WATERLESS OFFSET PRINTING // PERFECT PRECISION

WATERLESS OFFSET PRINTING // PERFECT PRECISION
The Ernst Marks PLC − in 1843 still a small enterprise − developed into one of the Ruhr
District‘s leading printing concerns. The bombing raids in the year 1943 marked the end
of operations as a printing house and the beginning of operations as a supplier to printing
houses. marks-3zet is the inventor of and world market leader in calibrated underpacking
sheets; it supplies self-adhesive underpacking foils and was the first dealer in Europe to
commit itself to waterless offset printing.
The beginning of waterless offset printing extends back to the nineteen thirties. Only later
was it recognized how revolutionary this idea was with its completely new possibilities of
printing reproduction. After a considerable amount of development two American companies (3M and Geipe) brought the first waterless offset printing plates on to the market at
almost the same time in 1967. However, they withdrew the plates (and themselves) from
the market after a short time, because the surface proved to be extremely sensitive to
scratches and thus in the end unsuitable for practical use.
Years later the sun also seemed to rise on waterless offset printing in the Far East. In Japan,
one of the world‘s largest plastic, film and chemical manufacturers took up the hitherto unsolved problems: fascinated by the idea and its marketing possibilities, the Toray Industries
went down different paths with their cumulative expertise, and marks-3zet also became
involved as a Toray sales partner for the new plate presented in 1977. A number of teething
troubles had to be dealt with before final market maturity was achieved, but the euphoric
opinion was that by 1982/83 the goal would be reached and a market breakthrough achieved.
The industry’s high expectations could only be partly fulfilled. The plates were still too
sensitive to scratches.
marks-3zet makes history
− A short excursion into the past
The history of waterless offset printing... There was also the fact that the plates tended to tone in image-free areas and the paper
picked slightly (due to the high viscosity of the inks). Toning and picking could be avoided
by adding inks of different consistencies during the print run, thus „touching up“ the failure, but in no way did this lead to success.
This further setback was also painful and costly for marks-3zet; it did not cause resignation however, but rather added an incentive. The difficulties have been resolved for a number of years now: through an improved silicon coating the plates have become much less
sensitive to scratches. The inks have been adapted by the manufacturers in an optimal way
to waterless offset printing so that toning and picking are no longer a problem.
The new technology of the time whereby the printing plate was directly imaged was also
taken into account, and in 1998 a thermal CtP waterless plate was brought on to the market. The development of this technology was promoted further following increasing customer demand, so that the fifth generation of the CtP plate is now on the market.
Following the trend towards waterless offset printing, well-known printing machine manufacturers have also increased their product range: on request the printing machine is
supplied ready-fitted with a temperature control unit. An investment in dampening units
can be dispensed with. Products, such as CD/DVDs or labels, which used to be produced
by other printing methods have experienced an unforeseen leap forward in quality through
the use of waterless offset printing and have given printing works a competitive edge.
Since 2004, newspaper companies for whom quality and environmental protection are
important have also recognised the advantages of waterless offset printing and in new
investments have decided for a newspaper rotary press that is specially developed for waterless offset printing. No ink mist, condensation and fan-out effects arise here, whereby
the ecological aspect such as the avoidance of waste water and chemical additives will
become increasingly significant.
Waterless offset printing today
−Technical problems are a thing of the past
...is also part of our own history
The minimal use of developing fluid, which plays only a supporting role in developing
through water and brushes, contributes to this.
marks-3zet has accompanied the introduction of waterless offset printing and its special
technical features for many years and has in this way gained a unique competence from
which the world of waterless offset printing can profit.
Waterless offset printing is a planographic printing method with indirect inking. In
planographic printing the printing (inking) areas of the printing plate take on the
ink (become wet); the image-free (non-printing) areas do not.
Wetting processes are described with the help of surface and interfacial tensions.
Described simply, this means that the printing areas on the plate (surface tension
approx. 35 mN/m) become covered with ink because of their high surface tension. The
non-printing areas are coated with silicon and repel the ink due to their lower surface
tension (approx. 20 mN/m).
The ink-conducting areas (polymer layer) of the Toray plate lie directly on the carrier material (aluminium) and the image-free areas on a 2 μm thin silicon coating over this.
