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Grafica’s NEW – Hybrid Dryer (Gas + Electric)

October 2, 2018 2 comments
Grafica_Hybrid_Dryer

Grafica’s Hybrid Dryer – Gas + Electric

Grafica’s hybrid dryer is meant for drying jobs printed with wide range of inks on a variety of substrates.

Single touch screen display automatically diagnosis for safety & faults during operation supported by artificial intelligence system with error message display on screen with alarm

Grafica_Hybrid_Dryer_TouchScreen

Grafica’s Hybrid Dryer – Gas + Electric (Touch Screen Panel)

It’s insulated with high density rock wool and double fabrication throughout to retain maximum heat inside the chamber while keeping the outside relatively cool

Exceptionally imposing airflow management system is facilitated by a very powerful low noise blower that discharges air circulating uniformly around the entire heating chamber’s inner hood through strategically placed holes. Incoming airflow passes through heating system to the printed surface. Because air creates a vacuum-like behaviour at the side of the conveyor and re-circulated to the top again.

Powerful air re-circulation with air purification system effectively scrubs solvents/ water away from the ink surface, thereby allowing faster drying times while lowering temperature requirements for a superior processing.

Grafica_Hybrid_Dryer_TopView

Grafica’s Hybrid Dryer – Gas + Electric (Top View)

Heated air is recycled, which in effect reduces power consumption considerably, the heating bank consisting of extremely effective heaters are not continuously engaged and drawing power in order to maintain temperature setting. Air circulation system maintains equal heat distribution all over the chambers. External variable airflow damper is provided to adjust exhausted air, according to solvent saturation during production, so that the drying system can always operate in its most efficient manner thus reduces power consumption.

To further improve efficient and energy conservation, a tool- free adjustable entry and exit stainless steel shields are provided to further prevent heat from spilling out to the production area. Exhaust fan below the electrical box is purposely intended to keep the electrical components cool and fully operational.

Single touch screen display with high quality thermocouple sensor, keeps precise temperature inside the chamber to ensure perfect control of drying.

The dryer’s inner chamber has a separate module from the heater to prevent escaping heat from spilling out into the production area.

High quality PTFE coated antistatic conveyor belt comes as standard, which is firmly driven by an AC geared motor with a frequency inverter for precise speed control—a handy feature at times when the belt is fully.

The rubberised conveyor drive roller is specifically cambered for superior belt tracking irrespective if the workload is off centred drying on the conveyor.

The dryer is completely portable in design for ease of mobility or it can be anchored to the floor with its own foundation bolts for a more permanent location.

Finally, to keep the dryer in optimum operation condition, a fine graded filter collects fine fibers and lint which prevents them from detrimentally sticking to the heaters themselves.

Grafica_Hybrid_Dryer_SideView

Grafica’s Hybrid Dryer – Gas + Electric (Side View)

Standard Features:

  • With removable filter to collect fine fibres, lints & dust particles
  • Compact design
  • Single touch screen display, simple to operate
  • High quality Antistatic PTFE coated conveyor belt
  • Powerful blower to recycle heated air circulation with exhaust system to remove solvent laden air from the chamber
  • Extremely effective heaters with special coating to deliver maximum efficiency and to maintain consistent temperature (max. 200 C / 390 F)
  • Equal heat distribution all over the chamber
  • Variable external airflow damper is provided to adjust the exhausted air, according to solvent saturation during production.
  • High density rock wool insulated heating chamber with double fabrication to retain maximum heat inside the chamber while keeping the outside body relatively cool
  • High quality thermocouple sensor, keeps precise temperature inside the chamber to ensure perfect control of drying
  • AC geared motor with a frequency inverter to set precise conveyor belt speed (Bidirectional)
  • Real Time conveyor belt speed control
  • Rubberised drive roller specifically cambered for superior belt tracking
  • Fine-graded air purification filter to collect fine fibres and lint which prevents them from detrimentally sticking to the heaters themselves
  • Sensor to detect filter choking with error message on screen and alarm
  • Tool-free adjustable entry and exit stainless steel shields provided to prevent heat spilling out to the production area
  • Castor wheel for ease of mobility
  • Exhaust fan inside the electrical panel to keep the components cool
  • In the event of electrical failure a special mechanism is designed to remove material from the chamber
  • The system automatically diagnosis for safety & faults during operation supported by artificial intelligence system with error message display on screen and sound an alarm
  • Safety button placed on both ends for emergency stop
  • High quality gas burner with solenoid and gas volume regulator with all safety
  • Single & double belt models available on request

Click on the link given below to download catalogue & technical specifications:

Grafica’s Hybrid Electric-Gas Dryer

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Reduce your electricity & labor cost with Wicket Dryers an ultimate cost effective solution


Hi folks,

Today I would like to draw your attention how to effectively dry solvent based ink system because still there are some applications such as automotive decals, outdoor signage and many industrial applications where UV ink system is still not successful and screen printers are forced to use solvent inks.

