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Published by edward.scheppink, 2019-04-19 12:42:09

Audit report Lux Global Label

Audit report Lux Global Label


Executed on March 19 and 20, 2019

Project owner : Erik Abromavage, Director of Production
Lux Global Label Company, LLC

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Pre-Press process with Andy Hull on March 19, 2019, supervised by Grace McDaid
The pre-press room gives a clean and well organized impression. There is a logical flow from one work station to the next within the
pre - press room, and enough of space to move around, which will prevent unwanted damages during screen making process.
Andy works very delicate and has made -based upon his experience- small and effective improvements, with the aim to extend the
life time of any screen (new and reclaimed). Andy puts pride in the number of reclaims he achieves.

In general, the pre-press process steps that are followed are matching the recommended process steps. A few minor deviations, as
well as logistical recommendations are:

Storage of new screens

Currently, new screens are stored horizontally in the original box, which are designed for longer storage. Nickel has, however, the
tendency to deform if stored in horizontal position. That will eventually influence the roundness off the screen. UniPrints
recommends to store screens vertical, to maintain the roundness of the screens.

Lux Global did not process new screens during the audit on March 19. During the audit we did review the end ring mounting device.
This is a Nilpeter made. The pre-press department is glueing end rings horizontal on a leveled table. That ensures that end rings are
mounted leveled. I suspect that end ring mounting is secured.

Transport of screen from pre-press to exposing unit (in storage room)

Did notice six screens were transported in one go from pre-press shop to exposing unit. As the pre press room is separated from
the exposing unit by an alley, where other operators have free access, transporting that many screens gives a higher risk of
damaging (unnoticed passing by of other staff members). In general, it is better to transport one screen at all time.

Storage of ready to engrave, engraved and used screens

The storage room for ready to engrave screens, as well as returned re-usable screens (image attached) is freely accessible to any
staff member. We recommend that only one person has access to and responsibility for the storage-room (also to release screens
for a print job).

One major recommendation:


The recommended coating process, as well as coating process in the SOP of Lux Global Label, is a first coat (without a bladder),
followed by drying of the emulsion, followed by 4 coatings (with a bladder), and drying after each coating (called wet on dry
process). Currently, in the pre-press process 4 subsequent coatings are applied, followed by one single time drying (called wet on
wet coating) at the end of the fifth coat. This procedure can result in small air inclusions (easier to pinhole the coating), as well as
that the total thickness of the coating is slightly less than what would be achieved when wet on dry process is followed.

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Pre-press process steps Internal Lux Global Label process Observation on 03/19 Remarks
steps protocol
From here process of new Wipe screen of dry, then wipe QR - 708 being used
and reclaimed screen is Wipe screen dry, apply liquid haze with with haze remover. Then
equal remover, let haze remover sit for 10 wipe the screen with ghost Wipes of end rings with non-
Mix Emulsion minutes remover and remove the ghost woven cloth and checks end
remover QR 708 inside the rings on trueness
Remove haze remover from screen in screen
wash-out machine high The above process has no
Screen back into rinsing (3 direct influence on the final
minutes) print quality. However,
controlling this process can
Place screen in dryer Screen into drying oven significantly contribute in
Screen is ready to coat spend of screens.

Coating of Screen

Add distilled water to Diazo, 50. ml. two
times, shaking well in between and
pouring into emulsion container
Stir Emulsion well (2 min)
Let sit 24 hours before use

Tape End rings

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Pre-press process steps Internal Lux Global Label process Observation on 03/19 Remarks
Preparing coating process steps protocol
Start with cleaning sandpaper
Coating process Place coating ring on coating ring 1,200 - 1,300 and IPA to soften
adapter and invert. the rubber of the squeegee
1. Fill Coating Ring Sponge and water to clean the
Fill coating ring with emulsion coater
An annular sealing collar
which lies round the stencil Places coating ring on coating
and be filled with ring adapter
photographic emulsion Fills the coating ring with