Depending on the type of plate there are differing layers for surface protection, print run
stability or for activating imaging processes (analogue, digital).
Plate imaging can take place photo-mechanically with subsequent development through
releasing (negative copy), or with laser beams (IR laser). In this case it is part of the CtP
workflow. At the same time thermal exposure is an imaging technique producing the highest definition, and this particularly predestines it for the modern fine screens, whether
periodic (AM, amplitude modulated) or non-periodic (FM, frequency modulated).
Printing principles and plate set-up Silicon layer
Polymer layer
Primer layer
Aluminium base
Unexposed plate
Plate imaging
Imaged plate
(CtP)
Plate after
development
In the typical case the application rollers provide the plate surface with a 6 to 8 μm thick
layer of printing ink. A 3 to 4 μm thick layer of ink remains on the image areas. The inking
of the printing surfaces is very precise and gives sharp contours, which is one of the great
advantages of waterless offset printing. No typical dot gain as in „wet offset“ (over-inking
of the printing areas into the non-printing areas) occurs in this method. Fluctuations are
thus ruled out, and in comparison to wet offset the print run constancy of the dot size also
increases, which is likewise an advantage. Only the ink is applied to the plate: the printing
image is stabilised after just a few rotations. Start-up waste is reduced to a minimum.
− How does waterless offset printing work?
− How do the printing plates differ from those in wet offset?
− Why does the printing plate or the inking unit need to be cooled?
As the temperature increases the surface tension of the ink (i.e. surface versus air) falls
more rapidly than that of the silicon used. At higher temperatures, from approx. 35°C, ink
can thus be applied further in various places over the silicon. The plate then tones in a
punctiform or overall way. For this reason the printing plate or the inking unit needs to be
cooled in waterless offset printing.
OPERATING
PRINCIPLE:
In order to achieve an optimal developing result, it is recommended using the developing
machines specially constructed for waterless offset printing plates, which were produced
in close cooperation with the Toray firm.
marks-3zet offers the right developing machine for all formats and uses. The developing
machines process an imaged waterless plate in 4 or 5 stages..
1. Pre-treatmentThe plate passes through a temperature-controlled pre-treatment bath causing the silicon
printing areas to soften.
2. Brushing outAfter the pre-treatment solution has been squeezed out, the softened silicon layer is removed with a rotating and oscillating brush. Pure tap water is then applied, and through
the use of a water-saving system the amount used per plate is reduced to 0.5-2 litres. The
overflow then washes out the silicon rubber remnants.
3. Brushing outStep 2 is repeated to remove any remaining silicon residues.
4. After-treatmentOnce the silicon is removed, the printing plate is
dyed with a special after-treatment solution by
means of rotating and oscillating brushes, making the print visible.
5. RinsingThe fully developed plate is rinsed with water in
order to remove any residual dye. After a final
squeezing, the printing plate is now dry and ready for printing.
Operating principle of the developing machines
Developing the printing plate 1. Pre-treatment
2. Brushing out
3. Brushing out
4. After-treatment
5. Rinsing
During the pioneer years of waterless offset printing, which extended into the nineties,
old and also increasingly frequently new printing machines were used. The damping unit
was not always completely disassembled or removed, but instead a plate cooling system
was organised, for example with blast air. It was not until the construction of the GTO DI
from the „Heidelberger Druckmaschinen AG“ that a sheet-fed offset press working on a
waterless basis was conceptualised. Other machine manufacturers soon followed suit.
In conventional sheet-fed offset presses there are increasingly frequently
temperature-controlled plants for the oscillating rollers, as a constant quality during the print run is required, and this is not possible when there are
temperature fluctuations. This is also a reason to favour waterless offset printing. In sheet-fed offset, beginning with smaller formats then continuing with
constantly larger ones, „KBA“ brought the „Genius“, „Karat“ and „Rapida 74G“
printing presses on to the market, which function on a purely waterless basis.
Printing machines
With the development of the short inking unit, KBA made a major contribution to the triumph of waterless offset printing. The ink is applied to the printing plate through a screen
roller via a transfer cylinder. This greatly simplifies machine construction because the
long roller frame and costly zone control are no longer necessary. The enormous potential
in this development is today far from exhausted.
