NWP RotaMesh PP Process En-08-2

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NWP RotaMesh Pre-press process manual
NWP RotaMesh® Pre-press

Process Manual
Version EN 08-3 SPGPrints 1

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Contents
1 INTRODUCTION ........................................................................................................................................ 3
1.1 The system that works ........................................................................................................................ 3
1.2 Process flow for RotaMesh Pre-press system .................................................................................. 4
2 WARNINGS / SAFETY PRECAUTIONS ................................................................................................... 5
3 NECESSITIES ............................................................................................................................................ 6
4 SPGPRINTS RECOMMENDS THE FOLLOWING CHEMICALS ............................................................. 8
5 PRE-PRESS PROCESS GUIDE LINES .................................................................................................... 9

5.1 Prepare for gluing ............................................................................................................................... 9
5.2 Gluing ................................................................................................................................................ 10
5.3 Prepare for coating ........................................................................................................................... 12
5.4 Drying time ........................................................................................................................................ 13
5.5 Coating first layer .............................................................................................................................. 14
5.6 Checking seam of first layer ............................................................................................................. 15
5.6.1 Coating without a bladder ........................................................................................................... 16
5.6.2 Coating with bladder ................................................................................................................... 17
5.7 Storage of coated screens (only for Kiwo emulsion) ........................................................................ 18
5.8 Prepare for exposing ........................................................................................................................ 19
5.9 Mounting film ..................................................................................................................................... 20
5.10 Exposing and developing .................................................................................................................. 21
5.11 Checking image ................................................................................................................................ 22
5.12 Touching up ...................................................................................................................................... 23
6 RE-USING A SCREEN ............................................................................................................................ 24
6.1 Stripping image (only Kiwo emulsion)............................................................................................... 24
6.2 Remove ghost image ........................................................................................................................ 25
7 WASHING AFTER PRINTING ................................................................................................................. 26
8 RE-USE OF ENDRINGS .......................................................................................................................... 27
9 EXPOSURE TIME TABLE FOR KIWO RS AND SCR63 EMULSION .................................................... 28
10 PREPARING THE COATING APPLICATOR FOR GENERAL PRINT APPLICATIONS ...................... 30
11 PREPARING THE COATING APPLICATOR FOR ROTAMESH 75 AND 215 ...................................... 31
12 PROBLEM SOLVING GUIDE .................................................................................................................. 32
13 CONTACT DETAILS SPGPRINTS .......................................................................................................... 36

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1 Introduction
With more than 35 years experience in Rotary Screen Printing, you can count on SPGPrints for
practical instructlons and assistance through our:
 Demonstration centre with full scale RSI printing units and RotaMesh® pre-press systems
 On-site visits to optimise your process logistics and applications
 Hands-on training for printing, pre-press (screen engraving) and maintenance at SPGPrints or
at your company
1.1 The system that works

The simple in-house engraving concept offers your company fast engraving of rotary screens at the
lowest cost.
Now upgraded to handle the full RotaMesh® screen program (print width range: 10"-26") for both
SPGPrints RSI" rotary screen printing units (RSI-RotaMesh program) and non-SPGPrints printing
units (RotaMesh® Retrofit program).
The patented RotaMesh® pre-press system enables your company to use and re-use RotaMesh®
screens for repeat jobs and new print jobs. The unique RotaMesh® screens can be re-engraved up
to15 times. This guarantees a significant reduction of print job costs, especially if compared to the
other "silk screen" technology that can be used only once.
The RotaMesh® pre-press system offers optimal performance as all relevant stages in the
engraving process are machine controlled ensuring accuracy and reproducibility.
The SPGPrints RotaMesh® pre-press system includes the following components (see flow chart on
next page):
 Endring gluing and coating unit

 Drying cabinet
 Exposure unit
 Developer/stripping unit
 Inspection stand/wash-out booth
 Screen and squeegee washer

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1.2 Process flow for RotaMesh Pre-press system
START
ENDRING GLUING/COATING DRYING EXPOSING
RE - USE
DEVELOPER/ DEVELOPER/
STRIPPING UNIT STRIPPING UNIT
RE - PRINT
ROTAMESH SCREENS
INSPECTION STAND/
WASH-OUT BOOTH
SCREEN AND PRINTHEAD

SQUEEGEE WASHER

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2 Warnings / safety precautions
 SPGPrints RotaMesh® material has sharp edges. Handle with care to prevent injuries.
 When working with chemicals, always work according to product specific safety precautions
(see product labels and safety data sheets).
 When working with SPGPrints equipment always work according to safety precautions as
stated in the product manual. Familiarise with these specific product manuals and operation
methods before using SPGPrints equipment.
 SPGPrints only accepts responsibility as stated in SPGPrints equipment manuals.

