Patent Description:
Printing units of offset printing presses comprise a plurality of rollers, which transfers the colour to be printed onto a substrate from an ink fountain to a surface of the substrate. More specifically, the ink fountain comprises an ink key opening, through which the printing ink included in the ink fountain is transferred to the first of the plurality of the rollers, namely to the ink duct roller. Via a gap of the ink key opening (which is the gap between the ink key opening or a zone of the ink key opening, respectively, and the closest surface of the ink duct roller, the amount of printing ink per time period leaving the ink fountain can be controlled. A vibrator roller periodically jumps back and forth between the ink duct roller and another roller and transfers the printing ink from the ink duct roller to the other roller, such as a friction cylinder. The frequency, with which the vibrator roller periodically jumps back and forth between the two rollers, i.e. the number of vibrator roller contacts to the ink duct roller within a time period, controls the amount of printing ink transferred from the ink duct roller via all of the downstream rollers to the surface of the substrate. The total (surface) area of all rollers included in the printing unit can amount to several square meters, such as about <NUM> square meters or even more.

Before the first use of an offset printing press or after cleaning of the printing press between two different printing jobs, the rollers of the printing unit need to be appropriately wetted within a so-called pre-inking process with the printing ink so that on each part of the substrate surface the desired amount of printing ink per area, which is denoted as specific ink coverage, is obtained. Since the colour strength or colour coordinates of a colour, more or less depend on the specific ink coverage, it is essential for the quality of the printing result that on each part of the substrate surface the desired amount of printing ink per area is obtained. This is in particular due for spot colours, i. colours printed from a unique colour recipe including the pigment(s) in the concentrations necessary to achieve the intended colour coordinates, if the spot colours are printed with a defined specific ink coverage on the substrate. Such spot colours are used for instance in packaging and commercial printing. For spot colours, a particular exact specific coverage of the printing ink on the substrate needs to be obtained, in order to achieve the predetermined colour coordinates, because spot colours have only a small tolerance for the specific ink coverage on the substrate. In other words, if the defined specific ink coverage of the spot colour on the substrate is slightly exceeded or if the defined specific ink coverage of the spot colour on the substrate is slightly below the defined specific ink coverage on the substrate, the spot colour on the printed substrate does not have the desired colour coordinates. However, it needs quite a long time, namely up to <NUM> roller rotations, until the printing ink is appropriately and in the correct thickness distributed over the (surface) areas of the rollers. During this time a significant amount of printed substrate is obtained as waste. Moreover, the longer the pre-inking time is, the longer the press cannot be used for the printing job.

During the pre-inking, the press operator starts the pre-inking of the printing unit with arbitrary selected press parameters, such as an arbitrarily selected gap of the ink key opening of the ink fountain, an arbitrarily selected ink duct roller speed and/or an arbitrarily selected number of vibrator roller contacts to the ink duct roller per time period and then evaluates the obtained specific ink coverage on the substrate. If the specific ink coverage of the substrate is too high or too low, the press operator changes one or more of these selected settings so as to try to come step by step closer to the desired specific ink coverage on the substrate. This procedure is time consuming and produces a lot of printed substrate as waste. For frequently used colours, such as standard colours, such as those used in CMYK printing, the press operator has due to his experience indications, which number of vibrator roller contacts to the ink duct roller within a time period and other parameters might come at least quite close to the desired specific ink coverage on the substrate surface, this minimizing the time and amount of colour needed for the pre-inking. However, usually press operators have less or even no experience with rarely used spot colours, thus requiring more time for the pre-inking. This is particularly disadvantageous, because spot colours are usually more expensive as those used for CMYK printing. Thus, it would be desirable to have a method available, which calculates the most important parameter for the pre-inking so as to reduce the time and effort for the pre-inking of a printing unit of an offset printing press.

<CIT> discloses a method of presetting ink in a printing apparatus, wherein the apparatus comprises an ink supply mechanism capable of variably supplying ink and an ink transfer mechanism capable of receiving the ink from the ink supply mechanism and transferring the ink onto a plate cylinder provided to print an ink image on a printing sheet being fed in a predetermined feeding direction, wherein the method comprises the steps of a) setting a first target density for a plurality of ink key regions defined on each printing sheet along the feeding direction, of b) performing a first printing operation under a first feedback control of the ink supply mechanism using the first target density, of c) performing a second printing operation under a second feedback control of the ink supply mechanism using a second target density lower than the first target density after a required number of sheets are printed in the step b) and d) when a printed sheet has a density lowered to the second target density, judging that the amount of ink remaining on the ink transfer mechanism is equal to an amount required to restart the printing apparatus for a next printing operation, thereby to stop the second printing operation.

In view of this, the object underlying the present invention was to provide a method allowing to minimize the time required for pre-inking the printing unit of an offset printing press with a spot colour.

In accordance with the present invention, this object is satisfied by providing a method for calculating the parameters for the pre-inking of a printing unit of an offset printing press with a spot colour in accordance with claim <NUM>. This method comprises the following steps:.

