Process Technology for Printing Inks

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a Business Field of
CHEMICAL INDUSTRY NETZSCH Grinding & Dispersing
 PRINTING INKS

Overview

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Page
Printing inks 2

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Process and plant technology 4
Raw material handling 6

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Pre-dispersion 8
Flexographic printing / Rotogravure 14
Offset / Screen printing 16
Always an idea ahead for you ...
Various requirements are imposed in the production of
printing inks, such as color intensity, transparency and gloss,
chemical and mechanical resistance, as well as properties
related to production technology, which are necessary for
further processing with respect to bending or deformation.

That is why you, as a printing ink manufacturer, demand

efficient grinding and dispersing plants in order to
guarantee that your products are of reproducible, consis-
tently high quality for the consumer.

Savings on the raw materials side on the one hand, and the
increase in productivity that accompanies a fully-automated
plant design on the other hand, offer great potential for
long-term market success with consistent quality.

FLEXOGRAPHIC PRINTING
ROTOGRAVURE OFFSET / SCREEN PRINTING

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RAW MATERIALS HANDLING
For Wet and Dry Materials

4
The dosing of raw materials is selected as a function of continuous or discontinuous process
control. In general, a distinction is made between transport systems for wet and dry material.
Intelligently-designed feed systems can be tailored to a number of machines and plants.

Many references demonstrate our know-how and capability for the design and implementation
of feed systems.

Tank Storage

Silo Systems Big Bags

AUTOMATIC
Mini/Medi Bulks FEED Dosing Systems

MIXING AND DISPERSING PLANTS

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PREDISPERSION
of the pigments into a binder solution
MasterMix® Dissolver

MasterMix® Dissolver is used for the dispersion of

solids in liquids. The mixing process takes place in
batches in an interchangeable tank. The speed of
the high-speed dispersion disk is infinitely adjustable
via a mechanical V-belt drive, hydraulically or via a
frequency-controlled drive.

PMD-VC Intensive Mixer

The PMD-VC Intensive Mixers are stationary mixing

and dispersing units for the processing of large
batches. Separation of the mixing and dispersion
functions provides for an extremely energy-efficient
process that is especially useful for batches larger
than 2,000 l. The compact and closed design of the
Intensive Mixer facilitates integration into fully-
automated plant designs and prevents exposure to
gases and dust.

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Epsilon Inline-Dispergierer

The Epsilon Inline Disperser is used in circulation mode,

where the powder can be fed from a sack via suction
lance, or from a sack feed station, or alternatively,
BigBag or silo. The Epsilon operates similarly to a feed
pump – with optimal flow control, an underpressure is
created in the processing chamber during operation.
This underpressure is used for powder induction,
whereby, when combined with a suitable powder feed
system, the intake of external air is minimized.

Ψ-Mix® Inline Disperser

The Ψ-Mix® Inline Disperser combines a new dispersion

method, whereby the solid components are wetted on
a large liquid surface, with emission and dust-free
inline operation. With high productivity within a
controlled process, the combination of vacuum
dispersion, shearing and pressure wetting results in
homogeneous, fine dispersions with very reproducible
quality.

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 FLEXOGRAPHIC PRINTING
ROTOGRAVURE

NETZSCH develops machines and plants for the

production of flexo- and rotogravure printing
inks. The most important quality characteristics
for these printing inks are color intensity,
transparency and gloss.

In the NETZSCH Neos and Discus agitator bead

mills, small grinding beads can be used at very
high throughput rates under stable production
conditions.

This means that the defined quality

characteristics can be achieved with
reproducibility and high productivity.

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 RAW MATERIAL
HANDLING
PREDISPERSION FINE GRINDING
OF WET AND DRY
MATERIAL

The Neos Grinding System

The agitator cooling with the newly-developed Neos

grinding system stands for maximum performance,
product quality and efficiency. Coupled with the
reliable use of extremely small grinding beads, the
required product quality can be achieved with lower
specific energy consumption.

The grinding tank, agitator shaft and product

outlet are designed for cooling and thus prevent
overheating of the product despite extremely high
power inputs. This guarantees a significant increase
in production output.

The Discus Grinding System

The Discus Grinding System is the quantum

leap in disk grinding technology.

With the combination of the further-optimized

Discus disk agitator and the NETZSCH DCC®
separator system, you are guaranteed the
highest throughput rates with considerably
narrower residence time distribution and
thus more intensive grinding with consistent
stress intensity. The power input of the mill is
significantly increased, with a simultaneous
increase in energy efficiency. The Discus
grinding system activates and optimizes the
movement of the grinding media between
the disks, which leads to a higher power
draw and grinding efficiency with low specific
energy consumption. Thus, you benefit
from a significant reduction in production
costs, since the specific energy consumption
decreases with increasing productivity.

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10
Successfully implemented System Concept for
Flexo Printing Inks
From site preparation through to commissioning and final plant inspection –
NETZSCH delivered a true turnkey solution. An essential part of the project was the
design and construction of the new PMD batch mixer for the production of NC
whites without a milling phase and use of the upgraded Zeta® horizontal circulation
mill as well as the revolutionary Ψ-Mix® inline disperser.

All products manufactured are either shipped directly to the end user or held in
stock, ready to be bottled with one of the largest dispensing systems in Europe,
provided by INKMAKER of Italy and installed by NETZSCH.