The path was crowned by a very similar concept being realised in the „KBA Cortina“ for
high-speed rotating newspaper presses − after long and certainly difficult years before
the current commercial success. The latest innovation from the house of KBA MePrint is
called „Varius“ and offers completely new possibilities in packaging printing.
THEN
Up until the nineteen eighties ink manufacturers were still producing inks for waterless
offset printing from the raw materials familiar to them. There were inks that could be used
for printing in both methods. However, the risk of toning at higher temperatures in waterless offset printing only allowed the use of extremely viscous and thick inks.
With increasing temperatures the viscosity of the printing inks decreased. The ink manufacturers discovered that the risk of toning could be diminished through high viscosities
and they had to continue further development work. However, the newly developed printing inks were not pleasant to work with as they were difficult to apply and picked easily.
NOW
The ink development initiated by marks-3zet with conventionally structured bonding
agents is very successful.
The current viscosities thus correspond to those in wet offset with a low toning tendency.
In addition to oxidative, IR, UV, heatset and coldset inks, all of the HKS, Pantone inks and
print varnishes etc. have been realised.
When highest quality in combination with expensive print material is required, waterless
offset printing is unbeatable.
Not just a pigmented mass!
The difference is in the detail...
Printing inks
Packaging printing
Commercial printing
Technische
he
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Seite
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Der
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-3zet
als kompe marks
-3zet
Hinter 60 Jahren
marks
How.
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RUM
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* Aufl
der Zeitungspr
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tssiche
Daten
Für jedes Format,
jede Anwendung
und Anforderung
steht ein passendes
CtP-System
One 540
zur Verfügung:
Trommeleinheit
One 750
One DU Außentrommel
Lasertechnologie
Papier und Karton
One 1100
One DU Außentrommel
One ILH Thermo,
CtP-Plattentechno
Sahara Classicure wird erfolgreich zum Bedrucken von Papier und Karton
eingesetzt, bei
Violett
One DU Außentrommel
logie
One ILH Thermo,
T-Thermo,
nur geringer Rupfneigung. Dies gilt für alle Druckmaschinen mit konventionellem DruckViolett
One ILH Thermo,
V-Violett (optional)
T-Thermo,
werk als auch mit Kurzfarbwerk.
Maße (BxTxH)
Violett
AusV-Violett (optional)
in 5 Stufen.
T-Thermo,
1370 x 1145
Wasserlos-Platte
Gewicht
Arbeitsweise
x 1230 mm
Kunststoff
V-Violett (optional)
eine bebilderte
Stufen entwickelt.
1370 x 1145
850 kg
650 die in 4
hinen bearbeiten
x 1230 mm
Max.
die KTWsollte
ng
Plattengröße
Der passende
Kunststoff
vor der Produktion ermittelt werden. Nicht
alle
Kunststoffe
Stufen und
1710 x 1210
Die Entwicklungsmasc
850 kg
die nur in 3
x 1260 mm
die Entwicklu
520 x 540 mm
die KTW 450,
sind „offsetfähig“. Deshalb ist es nötig,
eine Plattengröße
bessere Farbdurch
5. einen Primer vorzudrucken, umMin.
nahmen sind
950 kg
750 x 668 mm
haftung zu
wird eine maximale
4.erzielen. Durch Applikation eines UV-Lacks nach dem DruckPlattenstärke
240 x 200 mm
1075 x 850
ienbe3.
Kratzfestigkeit erreicht.
240 x 200 mm
mm
0.15 > 0.40
Chemikal
Adressierauflösung
2.
mm
chen
guten
240 x 200 mm
Die
Haftung
der
Farbe
hängt
von
folgenden
Parametern
ab:
Farbtyp,
Art
des
Kunststoffs,
sehr
0.15 > 0.40
mechanis
Niederder
2540/5080 dpi
mm
mit der
gegen
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dessen Oberflächenspannung, Alter und Intensität der Coronabehandlung,
Art des vernhang
rn undDie mit
r der
0.15 > 0.40
ndlich
bei 2540 dpi
2540/5080 dpi
mm
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T-34 Platten/Std.
Erfinde
druckten Primers u.v.m.