This solution bases on the surprising finding that using at least two different reference spot colours and printing them, each with a different predetermined specific ink coverage, with the printing unit to be used for the printing of the spot colour onto the substrate to be used for the printing of the spot colour, allows to easily determine the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the printing unit onto the substrate, the specific ink coverage for the spot colour being necessary to achieve the predetermined colour coordinates of the spot colour. The inventors have found that there is a mathematical relationship, which is described further below, between the area to be inked, the colour strength (i.e. colour coordinates) and the required ink film thickness of the ink in the delivery form and printing unit parameters, such as ink duct roller speed, gap of ink zone opening and others. All in all, the method in accordance with the present invention allows to drastically reduce the time needed for pre-inking the printing unit of an offset printing press with a spot colour.

Specific ink coverage means in accordance with the present invention the ink coverage per area of the substrate, namely the amount of printed ink in gram per square meter of the substrate. Accordingly, ink coverage means in accordance with the present invention the amount of ink to be printed onto the area to be inked driven by the print sujet (percentage in relation to the total format which is printed) in gram, i.e. the amount of ink of the area printed on the substrate in gram.

The ink coverage may be calculated by multiplying the predetermined specific ink coverage with the total area to be inked of all rollers in the inking unit optionally together with the area of the dampening rollers, if the dampening unit is connected during the pre-inking process to the inking unit. In turn, the specific ink coverage is measured in accordance with the present invention by inking a proof roller of e.g. of the type CG1 of the company IGT Testing Systems, Almere, Netherland and measuring with a fine scale (e.g. type Series 321LT from manufacturer Precisa Gravimetrics AG, Dietikon, Switzerland) having an accuracy of measurement of at least <NUM>,<NUM> the total weight of the proof roller and of the applied ink. Afterwards, a lab print is made with the proof roller on the predetermined substrate and after the lab print the weight of the proof roller is measured with the fine scale. The difference between the total weight of the proof roller and of the applied ink before the lab print and the weight of the proof roller after the lab print is the amount of ink being transferred to the substrate in gram. This amount is divided by the printed area in cm<NUM> so as to obtain the amount of transferred ink per <NUM><NUM>, wherein this numeric value is multiplied by <NUM>,<NUM> so as to obtain the amount of transferred ink per square meter.

Moreover, colour coordinates mean in accordance with the present invention the position of the colour in a colour space, such as the L-, a- and b-values of the Lab-colour space, the R-, G- and B values in the RGB-colour space or the like. Usual reference standards are the CIELAB or CIEXYZ colour spaces which were specifically designed to encompass all colours the average human can see.

As set out above, the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a) is determined in accordance with the present invention from at least two different reference spot colours, wherein each of the at least two different reference spot colours has been printed with the printing unit having been predetermined in step a) onto the substrate having been predetermined in step a) with a different predetermined specific ink coverage. In tendency, the larger the differences of the different predetermined specific ink coverages of the at least two different reference spot colours, the better. In accordance with the present invention in step b) the difference between the predetermined specific ink coverage on one of the at least two different reference spot colours on the substrate and the predetermined specific ink coverage on another one of the at least two different reference spot colours on the substrate is at least <NUM>/m<NUM>, preferably at least <NUM>/m<NUM>, more preferably at least <NUM>/m<NUM>, still more preferably at least <NUM>/m<NUM>, yet more preferably at least <NUM>/m<NUM> and most preferably at least <NUM>/m<NUM> of the substrate. The upper limit of the difference between the predetermined specific ink coverage on one of the at least two different reference spot colours on the substrate and the predetermined specific ink coverage on another one of the at least two different reference spot colours on the substrate is preferably <NUM>/m<NUM>, so that the preferred difference between the predetermined specific ink coverage on one of the at least two different reference spot colours on the substrate and the predetermined specific ink coverage on another one of the at least two different reference spot colours on the substrate is <NUM> to <NUM>/m<NUM>, more preferably <NUM> to <NUM>/m<NUM>, even more preferably <NUM> to <NUM>/m<NUM>, still more preferably <NUM> to <NUM>/m<NUM>, yet more preferably <NUM> to <NUM>/m<NUM> and most preferably <NUM> to <NUM>/m<NUM> of the substrate. Thus, in case of exactly two different reference spot colours being used in step b), both different reference spot colours differ from each other as described above. If more than two different reference spot colours are used in step b), the predetermined specific ink coverage on one of the at least two different reference spot colours on the substrate differs from the predetermined specific ink coverage on another one of the at least two different reference spot colours on the substrate by at least <NUM>/m<NUM>, preferably at least <NUM>/m<NUM>, more preferably at least <NUM>/m<NUM>, even more preferably at least <NUM>/m<NUM>, still more preferably at least <NUM>/m<NUM> and most preferably at least <NUM>/m<NUM>, such as by <NUM> to <NUM>/m<NUM>, more preferably <NUM> to <NUM>/m<NUM>, even more preferably <NUM> to <NUM>/m<NUM>, still more preferably <NUM> to <NUM>/m<NUM>, yet more preferably <NUM> to <NUM>/m<NUM> and most preferably <NUM> to <NUM>/m<NUM> of the substrate, wherein the rest of the more than two different reference spot colours may or may not differ from each other by the aforementioned values. More preferably, each of the different reference spot colours is printed onto the substrate with specific ink coverages differing concerning its specific ink coverage from all others of the different reference spot colours by at least <NUM>/m<NUM>, more preferably by at least <NUM>/m<NUM>, even more preferably by at least <NUM>/m<NUM>, still more preferably by at least <NUM>/m<NUM>, yet more preferably by at least <NUM>/m<NUM> and most preferably by at least <NUM>/m<NUM>, such as by <NUM> to <NUM>/m<NUM>, more preferably <NUM> to <NUM>/m<NUM>, even more preferably <NUM> to <NUM>/m<NUM>, still more preferably <NUM> to <NUM>/m<NUM>, yet more preferably <NUM> to <NUM>/m<NUM> and most preferably <NUM> to <NUM>/m<NUM> of the substrate.