Many screen printers so called themselves modern still use those outdated racking system till today when there are cost saving solutions like Wicket Dryer available easily from Grafica. Wicket dryer is not only effective in drying solvent inks at high speed but also reduces your rejection and electrical consumption drastically.

Wicket dryer is very useful for slow drying solvent based inks which requires longer drying time before stacking simultaneously maintaining high printing speeds above 2000/Hour which otherwise is not practical or expensive using conveyor based Hot Air Dryers.

It is also useful and practical for heat sensitive substrates mainly used for Printing Ceramic Decals, Automotive Decals, Labels & Stickers, in general very useful for heat sensitive substrates. Due to fairly low temperatures and efficient air flow with extended ambient cooling fans ensure perfect dimension stability thus delivers perfect registration accuracy.

A persistent problem associated with screen printing is to provide sufficient drying time using ambient air prior to stacking to avoid smearing of newly printed stock. Immediate stacking is undesirable for several reasons. A slight shifting of the stock during the stacking process or when the stock is moved for storage only results in smearing the ink. Premature stacking before drying is complete, results in the sheets sticking together. Excessive drying time is unacceptable for most smaller operations having limited plant space since stock must be removed from the premises relatively soon after printing to make room for additional stock.

Where ambient air is used, the drying time is limited to the length of the conveyor travel. Accordingly, various types of drying systems have been developed to increase the drying time of newly printed work prior to stacking. One of the most inexpensive and efficient types of dryers yet developed is the wicket dryer. A wicket dryer comprises a plurality of rows of wickets, each row supporting a separate piece of stock, which are mounted at spaced intervals along the upper and lower surfaces of a dryer frame for travel.

The primary advantage of a wicket dryer, in addition to the low costs of purchase and operation, is the excellent and efficient use of plant space. The artificial dryer also requires large amounts of energy which adds to the cost of printing.

The wicket dryer, however, carries the stock upright as it dries with ambient air, greatly increasing the number of pieces of stock that can be dried at one time in a given space as compared to belt dryers. When a row of wickets reaches either end of the dryer frame, it is pivoted to the opposite surface of the frame. The row of wickets is depicted in a position mid-way between the upper and lower surfaces of the frame.

Complete electrical & electronic components are of high quality standards to avoid failures and breakdowns thus minimizes maintenance. The machine is designed with proper exhaust system to throw away solvent laden air from the closed heating chamber thus minimize solvent smell inside the shop-floor and maintains healthy and safe working environment.

Now available in smaller lengths with 500 wickets a space saving solutions. You can also order any custom size lengths to suit your workspace.

With 500 wickets and printing speed of 2000 per hour on our automatic screen printing press will have rotation cycle of 15 mins, with 1000/imp rotation cycle will increase to 30 mins for complete natural drying process of any solvent based inks. A complete replacement solution in compare to manual traditional racking system.

To know more about Wicket Dryer I would request you to watch this video in order to understand how it work. CLICK HERE TO WATCH LIVE DEMO…

You can use Wicket Dryers even with semi-automatic screen printing machines. For technical details download the catalogue… CLICK HERE TO DOWNLOAD CATALOGUE

Have a cost saving week…

Bhargav

Factors that influence UV curing

October 30, 2010 10 comments
Grafica's UV Curing Machine

Grafica's UV Curing Machine


Type and color of the substrate

There are substrates and colors that absorb UV more than other ones. They make curing slower. Curing may change depending on the grade of the substrates even though they are of the same kind.

Color of the ink (quality of pigment and influence of color-matching) The pigments that absorb more UV make curing slower. The more these pigments are contained, the slower curing becomes. Therefore, there is a limitation to the density and opacity of UV ink. Curing of matched colors may be poorer than each standard color which is used to make these matched colors. Printers must be careful of such matched colors as the mixture of opaque white plus other dark colors like black and blue.