Plattendurchsatz
200
trotzdem
bestimmt
t werden.
in engem
al
– eines
2540/5080dpi
ist der en
rund
bei 5080 dpi
sie ist
steht
T-28 Platten/Std.
verursach
materi
T-19 Platten/Std.
Marks agebog
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rer mit
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agenhöhe
Aufzug
Haftung und Kratzfestigkeit
T-19 Platten/Std.
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T-14 Platten/Std.
Monokassettenload
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bei
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T-10 Platten/Std.
kann
optional erhältlich er
tes.
Monokassettenload
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Vorbehandlerbad,
1. Vorbehandlung
lassun
Dieser
sind:
Stanzvorrichtung
Auch wenn
der Scotch Test erfolgreich durchgeführt wird,Separate
garantiert
dies nicht
Produk
temperiertes
kannte
ein geführt.
Abrieb.
optional erhältlich er
Monokassettenload
Faktoren
erforderlich
läuft durch
weltbe High Tech
automatisch, dass auch eine sehr gute Kratzfestigkeit gegeben ist. In bestimmten Fällen ist
dieser
Die Platte
optional erhältlich er
lässt.
Einige
ch etc.)
t
erforderlich
aufquellen es nötig, einen Primer vorzudrucken oder nach dem Druck zu lackieren
echten
Inline
oder
zu laminieren.
Stanzvorrichtung
Gummitu
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Silikonstellen
erreich
toffart
ohne Autoloader-System
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p
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mittels einer
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schinenty
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Silikonschicht
Tonen
Optional
Oft
(Zylinderp
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terialie
Optional
• Druckma
2. Ausbürsten
de Unterlagema
wird die aufgequollene kommt reines Leitungs- Inline Prozessor
ingungen
Optional
• Kalibri kleben
Die Sahara Classicure Farben
haben eine sehr geringe Neigung zum Tonen. Die silikonfreie
des Vorbehandlers
Optional
Zum Einsatz
Platte (Nass- und
Unterl
• Druckbed e
Optional
2 Liter proDruckplattentemperatur.
wasserlos)
Nach Abquetschen
Bürste entfernt.
bis geringere
Nevada-Serie
benötigt eventuell eine
etwas
Sollte es
• Selbst essible
auf 0,5
Optional
eit
und changierenden
Optional
• Druckfarb
Plattenstapler
s ist der Verbrauch
rotierenden
chwindigk
doch zu Tonerscheinungen
kommen, kann
• Kompr n
aus.dies folgende Ursachen haben:
geWassersparsystem
Optional
Silikongummi
• Druckges
Optional
Durch ein
Umgebungstempe
• Straffe
das abgelöste
wasser.Wellenlän
• Die Druckplattentemperatur ist zu hoch
schwemmt
ratur
druck
Optional
mit einer
Der Überlauf
20°C – 28°C
• Die Farbe hat eine zu geringe Viskosität/Tack Luftfeuchtigkeit
Offset
chtung reduziert.
Optional
Laserbeli
rloser
• Reste des Waschmittelsentfernen.
befinden sich noch auf dem Gummituch
45 – 75% relative
)
e für die
Wasse
Elektrischer
Silikons zu
Luftfeuchtigkeit
ruckplatt
Anschluss
MX-10
– digital
• ZuReste
hohe des
Farbschichtdicke
3. Ausbürsten
aterial
letzte
(nicht kondensierend)
TAC
Einphasen-Wechse
e Thermald
2, um auch
ittel
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uchsm
von Schritt
• Maschinengeschwindigkeit ist zu langsam
lstrom 16A,
arbeitend
Type P+N+E
ungsm
Verbra
Wiederholung
Platten Daten
Chemi
220-240V Abzweigstromkreis
Luftversorgung
Dose. 1,6kW
und
Reinig Negativ nm
• Einstellung der Farbauftragswalzen ist nicht
korrekt
TORAY sche
maximal
mittels
• Techni
ares
mit Industriestecker
arben
von 830
Ölfreier Luftkreislauf:
Nachbehandler
• Axialspiel
der speziellen
Auftragswalzen oder Changierung eingestellt
IEC309,
8 bar-550l/m
• Druckf isch abbaub
4. Nachbehandlung
Anschlussstück
wird mit einem
(mit Luftschlauch
Laser
wird sichtbar.