The method in accordance with the present invention is not particularly limited concerning the number of different reference spot colours used in step b). In tendency, the more different reference spot colours are used in step b), the more precise results may be expected, but the more experimental effort is needed. In view of this, it is preferred that in step b) two to ten, more preferably two to five, even more preferably two to four and still more preferably two or three different reference spot colours are used. However, it has been shown during the development of the present invention that already the use of two different reference spot colours is sufficient to reliably determine the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a). Accordingly, it is most preferred that in step b) exactly two different reference spot colours are used.

In addition, it is preferred that different reference colours used belong to the same colour series as the spot colour used in the subsequent process, i.e. that the reference colours are based on the same binders and solvents as well as to the same drying mechanism.

In accordance with the present invention in step b) at least two different reference spot colours are used. However, the present invention is not restricted concerning the kind of difference of the at least two different reference spot colours. For instance, the at least two different reference spot colours may differ concerning the kind of pigment(s) included in the respective spot colours, but may have the same concentration of pigment(s). Alternatively, the at least two different reference spot colours may contain the same kind of pigment(s), but may differ concerning the concentration(s) of the pigment(s). Still alternatively, the at least two different reference spot colours may differ concerning the kind of pigment(s) included in the respective spot colours and differ concerning the concentration(s) of the pigment(s).

In view of this, according to a preferred embodiment of the present invention, at least one of the at least two different reference spot colours used in step b) has different colour coordinates than at least one other of the at least two different reference spot colours. In this embodiment it is further preferred that in case of more than two different reference spot colours being used in step b), each of the different reference spot colours has different colour coordinates than all other of the different reference spot colours. This may be easily realized by including in at least one of the at least two different reference spot colours used in step b) at least one pigment being different from pigment(s) being contained in the one or more others of the at least two different reference spot colours.

In accordance with an alternative preferred embodiment of the present invention, at least one of the at least two different reference spot colours used in step b) has the same colour coordinates as at least one other of the at least two different reference spot colours. If more than two different reference spot colours are used in step b), it is preferred, but not mandatory, that all of the different reference spot colours have the same colour coordinates. This may be easily realized by including the same pigment(s) into the concerned reference spot colours, but in a different concentration so as to fulfil the requirement of being different reference spot colours.

In accordance with the present invention, the printing unit predetermined in step a) is an offset printing unit and preferably a sheetfed offset printing unit or a rotary web offset printing unit.

In a further development of the idea of the present invention it is suggested that the printing unit predetermined in step a) comprises an inking unit, a fountain unit, a plate cylinder, a blanket cylinder and an impression cylinder, wherein the inking unit preferably comprises an ink fountain, a vibrator roller, an ink duct roller and one or more ink rollers.

In accordance with the present invention, the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a) is determined in step b) from at least two different reference spot colours, wherein each of the at least two different reference spot colours has been printed with the printing unit having been predetermined in step a) onto the substrate having been predetermined in step a) with a different predetermined specific ink coverage. Preferably, the determination in step b) considers in addition to the different specific ink coverages of the at least two different reference spot colours also further parameters.

More specifically, it is preferred in a first aspect of the present invention that the determination in step b) of the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a) comprises for each of the at least two different reference spot colours the consideration of:.

The consideration of any of the aforementioned parameters during the determination of step b) means that any of the aforementioned parameters being adjusted during the printing of the at least two different reference spot colours is used for determination of the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a).

Moreover, it is preferred that each of the at least two different reference spot colours has not only been printed with the printing unit having been predetermined in step a) onto the substrate having been predetermined in step a) with a different predetermined specific ink coverage, but also with at least one further different or same parameter, such as a different or the same predetermined ink duct roller speed and/or with a different or the same predetermined gap of ink key opening of the ink fountain. Thus, preferably, the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the spot colour with the printing unit onto the substrate, the specific ink coverage having been predetermined in step a) is determined in step b) from at least two different reference spot colours and preferably from two different reference spot colours each of which having been printed with the printing unit having been predetermined in step a) onto the substrate having been predetermined in step a) i) with a different predetermined specific ink coverage and ii) with a different or preferably the same predetermined ink duct roller speed and/or iii) with a different or preferably the same predetermined gap of ink key opening of the ink fountain.