2. First Coat on Screen, No Place screen in center of coating ring Places screen in center of
Bladder coating ring
Place second coating ring adaptor on
top of screen Place second coating ring
Lock screen into place adapter on top of screen

a container with liquid Coating from downward to top Locks screen into place The first coat on screen is
photographic lacquer is Unlock screen completely matching the
moved upwards along the Coating from downward to top recommendations for coating a
stencil, and in which there is screen
also a sealing collar resting
against the outside of the

Remove coating ring (set aside) Unlocks the screen
Remove coating ring (set aside)

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Pre-press process steps Internal Lux Global Label process Observation on 03/19 Remarks
3. Drying of emulsion steps protocol Places screen in dryer
Cleanses the rings and seam Right coating temperature,
Place screen in dryer (45 degrees C for recommended time is 60 min.
15 minutes)

Clean empty adaptor ring

The first screen coat matches
the recommendations for
screen coating

4. Coats 2-5 Using Bladder Place coating ring on coating ring Places coating ring on coating
adapter and invert ring adapter

Place screen on bladder and inflate (5 - 8 Places screen on bladder and

lbs Psi) inflate bladder

Place screen and bladder in center of Places screen and bladder in
coating ring center of coating ring

Place second coating ring adapter on top Places second ring adapter on

of screen top of screen

Lock screen into place Lock screen into place

Coat from top to bottom Coats from top to bottom,
Unlock screen applies 4 coatings wet on wet

Unlocks the screen

Remove coating ring (set aside) Removes coating ring (set aside)

Deflate bladder and remove screen Deflates bladder and removes
the screen
Place screen in dryer rotating ends after
each coat for 5 minutes Places screen in dryer rotating
Clean empty adaptor ring ends

Cleanses empty adapter ring

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Pre-press process steps Internal Lux Global Label process Observation on 03/19 Remarks
The photographic emulsion steps protocol
coating can, if desired, be The SOP describes 5 coats, wet
made up of several Repeat process until a total of 5 coats on dry. Lux Global practices 1
separately applied coats, have been achieved first coat, drying. Second coat
each coat being dried on dry first coat surface and
following its application Screen removed from the oven, remove subsequent 3 coats wet on wet.
the end ring tape This will reduce the coating
5. Exposing of emulsion Screens directly into developer thickness and may have a slight
influence on registration (as total
repeat size is slightly lower).

The subsequent 4 coats are
applied wet on wet. This does
not match the recommended
screen coating process.

Screens are removed from the
oven and end ring tape is

Screens are moved to a next In total 6 screens were prepared
room for development and moved into the next room
for development. This room is
separated from the pre press
room by an alley. The operator
took all 6 screens at once to the
next station. This is risky, as
some one may walk through the
alley. Recommend to carry one
screen per hand instead to
reduce unwanted bouncing.

Emulsion exposing is done are We recommend to use an
light bulbs and screens are emulsion exposing unit where
positioned on a flat bed side by the screens are turning freely (on
side. The screens are turned an axis) around. This will provide
after each development cycle (3 evenly exposing of the emulsion.
times in total)

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Pre-press process steps Internal Lux Global Label process Observation on 03/19 Remarks
6. Engraving process steps protocol

Return to pre-press shop Checks gear side. Lines up the
engraving machine and checks
the clamping pads

Centrals liner on the seam

Inflates air in the bladder

Folds the engraving sheet over
the bladder

Sets screen to engraving

Engraving process

Checks the repeat on the seam
-> checks engraving quality

Removes the sheet, deflates the

Checks the marks on the screen

The engraving process
matches the recommended
process steps

Closes some of the design
(used for engraving purposes,
not for printing) with emulsion

Removes the cross marks (with

Visual inspection of the total
screen (pinholes and other
imperfections of the screen)