Thickness of ink film
The thinner the ink film is 10-12 microns, the better curing is. Thicker ink film than 15 microns may result in poor adhesion due to insufficient curing. CLEAR INKS cure even if ink film is thicker than 100 microns.

UV power and integral light
There are two ways to measure curing: UV power and integral light, decided by lamp power and the type of the lamp. UV power plus curing time make the integral light. Integral light changes depending on the number of the lamps and curing time with different conveyor speed.

Although general curing efficiency is measured by the integral light, UV power has more effects to the thickness of the ink film stated in 3-d and inner curing. If UV power is not strong enough, inner curing cannot be improved even if the integral light is increased by more curing time. In this case, lower the height of the lamp or strengthen the lamp power.

Temperature of UV dryer and pre-heating
Environmental temperature of UV irradiation gives much influence to curing. The higher the temperature is, the better curing is. For this reason, pre-heating before UV irradiation improves curing, which leads to good adhesion.

Convert an ordinary job into extraordinary piece of creativity thru screen printing

August 3, 2010 2 comments
DMI's Creative Folder

DMI's Creative Folder

First the impression what one gets by looking at this folder is innovation. That is how I use special effect techniques by using screen printing process.

This folder is designed and printed jointly by me and my 6th batch of students as their project work. It was printed on laminated foil with 16 special effects UV inks and varnish including process color CMYK screen printing. I used 100 LPI screen to print very fine halftones.

Practically and commercially this may be not economical as a regular job unless some premium customers demand for it and ready to pay the price. But my point was to show how speciality inks can makes a normal product to an extraordinary piece of creativity folder. I am sure there is a market for high end corporates who wants to use it for their conferences etc.

I started first operation using Matt varnish which was to be printed below CMYK flower image.  The reason we printed on Matt Varnish to is give a soft metallic effect which reflects from the foil.

There after I printed CMYK process color UV inks. The image was also over printed with a gloss varnish to give a SPOT UV effect only on the flower.

Then I printed solid black leaving some fonts reverse to give a foil stamping effect. On the solid black and some part of silver foil was printed with 3 different micro embossing effects using only one screen at one time. Also some parts of black was overprinted with transparent ink with rainbow color glitters to get some sparkling effect.

Some portion of black was also overprinted with wrinkle varnish to give a leather like effect. There was also the title of the folder “INNOVATION” was printed with thick varnish using 150 micron stencil on a 24T polyester mesh to give an embossing effect which we always call as ticky in Indian language.

The logo of Grafica and DMI was printed with special metallic orange for giving a vibrant look of the logo.

Since the folder had one side foil laminated so to add dramatic effect on the other side I printed solvent based pearl two tone ink overprinted with light yellow UV ink to add some sort of soft designing which can also be called as water mark.

I am sure its very difficult to get the same effect by offset or any other printing process considering the richness of multiple effects.

The advantage of screen printing process is that you can convert an ordinary product to an extraordinary high value product with the availability of speciality inks and varnish thus you can also produce jobs in small quantities with very high profit margins.

This is an classic example what I produced in making this folder but such effect and design can be implemented in packaging in a very effective and large scale using fully automatic screen printing lines where you can also achieve higher speeds.

DMI's Creative Folder

DMI's Creative Folder

Lights Camera Action and the training begins

Meet my 6th batch of students starting their new journey in screen printing getting advance training on modern machines at DMI.

Twelve students from Don Bosco School of Printing, New Delhi and one student from GIPT, Mumbai are currently undergoing one month’s rigorous training in advanced screen printing process at DMI under my guidance. This fresh batch began their journey from 12th May 2010.

Principal of Don Bosco, Fr. Noble George, manager Fr. Reji Tom Antony and placement officer Mr. Michael were all instrumental and supportive behind them to take an advance study on screen printing process under my guidance in my institute DMI.

All the students from Don Bosco have few things in common to share here. They have just completed their ITI in printing technology. Most of them come from a average family background.

It is really hard to believe that these students got convinced to join DMI even before seeing the roofs of my institution. That indicates the growing popularity of DMI which has today successfully completed over 3 years and 6 months in teaching advance screen printing in various applications. Till now thru DMI I have trained more than 1200 professionals and 90 students including this batch.

To their great surprise, these students got a unique experience to participate in DMI’s workshop which was held on 13 to 15 May 2010. This 3 days of workshop at the beginning of our course really helped them in getting insights about screen printing. They also got chance to exchange ideas with many printing professionals who participated in this workshop.