In accordance with a particular preferred embodiment of the present invention, each of the at least two different reference spot colours has not only been printed with the printing unit having been predetermined in step a) onto the substrate having been predetermined in step a) with a different predetermined specific ink coverage, but also with the same predetermined ink duct roller speed as well as with the same predetermined gap of ink key opening of the ink fountain. Thus, it is preferred that the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the spot colour with the printing unit onto the substrate, the specific ink coverage having been predetermined in step a) is determined in step b) from at least two different reference spot colours and preferably from two different reference spot colours each of which having been printed with the printing unit having been predetermined in step a) onto the substrate having been predetermined in step a) i) with a different predetermined specific ink coverage, ii) with the same predetermined ink duct roller speed and iii) with the same predetermined ink key opening.

In a further development of the idea of the present invention, it is proposed that the method comprises:.

Moreover, it is preferred that in the aforementioned step i) the ink coverage for each of the reference spot colours is calculated as product (i.e. by multiplication) of the total area to be inked of all rollers in the inking unit optionally together with the area of the dampening rollers, if the dampening unit is connected during the pre-inking process to the inking unit, and of the predetermined specific ink coverage on the reference spot colour to be achieved on the substrate.

According to a further particular preferred embodiment of the present invention, in step b) for each of the reference spot colours a coefficient is calculated according to the following formula (<NUM>): <MAT> wherein:.

It is particularly preferred that the method of the aforementioned embodiment further comprises:.

wherein the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a) is calculated from the predetermined ink coverage (e.g. using small scale laboratory printing machines for printing and measuring the applied amount of ink), the predetermined ink duct roller speed (preferably originating from pre-press data), the predetermined gap of the ink key opening and the coefficients Kn of the at least two reference spot colours.

In a further development of the idea of the aforementioned embodiment, it is suggested that two reference spot colours are used in step b) of the method, wherein the method further comprises:.

In accordance with an alternative particular preferred embodiment of the present invention, the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a) is not determined by calculating and using the aforementioned coefficients, but by using a polynomial trend line of the specific ink coverage of each of the reference spot colours versus the appropriate number of vibrator roller contacts to the ink duct roller of each of the reference spot colours having been determined in the aforementioned step iii). More specifically, in this embodiment a polynomial trend line of the specific ink coverage of each of the reference spot colours versus the appropriate number of vibrator roller contacts to the ink duct roller of each of the reference spot colours having been determined in the aforementioned step iii) is determined, wherein the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a) is determined from the polynomial trend line. For instance, the specific ink coverage of each of the reference spot colours is plotted in a graph at the ordinate, whereas the appropriate number of vibrator roller contacts to the ink duct roller of each of the reference spot colour having been determined in the aforementioned step iii) is plotted at the abscissa of the graph, before the polynomial trend line is determined by using the method of least squares.

The present invention is not particularly limited concerning the order of the polynomial trend line. Good results are, however, achieved, when the polynomial trend line is of order <NUM> to <NUM> and more preferably of order <NUM> to <NUM>. Again, it is preferred that the polynomial trend line is determined by using the method of least squares.

In a further development of the idea of the present invention, it is suggested that three to twenty, more preferably five to twenty and most preferably eight to twelve reference spot colours are used for determining the polynomial trend line.

Furthermore, it is preferred that the predetermined specific ink coverages of all reference spot colours cover at least a numeric value range of <NUM> to <NUM>/m<NUM>, more preferably of <NUM> to <NUM>/m<NUM> and most preferably of <NUM> to <NUM>/m<NUM>.

In accordance with a second aspect of the present invention, the determination in step b) of the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a) comprises for each of the at least two different reference spot colours the consideration of:.

The consideration of any of the aforementioned parameters during the determination of step b) means that any of the aforementioned parameters being adjusted and measured during the printing of the at least two different reference spot colours is used for determination of the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a).

Preferably, the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the spot colour with the printing unit onto the substrate, the specific ink coverage having been predetermined in step a) is determined in step b) from at least two different reference spot colours and preferably from at least three different reference spot colours each of which having been printed with the printing unit having been predetermined in step a) onto the substrate having been predetermined in step a) i) with a different predetermined specific ink coverage and ii) with a different or preferably the same predetermined ink film thickness on the vibrator roller and/or iii) with a different or preferably the same predetermined contact length between the duct roller and the vibrator roller and/or iii) with a different or preferably the same predetermined ink fountain width.

In a further development of the idea of the present invention, it is suggested that the method comprises:.