Typ
Aluminium
Druckplatte
M12x1 ext.
ruck
mit
Das Druckbild
Ø 8mm, int.
2,5m)
• Biolog
– 99% befreite
von Silikon
Zeitungsd
Ø 4mm
Die
Klasse 4, CEI-EN
Bürste eingefärbt.
rung 1
Garantie
ter
für den
0,30 mm
inen
60825/1, CEI-1284
äger
und changierender
Oxidativ trocknende Systeme: Nevada Oxi
typ)
FM-Raste
formate
tionsgü
masch
rotierender
- 1381G, 21CFR
Schichttr
2 Jahre Teilegarantie,
L/cm),
240
Belichter
Investi
klungs
lpi (80
1040.10
Alle Standard
2 (je nach
Laser: 2 Jahre/5000
ärke
zu entfernen.
Die Nevada Oxi ist eine rein oxidativ trocknende
Farbserie,
für Papier und nicht saugende
bei 200 – 99% mit Sublima
Entwic
•Plattenst
Betriebsstunden
– 98 %
180 mJ/cm
um letzte Farbreste
steme
g1
130 –
rung 2
5. Spülen
Bedruckstoffe.
eignetgespült
sich auch hervorragend für eine spätere Bedruckung in einem
Wasser
Kühlsy
Rasterun
mitSie
druckfertig.
•Formate
Platte wird
ulierte
trocken und
dpi, AM-Raste
t entrum
2.540
Die fertig entwickelte Laser Drucker.
ist die Druckplatte
Druckz
25, Crossmod
ndlichkei
letzten Abquetschen
Empfi rlos
Staccato
Die Trocknungszeit beträgt auf Kunststoffen
4 – 8 Stunden.deutschen
Sollten Sie
Nach einem
Wasse
und entsprechen
lt
Fragen haben,
verarbeitet
Consu
ösung
Entwicklungsµm
wir
hochwertig
Aufl
helfen Ihnen
Erhältlich
sind Skalen- als auch alle Pantone-Sondergrundfarben.
25
für jeden
chinen
hinen sind
gerne weiter.
Ersatzteile
& Media
ungsmas
sind auch
Entwicklungsmasc
ibilität
3 Stunden
Alle
Print
bis zu
-Entwickl
r-Kompat
en. Selbstverständlich
3-BürstenQualitätsansprüch
verfügbar.
- 300.000
FM-Raste
gkeit
PA-F
enen
Mehr Informationen
langfristig
160.000
sofort und
tbeständi
Farbstoff
freigegeb
finden Sie unter:
maschinentyp
DP-1,
Tageslich
-Prozess
*
Aktivator
Toray-WL
Sollten SieinFragen haben, wir helfen Ihnen gerne weiter.
für den
Auflagenhöhe
en
marks-3zet
Mit allen
ng
GmbH & Co.
Bedingung
KG
Entwicklu
Lahnstraße
auf typischen
35 – 40°C
38 · D-45478
sdruck
r
basieren
Mülheim an
Tel. +49 (0)
2
Prozesso
r
180 cm/min.
der Ruhr
Angaben
208 / 999 46
im Zeitung
100 –
ml/m
ab. Die
0 · Fax +49
emperatu
t
dung
Mehr Informationen finden Sie unter:
ca. 0,5
info@marks-3zet.
(0) 208 / 999
ngungen
Aktivatort
weiter.
Anwen
windigkei
46
gering,
29
gerne
de
die
·
www.marks-3zet.
sehr
ngsgesch
den Druckbedi
wir helfen Ihnen
e für
de
g und
Fragen haben,
Entwicklu
ckplatt
Sollten Sie
Entwicklun
rbrauch
marks-3zet GmbH & Co. KG
von der
le CtP-Dru
Chemieve
Auflagenhö
ssig
Sollten
Mehr
Sie Fragen
Informati
habe,
onen
IBRI
ERT
E UNT
ERL
AGE
BOG
EXA
EN //
Ihnen
gerne
weiter. Mehr Informationen
finden Sie unter:
Tel. +49 (0) 208 / 999 46 0 · Fax +49 (0) 208 / 999 46 29
KTE
WASS
Lahnstraße 38 · D-45478 Mülheim an der Ruhr
wir helfen
Hochau
flösend
LEIS
TUN
ERLO SER
G
OFFSE
TDRU
TAC MX-1
TORAY
CK //
wasserlos
er offsetdru
e therma
0
ck // low-cHeM
INeN
eNtwIckluNGsMascH
CLASSIC COLOURS // DRUCKFARBEn FÜR DEn
CtP-BELICH
WASSERLOSEn OFFSETDRUCK
TER // OPTOTEC
ONE
[email protected] · www.marks-3zet.de
KG
GmbH & Co.
