Application of transparent laser film imprint transfer on single recess machine

The process of transparent laser film imprint transfer is straightforward and can be carried out using a single-sheet gravure printing machine, making it cost-effective. However, to ensure high-quality results, several critical factors must be carefully controlled throughout the production. This method is widely used in packaging and decorative applications, especially for products like cigarette packs where visual appeal is essential.

Material Quality Control

Controlling the quality of UV varnish is crucial. If the viscosity of the UV varnish is too low or the solid content is insufficient, the holographic image may not appear clearly after transfer. On the other hand, if the UV varnish has high viscosity and excessive solid content, it may not level properly, leading to uneven coating and a blurred or distorted holographic effect.

Process Quality Control

Controlling the viscosity and coating amount of UV varnish is essential for achieving optimal embossing and transfer results. The varnish should be formulated with an alcohol-based, anhydrous diluent to achieve the right consistency. The coating amount should be precisely regulated—ideally between 3.5 to 7 g/m²—to ensure even application and sharp image transfer. It's important to avoid excessively high viscosity, which can lead to poor coverage and defects.

The application of UV varnish is typically done using a gravure press, involving a gravure cylinder and an impression cylinder. There are two types of glazing methods: flexographic and gravure. For cigarette pack applications, gravure transfer generally provides better results. During plate making, the gravure cylinder must maintain concentricity and ellipticity within 0.1 mm, with a surface finish of at least 12 levels. The impression cylinder should have strong pressure resistance to ensure consistent contact during the transfer process.

During the glazing process, the squeegee should be positioned at a 45° angle relative to the gravure cylinder, and consistent pressure must be maintained. After applying the UV varnish, the substrate must be quickly transferred to the UV curing unit to prevent any delay that could affect the quality of the transfer.

Pressure curing, curing, rewinding, and winding processes also require careful control. The pressing roller should have a hardness of HS85–HS90, with good flatness, roundness, and concentricity. During pressing, attention must be given to minimizing bubble formation to avoid pinholes or other imperfections 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, making the process both efficient and sustainable.

　 This content is excerpted from the second edition of "Printing and Printing Technology," published in 2012 under the section on Packaging and Decoration. For more information, please visit the journal channel.

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