The calculation for each of the at least two different reference spot colours the number of vibrator roller contacts to the ink duct roller being required to ink the whole area of the printing unit of step ii) may be done as follows. The required volume (V) of the respective reference spot colour to achieve an accurate ink saturation so as to achieve the colour target is calculated, for instance by multiplying the total area to be inked of all rollers in the inking unit of the printing press (without the area of the dampening rollers, since the dampening unit was not connected during the pre-inking process to the inking unit) with the specific ink coverage predetermined for the respective reference spot colour. In addition, the amount (A) of the respective reference spot colour, which is transferred during one ink duct roller and vibrator roller contact, is calculated, for instance by multiplying the predetermined contact length between the duct roller and the vibrator roller with the predetermined ink film thickness on the vibrator roller and with the predetermined ink fountain width and with the physical density of the respective reference spot colour. The number of vibrator roller contacts to the ink duct roller being required to ink the whole area of the printing unit of step ii) may then be easily calculated by dividing the above mentioned volume (V) by the amount (A).

Since the ink transfer between the individual rollers in the inking unit is usually not the theoretical possible, but in practice less, it is preferable to determine a correction factor, which considers the difference between the theoretically achievable and the practical achieved amount of ink transfer between the rollers in the printing unit, and to use this correction factor for determining form the above calculated number number of vibrator roller contacts to the ink duct roller being required to ink the whole area of the printing unit of step ii) the actual number number of vibrator roller contacts to the ink duct roller being necessary. Preferably, as correction factor a polynomial trend line of the specific ink coverage of each of the reference spot colours versus the appropriate number of vibrator roller contacts to the ink duct roller of each of the reference spot colours is determined, as in more detail exemplified in the subsequent example <NUM>. Then, the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a) may be easily determined from the polynomial trend line. Namely, the theoretical number of vibrator roller contacts to the ink duct roller being required to ink the whole area of the printing unit of step ii) may be calculated for the predetermined spot colour as described above for the reference spot colours, before from this theoretical number of vibrator roller contacts to the ink duct roller the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a) is determined by using the polynomial trend line.

Good results are in particular obtained, when the polynomial trend line is determined using the method of least squares, wherein the polynomial trend line is preferably of order <NUM> to <NUM> and more preferably of order <NUM> to <NUM>.

In accordance with a further preferred embodiment of the present invention, in the aforementioned embodiment three to twenty, more preferably five to twenty and most preferably eight to twelve reference spot colours are used for determining the polynomial trend line, wherein preferably the predetermined specific ink coverages of all reference spot colours cover at least a numeric value range of <NUM> to <NUM>/m<NUM>, more preferably of <NUM> to <NUM>/m<NUM> and most preferably of <NUM> to <NUM>/m<NUM>.

Other ink-related, measurable variables that may have an influence on the pre-inking process, and therefore might be used in the calculation, are the L-value of the ink (light/dark), rheological parameters, such as tack and viscosity, the proportion of non-colouring components in the ink (transparent white), pigment type and quantity.

Measurable press-related parameters are the temperature in the printing unit - which influences rheological properties and transfer behavior of the ink from roller to roller in the printing unit -, the contact length between the duct roller and the vibrator roller during one contact, the size of gaps between the individual rollers in the printing unit, the ink fountain width, different or equal opening of the individual zones in the ink fountain and the like. These parameters might also be used in the calculation.

Furthermore, substrate-related properties, such as absorbency, surface smoothness and texture, the substrate whiteness or opacity, and the surface energy may influence the exact achievement of the colour targets. If the substrates are grouped together, for example coated paper, uncoated paper, recycled paper etc., and a calculator is generated for each group and ink type, the influence of the substrate may be accounted for.

Other press-related parameters that are difficult or impossible to measure are roller adjustment, the maintenance condition of the printing unit, roller planarity, roller types, the condition and quality of the polymeric roller coatings as well as the type and quality of the printing plates used.

Even if the pre-inking process is generally run without dampening solution, the emulsification behavior of the ink may have an influence on the ink colour shade or ink density obtained after printing. The amount of dampening solution and its composition may therefore also influence the print result.

Above three specific embodiments have been described for determining the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a). In one embodiment, parameters, such as the ink duct roller speed, the number of vibrator roller contacts to the ink duct roller and the gap of the ink key opening of the ink fountain, are predetermined for the reference spot colours and coefficients are determined from which the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a) is calculated. In another embodiment, parameters, such as the ink duct roller speed, the number of vibrator roller contacts to the ink duct roller and the gap of the ink key opening of the ink fountain, are predetermined for the reference spot colours and the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a) is calculated using a polynomial trend line of the specific ink coverage of each of the reference spot colours versus the appropriate number of vibrator roller contacts to the ink duct roller of each of the reference spot colours. In still another embodiment, other parameters, such as the ink film thickness on the vibrator roller, the contact length between the duct roller and the vibrator roller, the physical density of the spot colour and the ink fountain width, are predetermined for the reference spot colours and the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined in step a) is calculated using a polynomial trend line of the appropriate number of vibrator roller contacts to the ink duct roller from print trials versus the calculated number of vibrator roller contacts to the ink duct roller. A calculator may be programmed to automatically perform the respective calculations described above. Moreover, it is possible to connect this calculator directly or via an interface with the control system of the printing press. The calculator may also be linked to a prepress process, in which the respective parameters, such as printing plates and the ink duct roller speed, are calculated, possibly as a link to the press control system. Still alternatively, the calculator may, for example, be linked analogue or digitally, directly or via an interface with ink formulation software or systems for digital colour communication (HDCC of hubergroup Germany GmbH), in which the specific ink coverage of the commercial printing inks is already recorded or that of newly generated printing inks is also recorded. Furthermore, the calculator may also be linked to other databases, such as SAP, from which ink-specific data required for calculating the vibration roller contacts can also be accessed. The calculator may be expanded as a universal calculator by taking into account other influencing variables such as substrate types, dampening solution types, press types and ink series. The system for optimising the ink feed may use mobile devices, be linked to a database, be set up as an app, and be usable via various terminals. The calculator may have a control step built in if calculated ductor vibrator roller contacts do not produce the desired print result. This may serve as a tool for early detection of maintenance needs or adjustment problems.