der Ruhr
Mülheim an
46 29
38 · D-45478
(0) 208 / 999
Lahnstraße
0 · Fax +49
208 / 999 46
de
Tel. +49 (0)
de · www.marks-3zet.
info@marks-3zet.
marks-3zet
finden
Sie unter:
Ruhr
KG
an der
& Co.
46 29
Mülheim
et GmbH
208 / 999
· D-45478 Fax +49 (0)
e
ße 38
0 ·
ks-3zet.d
Lahnstra 208 / 999 46
(0)
de · www.mar
Tel. +49
Ruhr
rks-3zet.
an der 999 46 29info@ma
KG
/
& Co. Mülheim
8
(0) 208
GmbH
D-4547 · Fax +49
-3zet
zet.de
38 ·
marks
arks-3
46 0
traße
/ 999
· www.m
Lahns (0) 208
+49
zet.de
Tel.
arks-3
info@m
marks-3z
rzen
Diese
Seite
bitte
um
3 mm
einkü
Newspaper printing
Label printing
Safety printing
Plastic card printing
All conventionally produced products can be printed on using waterless offset
printing − with regard to dot definition and brilliance, they are even much better!
Fields of application
CD/DVD/Blu-Ray print
Web-to-Print
•minimal start-up waste (e.g. 10 sheets instead of
200)
•more precise printing of the screen dots, better
fine detail, less dot gain, thus suitable for particularly fine screens (over 300 lines/inch), particularly also for FM screens, also better reproduction
with a very fine periodic screen
• fine reverse lettering in solid areas remains open
•thicker ink layers can be transferred, useful for
the highly pigmented HiFi spectra
•simpler machine construction without damping
units
•lower investments without preparation, control
and disposal of the damping agent
All advantages of
waterless offset printing
No motif creation is too critical
for waterless offset printing,
full depth of focus, open even
with high ink densities
300 lpi (120 screen) is no
problem in waterless offset
printing
Exact fine detail down to the
finest colour nuances
•low maintenance
machines
and
cleaning
of
printing
• no emission because no isopropanol and no
damping agent required
•absence of damping agents means no corrosion
of steel parts and oxidation of metallic colours
• excellent colour stability of the colours printed
together in the screen throughout the print run
•as there is no dampening agent the paper does
not stretch, resulting in fewer register problems
and better printing of short grain paper
• fewer sources of error in ink drying
• very low machine set-up time, as no ink/water
balance has to be adjusted
... at a glance
Product RANGE
World market leader with over 220 distributors and branches worldwide. marks-3zet is the inventor of the internationally known calibrated
underpacking sheet − a real high tech product.
UNDERPACKING MATERIALS
• Calibrated underpacking sheets
• Compressible underpacking sheets
• Self-adhesive underpacking foils
• Tympan paper
WATERLESS OFFSET PRINTING
• TORAY printing plates
• Printing inks & auxiliary equipment
• Chemical and cleaning agents
PRE-PRESS STAGE
• CtP systems
• Workflow software
• Developing machines
• Plate transport systems
WATERLESS PRINTING CENTRE
• Seminars & training courses
• Research and development
• Extended printing hall
PRINT & MEDIA CONSULT
Weblinks
You can find further information on waterless offset printing on the following listed websites:
www.marks-3zet.de
www.ewpa.org
Member of the
marks-3zet GmbH & Co. KG
Lahnstraße 38 · D-45478 Mülheim an der Ruhr
Tel. +49 (0) 208 / 999 46 0 · Fax +49 (0) 208 / 999 46 29
[email protected] · www.marks-3zet.de