A study of the effects of the process parameters on the flexographic printing problem “dot bridging” – part II: experimental design and print contrast/density

Abstract

Purpose

The print fault “dot bridging” reduces the printing press efficiency. This study was designed to find the best combination of materials used in normal production which would reduce or eliminate the problems thus increasing efficiency.

Design/methodology/approach

Various statistical methods were used to design the experiments and to analyse the experimental results. The experiment included all of the factors which were considered to have an effect on the “dot bridging” print fault.

Findings

The most important conclusion that can be drawn from the results is that the complex interactions between factors included in the process can be characterised. The experiment proved that the problem was not random. The data gathered during the experiment had a direct correlation with the psychometric results. Various factors included in the experiment were found to have a significant influence on print density and print contrast. Contrast and density were selected for analysis as ink film thickness was thought to have an influence on the best looking print samples and the “dot bridging” print fault.

Research limitations/implications

The results of the experiment were used to optimise the production process particularly the platemaking technique. Data from further experiments would help to optimise more process parameters.

Practical implications

Minitab computer software was used to analyse the results of the experiment thus making it easier to communicate the results to non‐scientific production staff.

Originality/value

This was the first time that the printer concerned had used a scientific approach to problem solving. The end result for the printer was an increase in production efficiency which saved the printer a considerable amount on money.

Citation

Galton, D. (2005), "A study of the effects of the process parameters on the flexographic printing problem “dot bridging” – part II: experimental design and print contrast/density", Pigment & Resin Technology, Vol. 34 No. 2, pp. 94-100. https://doi.org/10.1108/03699420510585166