The present invention is not particularly limited concerning the kind of substrate. Good results are in particular obtained, when the substrate predetermined in step a) is a foil, a film, a coated or uncoated paper, a metal substrate, a metallized substrate, a laminate or a cardboard.

The present invention is also particularly suitable for physically and/or chemically drying offset inks, or inks with combined drying mechanisms, e.g. permeation drying offset spot colour inks, evaporation drying offset spot colour inks, oxidatively drying offset spot colour inks as well as for radiation-curing offset spot colour inks, radically curing and/or cationically curing and/or additional NCO/OH curing reactions, and inks with combined drying mechanisms.

Subsequently, the present invention is described by means of an illustrating, but not limiting figure.

The printing unit <NUM> of an offset printing press being suitable to be used in the method of the present invention shown as schematic side view comprises a plate cylinder <NUM>, a blanket cylinder <NUM> and an impression cylinder <NUM>, wherein between the blanket cylinder <NUM> and the impression cylinder <NUM> a substrate <NUM> to be printed with the spot colour is led through. The printing ink is transferred during the pre-inking process and the later printing process from the plate cylinder <NUM> to the blanket cylinder <NUM> and further onto one surface of the substrate <NUM>, whereas the impression cylinder <NUM> functions as counterpressure cylinder. Moreover, the printing unit comprises an ink fountain <NUM>, an ink duct roller <NUM>, a vibrator roller <NUM> and further rollers, through which the printing ink is transferred during the pre-inking process and the later printing process from the ink fountain <NUM> via the ink duct roller <NUM>, then via the vibrator roller <NUM> and then via the further rollers onto the blanket cylinder <NUM> and from there onto the surface of the substrate <NUM>. The ink fountain <NUM> includes an ink key opening (not shown) with variable adjustable gap through which the ink is transferred onto the surface of the ink duct roller, through which the amount of printing ink transferred per time period onto the ink duct roller <NUM> is controlled. The further rollers are friction cylinders <NUM>, <NUM>', <NUM>", friction rollers <NUM>, <NUM>', <NUM>", weight rollers <NUM>, <NUM>', <NUM>", friction cylinders <NUM>, <NUM>', <NUM>", colour application rollers <NUM>, <NUM>', <NUM>", <NUM>‴, <NUM>iv as well as rollers belonging to the fountain unit, namely a fountain bridge roller <NUM>, a fountain application roller <NUM>, a transfer roller <NUM>, a fountain dosing roller <NUM> and a rider roller <NUM>. There is a larger gap between the ink duct roller <NUM> and the friction cylinder <NUM>, so that the vibrator roller <NUM> does not contact simultaneously each of its neighbouring ink duct roller <NUM> and friction cylinder <NUM>, but the vibrator roller <NUM> periodically jumps back and forth between the two elements so that the vibrator roller <NUM> periodically contacts either the ink duct roller <NUM> or the friction cylinder <NUM> as indicated by the arrow <NUM>.

Subsequently, the present invention is described by means of illustrating, but not limiting examples.

The following colours, printing press and parameters were used or adjusted, re- spectively:.

Total area to be inked of all rollers in the inking unit of the printing press (the area of the dampening rollers, since the dampening unit was not connected during the pre-inking process to the inking unit): <NUM><NUM>.

This percentage number has been calculated or generated, respectively, via the ink coverage area calculation in the prepress process. This information has been transferred to the press using e.g. cip3 data format and has been used both for the printing and for the pre-inking. Cip3 means "Cooperation for Integration of Pre-press, Press and Postpress". This format is the current standard for transferring order related data in printing processes.

This percentage number has been calculated or generated, respectively, via the ink coverage area calculation in the prepress process. This information has been transferred to the press using e.g. cip3 data format and has been used both for the printing and for the pre-inking. This format is the current standard for transferring order related data in printing process.

The ink duct roller speed of the printing unit of the printing press has to be adjusted in % and thus needs to be recalculated into a numeric value in m/minute. Therefore, the printing press has been operated with an ink duct roller speed of <NUM>%(being the setting of the printing press during the pre-inking process) and the speed of the ink duct roller in m/minute has been measured with a digital hand tachometer. Thereby, the following ink duct roller speed was obtained:.

