Applications by Sector
Cooling for Flexography and Rotogravure
Chillers and temperature controllers for high-quality graphic printing
Precision cooling and thermal control systems for CI (central drum) flexographic, stack, rotogravure and offset printing machines. Cylinder temperature from 18°C to 25°C with ±0.5°C precision, essential for print quality, perfect color registration and maximum productivity. Solutions for printing on plastic films, paper, cardboard, aluminum and special substrates. Flow from 20 to 500 L/min with pressure from 2 to 8 bar.
Talk to SpecialistTechnical Specifications
Process Requirements
The central impression drum is the heart of CI flexographic machines. Its precise thermal control ensures substrate dimensional stability during printing, resulting in perfect registration between 8, 10 or 12 colors. Variations of just 1°C can cause registration shift up to 0.1mm.
Anilox rollers transfer ink to the printing plates. Temperature directly affects ink viscosity and consequently the volume of ink transferred. Precise control ensures uniform color density throughout the entire roll.
Cylinders where printing plates are mounted. Thermal control prevents differential expansion between cylinder and plate, preventing distortions in the printed image.
Chrome-plated cylinders engraved with the image. Temperature affects ink transfer from engraved cells to the substrate. Precise control is essential for faithful reproduction of halftones and gradients.
Water-based inks require temperature control to maintain stable viscosity. Too low temperature increases viscosity and hinders transfer; too high accelerates drying and causes clogging.
Solvent-based inks are sensitive to temperature which affects solvent evaporation rate. Proper control prevents premature drying and ink skinning issues.
UV or electron beam curable inks require controlled temperature for proper viscosity. UV curing systems generate significant heat that must be dissipated.
Ink drying between print stations. Controlled temperature and airflow for uniform solvent evaporation without damaging the substrate.
Refrigerated rolls after drying units to cool the substrate before the next print station. Essential to prevent blocking and adhesion issues.
Film lamination process with hot-melt adhesive. Precise lamination roll temperature ensures uniform adhesion without damaging the substrate.
Lamination with solvent-based or water-based adhesives. Temperature control of environment and rolls for proper adhesive curing.
Print environment climate control for relative humidity control. Inadequate humidity causes static electricity on the substrate, registration problems and print defects.
Technical Analysis
A Ciência da Impressão Flexográfica e o Papel da Temperatura
A flexografia é um processo de impressão rotativa que utiliza clichês flexíveis (fotopolímeros) e tintas de baixa viscosidade. É o processo dominante para impressão de embalagens flexíveis, rótulos, papéis de embrulho e caixas de papelão ondulado. A qualidade da impressão flexográfica depende criticamente do controle térmico em múltiplos pontos do processo.
Impacto da Temperatura na Qualidade de Impressão
A temperatura afeta praticamente todos os aspectos do processo flexográfico:
| Parâmetro | Efeito da Temperatura Alta | Efeito da Temperatura Baixa |
|---|---|---|
| Viscosidade da Tinta | Reduz viscosidade, excesso de tinta | Aumenta viscosidade, falta de tinta |
| Registro de Cores | Dilatação do substrato, desregistro | Contração, desregistro oposto |
| Secagem | Secagem rápida, entupimento | Secagem lenta, blocking |
| Qualidade do Ponto | Ganho de ponto excessivo | Pontos falhados, áreas abertas |
| Aderência | Pode prejudicar ancoragem | Aderência inadequada |
Máquinas Flexográficas CI vs. Stack
Existem dois tipos principais de máquinas flexográficas, cada uma com requisitos térmicos específicos:
- Máquinas CI (Central Impression): Utilizam um único cilindro central (tambor) de grande diâmetro ao redor do qual ficam posicionadas as estações de impressão. O controle térmico do tambor é crítico pois todas as cores são impressas sobre o mesmo cilindro. Capacidade típica de refrigeração: 30-100 kW.
- Máquinas Stack: Estações de impressão empilhadas verticalmente, cada uma com seu próprio cilindro de impressão. Requerem controle individual de cada estação. Capacidade típica: 5-15 kW por estação.
