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Printing, Bonding, & Bindery Static Solutions

Chill Roll Tacking, to increase press speeds and print quality. 

In the chill roll application, variations in press speeds and paper weight lead to web lift-off from the surface of the chill roll.  In the boundary layer between the web and the Chill Roll, condensate from the ink and solvent which has not been flashed off in the oven builds up on the surface of the chill rolls, forming a condensate.

Problem:

The  transfer, or “sling,” of condensate onto the printed web, causes re-softening of the ink on the printed material creating print defects in the form of streaks on the finished product.  Common terms for this problem are “chill roll marking,” “streaking” or “condensate buildup.” This problem often occurs on jobs with heavy ink coverage, such as magazines, and on presses that have extra printing units (cover presses).  Printers producing heavy coverage retail coupons or time sensitive inserts for newspapers will have marking issues as well.  Printers running jobs at high speeds on presses with “shorter ovens” also experience marking.

Solution:

Using a Simco-Ion static charging system is the most cost-effective way to eliminate chill roll marking. A typical system consists of a high voltage charging generator and a charging bar. The bar is mounted over the apex of the first chill roll where the web comes into contact first with it. When energized, the ion current flows to the web resulting in the charging bar forcing the printed web on to the Chill Roll.  Condensate or streaking is eliminated, allowing the operators to increase press speeds and improve print quality. Press speed increases of 5-20% have been observed.  The added benefits of electrostatic pinning include better thermal transfer of the heat from the web stock to the chill roll, better web tension, and less web weave.