Furthermore, the gap of the ink key opening of the ink fountain for reference spot colours <NUM> and <NUM> of <NUM>% (being the setting of the printing press during the pre-inking process) has been determined in mm by measuring the gap of the ink key opening of the ink fountain with a feeler gauge. Thereby, the following gap of the ink key opening of the ink fountain was obtained:.

The ink coverages for reference spot colours <NUM> and <NUM> have been calculated according to the following formula: <MAT> wherein:.

Thereby, the following ink coverages were obtained:.

A pre-inking of the printing unit of the above-mentioned printing press onto the above-mentioned substrate has been performed in two separate sets of experiments with each of the reference spot colours <NUM> and <NUM> using the above-mentioned ink duct roller speeds and the above-mentioned gaps of ink key opening of the ink fountain. Each set of experiments was started with a number of vibrator roller contacts to the ink duct roller of <NUM> and after the pre-inking the obtained specific ink coverage of the respective reference spot colour on the substrate has been measured. With a number of vibrator roller contacts to the ink duct roller of <NUM>, the obtained specific ink coverage was too high and thus in further printings for both of the reference spot colours the number of vibrator roller contacts to the ink duct roller have been reduced so long until the predetermined, above mentioned specific ink coverage was obtained, namely <NUM>/m<NUM> for reference spot colour <NUM> and <NUM>/m<NUM> for reference spot colour <NUM>. Thereby, the following numbers of vibrator roller contacts to the ink duct roller were obtained:.

With the above-mentioned parameters, the coefficients for reference spot colours <NUM> and <NUM> were calculated using formula (<NUM>). <MAT> <MAT>.

The ink duct roller speed of the spot colour of example <NUM> of <NUM>% (this percentage number has been calculated/generated via the ink coverage area calculation in prepress department; this information has been transferred to the press using the cip3 data format and has been used both for printing and for pre-inking). The ink duct roller speed in m/minute has been measured with a digital hand tachometer. Thereby, the following ink duct roller speed was obtained:.

Using this ink duct roller speed of the spot colour of example <NUM>, the coefficient of the spot colour of example <NUM> can be calculated according to formula (<NUM>) as follows: <MAT> which is <MAT>.

The ink coverage for the spot colour of example <NUM> can be calculated according to the above-mentioned formula Mn = F · SMn = <NUM> · <NUM>/m<NUM> = <NUM>.

Using the above calculated coefficient K= <NUM> (g · m<NUM>)/minute, the number of vibrator roller contacts to the ink duct roller for the spot colour of example <NUM> can be calculated according to formula (<NUM>) as follows: <MAT> which is <MAT>.

All in all, the required setting for the number of contacts of the vibrator roller, i.e. between the ink duct roller and vibrator roller, in the printing unit of the printing press is <NUM>.

The same printing press, reference spot colours, substrate and settings were used as in example <NUM>, except for the following:.

The ink duct roller speed of the spot colour of example <NUM> of <NUM>% (this percentage number has been calculated or generated, respectively, via the ink coverage area calculation in the prepress process. This information has been transferred to the press using e.g. cip3 data format and has been used both for the printing and for the pre-inking) in m/minute has been measured with a digital hand tachometer. Thereby, the following ink duct roller speed was obtained:.

Using this ink duct roller speed of the spot colour of example <NUM>, the coefficient of the ink duct roller speed of the spot colour of example <NUM> can be calculated according to formula (<NUM>) as follows: <MAT> which is <MAT>.

The ink coverages for the spot colour of example <NUM> can be calculated according to the above-mentioned formula Mn = F · SMn = <NUM> - <NUM>/m<NUM> = <NUM>.

Using the above calculated coefficient K= <NUM> (g · m<NUM>)/minute, the number of vibrator roller contacts to the ink duct roller for the spot colour of example <NUM> can be calculated according to formula (<NUM>) as follows: <MAT> which is <MAT> rounded to <NUM>.

The same printing press and fount solution were used as in example <NUM>.

Total area to be inked (F) of all rollers in the inking unit of the printing press (without the area of the dampening rollers, since the dampening unit was not connected during the pre-inking process to the inking unit): <NUM><NUM>.

The required volume of reference spot colour <NUM> to achieve an accurate ink saturation so as to achieve the colour target is calculated according to: <MAT>.

The amount of reference spot colour <NUM>, which is transferred during one ink duct roller and vibrator roller contact (IA) is calculated according to: IA = CL · IT · IFW · ρ1 = <NUM> · <NUM> · <NUM> · <NUM>/cm<NUM> = <NUM>.

Thus, the number of vibrator roller contacts to the ink duct roller being required to ink the whole area to be inked is V<NUM>/IA = <NUM> / <NUM> = <NUM>, being rounded <NUM>.

The amount of reference spot colour <NUM>, which is transferred during one ink duct roller and vibrator roller contact (IA) is calculated according to: <MAT>.

