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The transparent laser film transfer process is straightforward and can be carried out using a single-sheet gravure printing machine, making it cost-effective. However, to ensure high-quality results through this simple process, several critical factors must be carefully controlled and monitored.
Material Quality Control
Controlling the quality of UV varnish is essential. If the viscosity of the UV varnish is too low and the solid content is insufficient, the holographic image after transfer may not be visible or clear. On the other hand, if the viscosity is too high and the solid content is excessive, the leveling properties of the varnish will be poor, leading to uneven coating and a blurred holographic effect after imprinting.
Process Quality Control
Proper control of UV varnish viscosity and coating amount is crucial for achieving optimal embossing and transfer effects. The UV varnish should be formulated to an appropriate viscosity using an alcohol-based, solvent-free diluent. The coating amount should be precisely managed, typically between 3.5 to 7 g/m², to ensure the best results. It's important to avoid excessively high viscosity, as this can negatively impact the transfer quality.
The application of UV varnish is usually done using a gravure press, which includes a gravure cylinder and an impression cylinder. There are two types of coating methods: flexographic and gravure. For cigarette packaging, gravure transfer generally provides better results. During plate making, the concentricity and ellipticity of the gravure cylinder should be within 0.1 mm, and the surface finish should reach level 12. The impression cylinder must have strong pressure resistance. During the coating process, the squeegee should be positioned at a 45° angle relative to the gravure cylinder, with consistent pressure applied. After the UV varnish is applied, the substrate must be quickly transferred to the UV curing unit to prevent any issues.
Quality control during UV varnish pressing, curing, rewinding, and winding is also vital. The pressing roller should have a hardness of HS85–HS90, and its flatness, roundness, and concentricity must be maintained to a high standard. During the pressing stage, care must be taken to minimize bubble formation, which could lead to pinholes or defects in the laser holographic pattern. After the transfer is complete, the transparent laser film should be neatly wound for recycling, which can be repeated up to 20–30 times, ensuring efficient material use.
　 This information is excerpted from the second edition of 2012, "Printing and Printing Technology," Packaging and Decoration, and more journal content can be found in the journal section.
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