Rotogravura: Precisão Máxima
A rotogravura utiliza cilindros metálicos gravados com a imagem. É o processo de maior qualidade para impressão de embalagens, especialmente para reprodução de fotografias e gradientes. Os cilindros cromados são extremamente sensíveis à temperatura:
- Variação de 1°C causa expansão de ~11 μm/m no cilindro de aço
- Afeta diretamente o volume das células gravadas
- Impacta a transferência de tinta e densidade de cor
- Controle de ±0,3°C é ideal para trabalhos de alta qualidade
Dimensionamento de Sistemas de Refrigeração
O cálculo da capacidade de refrigeração para máquinas de impressão considera:
- Calor gerado por atrito: Contato entre cilindros, clichês e substrato
- Calor de secagem: Ar quente dos túneis de secagem transferido ao substrato
- Velocidade da máquina: Maior velocidade = maior geração de calor
- Largura de impressão: Máquinas mais largas requerem maior capacidade
Regra prática: 1-2 kW de refrigeração por metro de largura de impressão por estação de cor.
Controle de Umidade na Impressão
A umidade relativa do ambiente de impressão afeta:
- Eletricidade estática: Umidade baixa (<40% UR) aumenta cargas estáticas no substrato, causando problemas de alimentação e aderência de poeira
- Estabilidade dimensional: Papel e cartão absorvem/liberam umidade, alterando dimensões
- Secagem de tintas: Umidade alta retarda secagem de tintas water-based
- Conforto dos operadores: Ambiente controlado melhora produtividade
Sector Challenges
Print cylinders need temperature controlled with ±0.5°C precision to maintain correct ink viscosity and dimensional stability. Variations cause registration, color density and dot quality issues.
Modern machines operate at 400-600 m/min. At these speeds, minimal thermal variations cause visible misregistration between colors. The cooling system must respond quickly to load changes.
A flexographic machine can have 10+ zones with different temperatures: central drum, anilox, inks, drying, chill rolls, lamination. Each zone requires independent control.
Different substrates (BOPP, PET, PE, paper, aluminum) have different expansion coefficients. The system must allow quick temperature adjustments for each material.
Water-based, solvent-based and UV inks have distinct thermal requirements. Systems must be versatile to handle different formulations.
Cooling and drying systems represent a significant portion of energy consumption. Optimization is essential for competitiveness and sustainability.
Graphic industries frequently operate continuously. The cooling system must maintain consistent performance without interruptions.
Production environment temperature and humidity control to prevent static electricity, condensation and substrate dimensional variations.
Our Solutions
Dedicated cooling for print cylinders with ±0.5°C precision. Models from 5 to 50 kW with integrated pump and reservoir. Ideal for stack machines and dedicated applications.
View ProductPrecise temperature control for ink systems, anilox and plate cylinders. Heating and cooling in a single unit with fast response (<30 seconds).
View ProductCentralized system for multiple printing machines. Capacities from 50 to 500 kW with redundancy and superior energy efficiency. Ideal for printing parks.
View ProductWater temperature control for cylinder and plate washing systems. Proportional hot and cold water mixing for precise temperature.
View ProductProduction environment climate control for temperature and humidity. Prevents static electricity and substrate dimensional variations.
View ProductHumidity control in roll storage areas and production environment. Prevents condensation and static electricity issues.
View ProductClimate control for finishing, shipping and office areas. Comfortable environment for operators and temperature control for materials.
View ProductCustom projects for specific printing lines, including rotogravure, offset and large format digital printing.
View ProductRegulations and Standards
Benefits for Your Business
Success Case
Flexible Packaging Industry - Campinas/SP
Complete cooling system modernization for printing park with 6 CI flexographic machines of 8 and 10 colors, 2 rotogravure machines and 3 laminators. The project replaced a 15-year-old obsolete system with a centralized solution featuring high-efficiency chillers, individual temperature controllers for each machine and integrated monitoring system. Installation was carried out in phases to minimize production impact.
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