Mezzanine steelwork and big-bag lifting gantries; hoists and cruciforms, Big-Bag
and Small-Bag discharge units, process valve instrumentation, process pipe work
with lagging, the complex electrical installation, product filters, transfer pumps,
dust extraction system, fume extraction system, compressed air system, chilled
water and heating system and many hundreds of smaller items had to be
integrated.

The revolutionary cleaning system allowed Sakata Inx to install 3 color-graded lines
which included the Ψ-Mix®, mixing vessel, Zeta® agitator bead mill, let down and
adjustment vessel and pallet filling equipment.

The cleaning system, which is a combination of cleaning heads and surface

mounted nozzles, requires only 100 l - 2,500 l of cleaning fluid (some reusable for
future batches) to clean the whole line so that it is ready for the next color.

Production Output Batch Dispersion Time

Machines
[kg/h] [kg] [h]

Neos 20 220 1 000 4:30

Neos 10 135 500 3:40

Test your products with us in our pilot plant.

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 OFFSET / SCREEN PRINTING

NETZSCH develops machines and plants for the

manufacture of offset and screen-printing inks.

The most important quality characteristics

for these printing inks are color
intensity, transparency and gloss.

When using the TetraNex® disks with the Discus

grinding system, a production output of at
least 30% is achieved while, at the same time,
reducing the specific energy consumption
compared to the previous disk geometry.

This means that the defined quality

characteristics can be achieved with
reproducibility and high productivity.

12
 RAW MATERIAL
HANDLING
PREDISPERSION FINE GRINDING
OF WET AND DRY
MATERIAL

The Discus Grinding System

The Discus Grinding System is the quantum

leap in disk grinding technology.

With the combination of the further-optimized

Discus disk agitator and the NETZSCH DCC®
separator system, you are guaranteed the
highest throughput rates with considerably
narrower residence time distribution and
thus more intensive grinding with consistent
stress intensity. The power input of the mill is
significantly increased, with a simultaneous
increase in energy efficiency. The Discus
grinding system activates and optimizes the
movement of the grinding media between
the disks, which leads to a higher power The Macro Grinding System
draw and grinding efficiency with low specific
energy consumption. Thus, you benefit
from a significant reduction in production The Macro Grinding System represents
costs, since the specific energy consumption the systematic advancement of the John
decreases with increasing productivity. Annular Chamber Mill System combined
with the centrifugal force separator. The
new peg system is designed for high power
input in single and multi-pass operation.

The grinding system has an intensive cooling

system for the grinding chamber and agitator
shaft. This makes the Macro the ideal machine
for medium- to high-viscosity products, such as
UV systems, at a low processing temperature.

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Successfully implemented System Concept for
Offset / Heatset Printing Inks

Turnkey – from site preparation to installation and commissioning, through to final plant inspection –
NETZSCH was responsible for every step of the process. An essential part of the project was the design and
construction of the PMD batch mixer, the reliable and improved Discus horizontal agitator mill and the revolu-
tionary Ψ-Mix® inline disperser.

Mezzanine steelwork and big-bag lifting gantries; hoists and cruciforms, Big-Bag and Small-Bag discharge
units, process valve instrumentation, process pipe work with lagging, the complex electrical installation,
product filters, transfer pumps, dust extraction system, fume extraction system, compressed air system, chilled
water and heating system and many hundreds of smaller items had to be integrated.

Production Output Batch Dispersion Time

Material Machines
[kg/h] [kg] [h]

Ψ-Mix® + Discus® 300 3:00

Heatset 1 700 5 000
Single-pass Mode

5:45
UV Offset (yellow) Macro® 20 88 500
Circulation Mode

Ψ-Mix® + Discus® 300 5:15

Extender 1 900 10 000
Single-pass Mode

6:45
UV Offset (blue) Macro®20 75 500
Circulation Mode

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 The NETZSCH Group is an owner-managed, international technology
company with headquarters in Germany. The Business Units Analyzing &
Testing, Grinding & Dispersing and Pumps & Systems represent customized
solutions at the highest level. More than 3,700 employees in 36 countries and
a worldwide sales and service network ensure customer proximity and
competent service.

Our performance standards are high. We promise our customers Proven

Excellence – exceptional performance in everything we do, proven time and
again since 1873.

Business Unit Grinding & Dispersing – The World’s Leading Grinding Technology
NETZSCH-Feinmahltechnik – Germany NETZSCH Machinery and Instruments – China
NETZSCH Trockenmahltechnik – Germany NETZSCH Technologies India Private – India
NETZSCH Vakumix – Germany NETZSCH Tula – Russia
NETZSCH Lohnmahltechnik – Germany NETZSCH Makine Sanayi ve Ticaret – Turkey
NETZSCH Mastermix – Great Britain NETZSCH Korea – Korea
NETZSCH FRÈRES – France NETZSCH Premier Technologies – USA

G&D · Printing Inks· EN · 01/20 · Technical specifications are subject to change.

NETZSCH España – Spain NETZSCH Equipamentos de Moagem – Brazil
ECUTEC – Spain

NETZSCH-Feinmahltechnik GmbH
Sedanstraße 70
95100 Selb
Germany
Tel.: +49 9287 797 0
Fax: +49 9287 797 149
info.nft@netzsch.com