation. When printing albums, a commercial printing factory had a scrap rate of 8% due to registration deviation. After adding demulsifiers, the ink drying time was shortened by 20%, the registration accuracy was improved to ±0.03mm, and the scrap rate was reduced to less than 1%.Anti-sticking phenomenon in UV offset printingWhen UV ink is not completely cured, printed products are prone to anti-sticking during the paper collection stage. During high-speed printing, a medicine box printing factory had a defective rate of 6% due to anti-sticking. After using demulsifiers, the ink curing energy was reduced by 15%, the anti-sticking phenomenon was completely eliminated, and the production efficiency was improved by 15%.5. Environmental protection and energy saving, in line with the trend of green printingCompliance requirements for reducing VOCs emissionsAs environmental regulations become stricter, printing companies need to control VOCs emissions. A company reduced the organic waste gas generated by ink emulsification by 30% by adding demulsifiers. After cooperating with waste gas treatment equipment, the VOCs emission concentration dropped from 80mg/m³ to 30mg/m³, meeting local environmental protection standards.Energy consumption optimization in UV offset printingThe energy consumption of UV curing lamps accounts for more than 60% of the total energy consumption of UV offset printing. A company improved the ink curing efficiency by using demulsifiers, reduced the power of curing lamps by 10%, saved more than 50,000 degrees of electricity per year, reduced equipment heating, and extended the life of lamps.6. Strong adaptability to meet different printing needsPrinting compatibility of special paperWhen printing special materials such as gold and silver cardboard and laser paper, the ink has poor adhesion and is easy to emulsify. When a cosmetics packaging factory was printing laser film labels, the ink fell off, resulting in customer returns. After using demulsifier, the ink adhesion is improved to 5B (100 grid test), the wear resistance is increased by 3 times, and the customer satisfaction is 100%.Synergistic optimization of hybrid printing processIn the hybrid process of "offset printing + UV glazing", demulsifier can solve the problems of offset ink emulsification and UV glazing oil compatibility at the same time. A wine label printing factory shortened the drying time difference between offset printing and UV glazing from 30 seconds to 5 seconds by adjusting the amount of demulsifier, realizing "one-time paper feeding" production and improving efficiency by 40%.Through six core functions, ink demulsifiers show strong application value in Conventional Offset and UV offset printing. From emulsification control in high humidity environment to fluidity optimization in high-speed printing; from prevention of ink skinning to reduction of printing failure rate; from environmental protection and energy-saving compliance to compatibility of special processes, demulsifiers have become key additives for printing companies to improve quality, reduce costs and achieve green production. In the future, with the further refinement of printing technology, performance optimization and customized development of demulsifiers will become an important direction for industry technology upgrading.