Since the ink transfer between the individual rollers in the inking unit is usually not the theoretical possible, but in practice less, correction factors were determined by measuring the number of vibrator roller contacts to the ink duct roller being required to ink the whole area to be inked by printing the reference spot colours <NUM> onto the substrate. More specifically, a pre-inking of the printing unit of the above-mentioned printing press onto the above-mentioned substrate has been performed in three separate sets of experiments with each of the reference spot colours <NUM> to3 using the above-mentioned contact lengths, ink film thickness on the vibrator roller and other parameters. Each set of experiments was started with a number of vibrator roller contacts to the ink duct roller of <NUM> and after the pre-inking the obtained specific ink coverage of the respective reference spot colour on the substrate has been measured indirectly by measuring the colour strength. With a number of vibrator roller contacts to the ink duct roller of <NUM>, the obtained specific ink coverage was too high and thus in further printings for both of the reference spot colours the number of vibrator roller contacts to the ink duct roller have been reduced so long until the predetermined, above mentioned specific ink coverage by achieving the desired colour strength was obtained, namely <NUM>/m<NUM> for reference spot colour <NUM>, <NUM>/m<NUM> for reference spot colour <NUM> and <NUM>/m<NUM> for reference spot colour <NUM>. Thereby, the following numbers of vibrator roller contacts to the ink duct roller were obtained, which were significantly higher than the above calculated numbers:.

Considering these numeric values, the polynomial trend line of order <NUM> shown in <FIG> has been determined of the numbers of vibrator roller contacts to the ink duct roller of each of the reference spot colours <NUM> to <NUM> having been determined in the respective printing experiments versus the calculated numbers of vibrator roller contacts to the ink duct roller of each of the reference spot colours1 to <NUM>. In other words, the ordinate of the diagram of <FIG> shows the numbers of vibrator roller contacts to the ink duct roller of each of the reference spot colours <NUM> to <NUM> having been determined in the respective printing experiments, whereas the abscissa shows the calculated numbers of vibrator roller contacts to the ink duct roller of each of the reference spot colours1 to <NUM>. The formula of the polynomial trend line is: <MAT>.

Using this polynomial trend line, the number of vibrator roller contacts to the ink duct roller being necessary to obtain, by printing the predetermined spot colour of example <NUM> with the predetermined printing unit onto the predetermined substrate, the specific ink coverage having been predetermined is determined as follows:.

The required volume of the spot colour of example <NUM> to achieve an accurate ink saturation so as to achieve the colour target is calculated according to: <MAT>.

The amount of the spot colour of example <NUM>, which is transferred during one ink duct roller and vibrator roller contact is calculated according to: IA = CL · IT · IFW · ρ =
<NUM> · <NUM> · <NUM> · <NUM>/cm<NUM> = <NUM>.

Thus, the calculated number of vibrator roller contacts to the ink duct roller being required to ink the whole area to be inked is V<NUM>/IA = <NUM> / <NUM> = <NUM>.

Considering the above polynomial trend line, the actual number of vibrator roller considering the correction factor is: <MAT>.

Claim 1:
A method for calculating the parameters for the pre-inking of a printing unit (<NUM>) of an offset printing press with a spot colour comprising the following steps:
a) predetermining a printing unit (<NUM>), a spot colour, a substrate (<NUM>) to be printed with the spot colour and a specific ink coverage necessary to achieve predetermined colour coordinates of the spot colour to be achieved on the substrate (<NUM>),
b) determining the number of vibrator roller contacts to the ink duct roller (<NUM>) being necessary to obtain, by printing the predetermined spot colour with the predetermined printing unit (<NUM>) onto the predetermined substrate (<NUM>), the specific ink coverage having been predetermined in step a) from at least two different reference spot colours, wherein each of the at least two different reference spot colours has been printed with the printing unit (<NUM>) having been predetermined in step a) onto the substrate (<NUM>) having been predetermined in step a) with a different predetermined specific ink coverage, wherein the difference between the predetermined specific ink coverage of one of the at least two different reference spot colours on the substrate (<NUM>) and the predetermined specific ink coverage of another one of the at least two different reference spot colours on the substrate (<NUM>) is at least <NUM>/m<NUM>,
wherein the specific ink coverage is the amount of printed ink in gram per square meter of the substrate and is measured by inking a proof roller and measuring with a fine scale having an accuracy of measurement of at least <NUM>,<NUM> the total weight of the proof roller and of the applied ink, wherein afterwards a lab print is made with the proof roller on the predetermined substrate and after the lab print the weight of the proof roller is measured with the fine scale, wherein the difference between the total weight of the proof roller and of the applied ink before the lab print and the weight of the proof roller after the lab print is the amount of ink being transferred to the substrate in gram, wherein this amount is divided by the printed area in cm<NUM> so as to obtain the amount of transferred ink per <NUM><NUM>, wherein this numeric value is multiplied by <NUM>,<NUM> so as to obtain the amount of transferred ink per square meter.