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Pre-press process steps Internal Lux Global Label process Observation on 03/19 Remarks
steps protocol
Drying Storage vertical in well organized
Storage in the ware house for racks
the press shop
Storage is done properly. The
only point of attention is that
this ware house for screens
has free access to every one. It
is recommended to have
responsibility of screen release
assigned to one person

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Print process steps Internal Lux Global Label process Observation on 03/20 Remarks
steps protocol
1. Installing screen Slide in of the screen print Currently the cassette is one
cassette on printing cassette sided calibrated on the press
machine with. We strongly recommend to
use a jig that enables to calibrate
Checks the wheels on play both sides at the same time, to
prevent different settings.
Checks if the print head is
geared Check of play is manual. This
Checks the gap setting could lead to different levels of
accepting the amount of play.

Uses a small -plastic- flexible
tool to determine the gap setting
on three points, left, middle and
right. We recommend to use a
gauge of metal (we left one
sample that was used with the
gap settings for this job), with
0.04” that we believe every print
operator should have in his
standard tool box. This gauge
has a standard gap setting,
which will standardize the gap
setting over all screen print
cassettes on the machine and
between different machines

Checks the outsides
Does a skew check

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Print process steps Internal Lux Global Label process Observation on 03/20 Remarks
2. Printing steps protocol

Ink bucket is besides the screen
print cassette (open bucket).
Pump is besides the print

Brings in the squeegee. We recommend to use a jig to
Squeegee is positioned without position the squeegee. This will
using a jig make sure the level of squeegee
is correct both left and right

Pumps first level of ink into the

Brings up the ink pressure We noticed that the hose of the
ink pump did not have the right
diameter. That implies a lot of
manual inspection if the hose is
transporting ink into the screen.

We checked the print results and
this looked very good.

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Print Head Serial Number Status Recommendation
Easy Fit FA4 16” F724.000001
Easy Fit FA4 16” F718.000001 Wheels are loose

Easy Fit FA4 16” F712.000001
Wheels are loose

Lateral adjust has play


Wheels are tight



Screencassette for MO4 M107.000001 Wheels are a little tight

Screencassette for MO4 M111.000001 Missing knobs (operater side) We were hoping to make one
Bent frame (operator side) useful screen cassette of M111
and M103, however since both
Has new wheels in the frame is bend on the same
Was on the machine (912) side, this idea will not work.
Was on the machine (912)
Screencassette for MO4 M117.000001 Was on machine (909)
Screencassette for MO4 M109.000001 Was on machine (909)
Screencassette for MO4 M112.000001 On machine (910)
Screencassette for MO4 M188.000001
Screencassette for MO4 M194.000001
Screencassette for MO4 M113.000001

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Screencassette for MO4 M103.000001 In shop
We were hoping to make one
Bent frame (operator side) useful screen cassette of M111
and M103, however since on
both cassettes the frame is bend
on the same side, this idea will
not work.

General observation of the print cassettes

All the print cassettes have been kept up and running without a deep cleaning and thorough repair by the internal service and
maintenance department for a couple of years. Replacement of worn wheels is considered as regular maintenance. It is highly
recommended to perform a disassembly and cleaning once a year to keep the print cassettes in good shape, which requires a well
trained specialist on print cassettes.

We suggest two options for the print cassettes:

Option 1
Repair all units only (replacing worn wheels / defective parts) and calibrations. We expect to finish all the MO units (7) and the three
FA units (3) in one week, with some overtime. Based upon status of the print cassettes, this will improve the operation of the
cassettes, however we feel that this option is more of a band-aid, considering the condition of the print cassettes.

Option 2
Full cleaning of each unit -which we really recommend since units have not been cleaned for a considerable time. If you choose for
this option, we would either need a dedicated location at your site (or an off-site) for full disassembly, cleaning and re-assembly.
After re-assembling we would need time on the press to finish calibration. This may take up to 3 to 4 days per print cassette.

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