Let me introduce all these upcoming heroes to you one by one. Their names and other details are mentioned in the caption of each photos.

Rishu Patrick (21), Josephnagar Village, UP

Rishu Patrick (21), Josephnagar Village, UP

Sunil Kumar Bhatti (22), Rampur dist, UP

Sunil Kumar Bhatti (22), Rampur dist, UP

Rinku Singh (21), Behrampur-Buzurg, UP

Rinku Singh (21), Behrampur-Buzurg, UP

Sibin David (21), Born in Kerala, settled in Faridabad

Sibin David (21), Born in Kerala, settled in Faridabad

Samuel Mattu (25), Amritsar

Samuel Mattu (25), Amritsar

Nelson Kujur (25), Chhattisgarh

Nelson Kujur (25), Chhattisgarh

Simon Masih (21), Haryana

Simon Masih (21), Haryana

Babychen Sebastian (28), Varnapura, Kerala

Babychen Sebastian (28), Varnapura, Kerala

Sagar Hembron (19), Meerut, UP

Sagar Hembron (19), Meerut, UP

Pranav Nitesh (21), Muradabad, UP

Pranav Nitesh (21), Muradabad, UP

Albert D’Costa (23), New Delhi

Albert D’Costa (23), New Delhi

Thomas Pal (19), Ludhiana

Thomas Pal (19), Ludhiana

Nitin Kamble (36), GIPT Student, Mumbai

Nitin Kamble (36), GIPT Student, Mumbai

DMI also helps these students to get good offers, so if any one wishes to recruit these highly trained technicians under my guidance than please let me know. We shall make sure to send them once they complete their training.

Finally, may I request you to please send them encouraging wishes so that they are charged up till they complete their training at DMI.

Have a encouraging week.

Regards,

Bhargav

I happy to know DMI’s growing popularity globally

June 4, 2010 1 comment
DMI_Workshop_13to15May10

DMI_Workshop_13to15May10

This time I had participants from Bahrain which indicated the growing popularity of DMI all over the world. I was happy to receive Philip Eapen K and his colleague P. Madhusoodan Prabhu from Dar Akhbar Al Khaleej, Bahrain.

This time I printed a calendar on a transparent plastic sheet which I called it as a falling calendar. The design was such that as you turn from Jan till Dec it complete the whole fish aquarium because each month we printed some elements with special effect and metallic inks. Due to transperancy of plastic one could easily see the prints underneath which clears my concept of falling calendar.

In process color screen printing we printed a image of Santa Claus with 100 LPI which you will see in my workshop photo gallery as few participants holding it to see the uniqueness of CMYK screen printing.

Santa Claus screen printed during DMI workshop in 100 LPI

Santa Claus screen printed during DMI workshop in 100 LPI

Some participants expressed their unfading contentment after attending DMI’s novel workshop and said to me that for the last seven years he was into screen printing and only doing simple jobs due to lack of knowledge but after my workshop he vowed to change his attitude and I liked his spirit.

He also informed me that he will start experimenting on critical jobs because he has learnt many difficult techniques in a very simple manner from me in my workshop.

More than half of the workshop participants stayed back on the last day till late evening for the launching ceremony of world’s first 5-in-1 NANO-SCREEN MAKER, NANO-Sharpener and a presentation on Grafica’s super saver combination package NANO PREMIER LEAGUE (NPL), a complete in-house screen printing solution offered by my company Grafica. The presentation was made by me which compelled some participant to book the package even though they did not come with such planning to purchase any equipment.

My company managed to book 27 Nano-Premier League package on the spot.

DMI’s next workshop is scheduled from 1st to 3rd June 2010. This time we are going to print folders with special effect. This effect are very useful for printers who are into wedding cards business. Even industrial screen printer would enjoy this coming session because I have completely revamped my presentation with more video illustrations with many new topics which will help them to screen print better.

Have an enriching day.

Bhargav

I am proud to announce WORLDS FIRST 5-in-1 NANO-Screen Maker

May 31, 2010 4 comments

I am happy to inform that screen printers have shown tremendous interest in automation this year comparing last year, which is why we were able to sell over 150 NANO-PRINT in just 6 months and 30 Cylinder Presses. I thank all my customers who have extended their valuable support for our growth.

My dream is to turn every screen printer into automation and the way NANO-PRINT is rocking I feel the day is not too far which will make my dream into reality.

