Coating Blankets

What is a coating?
A coating is a clear layer applied to all, or part of a sheet after printing - achieving a variety of finishes. Before drying, most coatings are opaque liquids, quite unlike a sheetfed ink. Coating is commonest in carton printing, but also widespread in commercial printing.

In-line and off-line coating

In-line coating - Printed then coated on the same press in one pass.
PRINTING COATING
DEDICATED COATING UNITS

Off-line coating - Printed then coated as a separate process on another machine.

PRINTING COATING

Why are sheets coated?

Improved appearance - higher gloss, brighter look, special finishes etc. Protection - stops the image rubbing, scuffing etc. (also known as a sealer). Faster processing - cutting and creasing etc. Sometimes two coatings are applied to a sheet (double coating).

Coating types
Chemistry/drying process: Aqueous (or water based/dispersion) - dried with hot air or infra red radiation (80% of the market). UV - dried with UV radiation (20% of the market). Finish: Gloss Satin Matte

Terminology
Gloss: The ability of a surface to reflect directed light. Has an effect on colour and brightness. Slip: The slip value of a coating is chosen to suit processing (folding/gluing) and/or the final application. Laydown: How smooth and even the coating appears. Bad laydown means mottle or orange peel effect. More critical on matte than gloss coatings.

Coating terms and types

Knock outs or glue flaps (75% of carton market)
Selected areas only, e.g. carton work. No fine details. Use a Coating Blanket.

Flood coating (15%)

Whole sheet coated, no detail. Use any Printing Blanket.

Spot coating (10%)

Spot coating for detailed work

Detailed text or halftones. Use photopolymer plate (Cyrel, Nyloprint etc). Alternatively use a litho varnish (clear ink).

Why bother with knock-outs?

Coatings can cause problems in carton printing. Glues wont stick to most coatings. Nor will inks used to print sell by dates etc. Areas of the blanket must be cut and stripped away to make a STENCIL so they will not transfer coating.

Knock outs and glue flaps

Carton coating design
Coated areas Non coated areas Date box Glue flaps

Coating blanket stripping pattern

Non stripped areas Stripped areas Glue flap outline

How is the stencil prepared?

Cut by hand - on or off press Cheap but inconsistent, less accurate.

Cut by CAD/Plotter Fast and accurate.

The blanket is always stripped by hand!

Roller versus Anilox coater

Roller coater unit
Plate/ blanket cylinder Coating roller Fountain roller

Anilox coater unit

Plate/ blanket cylinder Anilox roller Coating Doctor blade

Pa pe r/

Coating
bo ard

Pa pe r/

bo ard

Impression cylinder

Impression cylinder

The coating roller is covered with solid rubber. The coating film weight is controlled by pressure between the rollers.

The anilox roller is solid metal or ceramic, with tiny cells in its surface. The coating film weight is controlled by the cell size.

Why use a Duco stripping blanket?

Dedicated coating blanket design. Consistent stripping properties. Optimum coating properties. High smash resistance/durability. Widest range available. 3 different backing options.

Whats wrong with the alternatives?

Old printing blankets Poor and inconsistent stripping properties. Poor and inconsistent coating performance. Often damaged by smashes etc. Photopolymer plates High costs - can be up to 4 x coating blanket cost. Easily damaged - printer may have to buy spare. Availability - off site processing. Limited gauge range. Processing waste. Environmental impact - chemical usage.

Duco coating blanket range

Worlds largest range of coating blankets. Available in gauges from 0.90mm to 1.95mm.

Fabric backed

Polyester backed

Sticky backed

Duco coating blanket range

Product
Superstrip FB & FBLR Superstrip PB Superstrip PB & UVPB Superstrip PB Ultra Superstrip SB

Gauges
1.68 & 1.95

Backing
Fabric

Surface
Cast Micro ground (*also cast) Cast

Strip to
Sponge

1.15, 1.30*, 1.35 & 1.40 1.95

Polyester

Base

Polyester

Sponge

1.95 0.95, 1.05, 1.68 & 1.95

Polyester

Cast

Sponge

Adhesive

Cast

Base

Duco coating blanket range

Press type
Heidelberg Manroland Komori KBA Mitsubishi Ryobi

Compatible blanket gauge

1.95 1.95 1.95 1.30 1.40 1.68 1.95 Please consider that thinner coating blankets or plates may be used with the appropriate adjustment in underpacking.