Using NANO-PRINT, printers are able to achieve quality, consistency with higher production. Some of them even started utilizing full print area of 15” x 20” multiplying their production by printing in ups but there was no much freedom and alternative for some screen printers to enhance their screen making quality.

In this regards my company invented WORLD’s FIRST, NANO-SCREEN MAKER 5-in-1 and NANO-SHARPENER.

NANO-SCREEN MAKER 5-in-1

NANO-SCREEN MAKER 5-in-1

Why 5-in-1?

Space is a major concern for printers and cost of property is becoming expensive.

Currently we have equipments in screen making for NANO-PRINT customers but it is not an economical solution because they have to buy everything separately like screen exposing machine, screen dryer and so on…

Buying individual equipment not only occupies precious space but also makes the whole project expensive. That is why some printers were hesitating to upgrade their screen making unit. I always mention in my workshops at DMI that “Screen is the heart of printing, good screen produces good quality printing.”

Hence NANO-SCREEN MAKER 5-in-1 is a perfect solution which saves space and reduces capital cost.

Let’s also remember that quality comes not only from good screen printing machine and screens but also by using sharper squeegees. But it is very much neglected. So, keeping this fact in mind NANO-SHARPENER was invented to force screen printers to getting used to best practices to achieve high quality prints.

NANO-SHARPENER

NANO-SHARPENER

I am also proud to announce a new package, NANO PREMIER LEAGUE (NPL) “A complete screen printing solution” which was launched on 15th May 2010at Grafica along with NANO-SCREEN MAKER and NANO-SHARPENER.

This unique package combines 11 items which shall give screen printers greater freedom to deliver high quality jobs with reasonable capital investments.

NANO-PREMIER LEAGUE (NPL)

NANO-PREMIER LEAGUE (NPL)

By selling a complete package we are able to reduce our production cost, overheads and due to volume purchase of raw materials, our suppliers have come forward to offer better discounts which we are able to pass on to our customers to help reduce their investment cost.

A good news, TATA CAPITAL LTD has come forward to finance deserving printers for buying any Grafica machine under their equipment finance scheme. So now I hope printers should take immense benefit to grow their business by getting easy finance from them.

I am happy to inform that screen printers have shown tremendous interest in automation this year comparing last year, which is why we were able to sell over 150 NANO-PRINT in just 6 months and 30 Cylinder Presses. I thank all my customers who have extended their valuable support for our growth.
My dream is to turn every screen printer into automation and the way NANO-PRINT is rocking I feel the day is not too far which will make my dream into reality.

Using NANO-PRINT, printers are able to achieve quality, consistency with higher production. Some of them even started utilizing full print area of 15” x 20” multiplying their production by printing in ups but there was no much freedom and alternative for some screen printers to enhance their screen making quality.

In this regards we invented WORLD’s FIRST, NANO-SCREEN MAKER 5-in-1 and NANO-SHARPENER. Why 5-in-1?

Space is a major concern for printers and cost of property is becoming expensive. Currently we have equipments in screen making to NANO-PRINT customers but it is not an economical solution because they have to buy everything separately like screen exposing machine, screen dryer and so on…

Buying individual equipment not only occupies precious space but also makes the whole project expensive. That is why some printers were hesitating to upgrade their screen making unit. I always mention in my workshops at DMI that “Screen is the heart of printing, good screen produces good quality printing.” Hence NANO-SCREEN MAKER 5-in-1 is a perfect solution which saves space and reduces capital cost.

Let’s also remember that quality comes not only from good screen printing machine and screens but also by using sharper squeegees. But it is very much neglected. So, keeping this fact in mind NANO-SHARPENER was invented to force screen printers to getting used to best practices to achieve high quality prints.

I am also proud to announce a new package, NANO PREMIER LEAGUE (NPL) “A complete screen printing solution” which was launched on 15th May 2010at Grafica along with NANO-SCREEN MAKER and NANO-SHARPENER.

This unique package combines 11 items which shall give screen printers greater freedom to deliver high quality jobs with reasonable capital investments. By selling a complete package we are able to reduce our production cost, overheads and due to volume purchase of raw materials, oursuppliers have come forward to offer better discounts which we are able to pass on to our customers to help reduce their investment cost.

A good news, TATA CAPITAL LTD has come forward to finance deserving printers for buying any Grafica machine under their equipment finance scheme. So now I hope printers should take immense benefit to grow their business by getting easy finance from them.

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