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3 Necessities
- Gearwheel and screws
- Endring
- RotaMesh® screen
- Endring
- Gearwheel and screws

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- Coating applicator
- Coating adapters
- Bladder
- Airgun
- Balloon
- Support blocks

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4 SPGPrints recommends the following chemicals

Table 1: Chemical products
Product Product name Supplied by Note

1. Degreaser Alcohol Local supplier
2. Glue Araldite 2012 A / 2012 B SPGPrints / 4 minutes potlife

Vantico (Ciba mix both (1 : 1)
Geigy)
Araldite 2010 A / 2010 B SPGPrints / 8 minutes potlife
Vantico (Ciba mix both (1 : 1)
Geigy)
3. Degreasing agent SCR 35 SPGPrints Mix with water (1 : 4)
Immerse 10 minutes
4. Etching agent Ferrric Chloride (FeCl3) Local supplier Meshcount ≤ 215  immerse
4% 4 minutes
5. Emulsion for:
a) UV/ solvent based inks KIWO Azocol Poly-Plus SPGPrints / Strippable
RS Kiwo
b) water based inks SCR 63 / SCR 61 SPGPrints Not strippable (after
polymerisation)
6. Touch up for:
a) UV / solvent based ink resistant Kiwofiller SR 401 SPGPrints / For Azocol Poly-Plus RS
Kiwo Drying time 15 min / 45 C
b) Water based ink resistant SCR 52 S SPGPrints For SCR 63 / SCR 61

Before polymerisation
7. Stripping agent (for emulsion):
a) UV / Solvent based ink resistant Pregasol CF 20 SPGPrints / Immerse 10 minutes
Kiwo
b) Water based ink resisant SCR 33 SPGPrints Only after exposing and
before polymerisation
8. Ghost-image remover Pregan NT-Paste / SPGPrints / Mix 1 : 1
Pregan Combi-Clean Kiwo
9. Screen cleaner SCR 40 SPGPrints Removing dried ink.

(Water based)
10. Glue stripping agent
Fast SCR 30 SPGPrints Process time 2-4 hours
Slow SCR 230 SPGPrints Process time 24-48 hours

(environment friendly)

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5 Pre-press process guide lines
5.1 Prepare for gluing
 Place balloon in screen and inflate.
Fig. 1
 Check endrings for irregularities.
 Degrease shaded parts (fig. 2) of endrings

and Rotamesh screen material with alcohol.
 Prepare glue and apply glue at endrings and

screen edges inside with spatula. (table 1,
no. 2)
Note:
Seamless screens have to be scoured with
sandpaper for better fitting in the endrings.
Fig. 2

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5.2 Gluing
1. Put endrings in the gluing station, zero cam in

front. Turn both clamps in position. (fig. 4)
1
2. Put screen on the bottom endring (fig 3)
 Batch number at the top.
3  For screens with seam, put seam (zero line)
just to the left of the zero cam.
2
1
3. Pull handle and guide the screen onto the
upper endring. Wipe off excessive glue
carefully.
 Without moving, let glue dry.
Note:
- Drying time for 2010 A / 2010 B is 20
minutes.
- Drying time for 2012 A / 2012 B is 15
minutes.
Fig. 3
Fig. 4

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1. Unscrew both clamps.

4 1
2. Pull and turn bottom endring 1 inch forward.
3. Release handle and take screen out

carefully.
4. Take out balloon.

2
Fig. 5
45C / 113F
Put screen into dryer for:
 Drying time for 2010 A / 2010 B is 40

minutes.
 Drying time for 2012 A / 2012 B is 30
minutes.
Fig. 6

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5.3 Prepare for coating
2
1/3
1. Rinse off screen with water.
2. Put the screen into degreasing agent for 10

minutes. (table 1, no 3)
3. Wipe off any loose glue using a sponge.

Rinse down the degreasing agent with water.
4. Dry top endring with cloth.

4
Note: Etching (only for Kiwo emulsion)
If using a new screen with a meshcount ≤ 215,
immerse screen (after step 3) for 4 minutes in
etching liquid. Rinse screen with water and go on
with step 4. (fig. 7)
Fig. 7
45C / 113F
 Put screen into dryer for approx. 30 minutes.
Fig. 8
 Tape both shaded parts of endrings.
Fig. 9

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5.4 Drying time
The drying time of the emulsion layer depends on the mesh size, emulsion layer thickness (EOM),
temperature and relative humidity. Table 2 indicates the drying time per meshcoiunt.
Table 2: Drying time in minutes for Azocol Poly-Plus RS and SCR 63.
Coating layers RM 305 RM 125/215 RM 75

time (min.) time (min.) time (min.)
1 10 15 30
2 to 5 5 5 5
Note:
Drying temperature for Kiwo Azocol Poly-Plus RS is 45 C.
Drying temperature for SCR 63 is 30 C.

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5.5 Coating first layer
1. Put coating adapter in the coating applicator.

5
2. Fill the coating applicator with sufficient
emulsion for 5 layers.
4 3. Put screen into coating adapter.
4. Put another coating adapter on top of screen.
2 3 5. Swing the clamping device above this

construction and clamp it in position.
1
 Wipe off excessive emulsion, on tape, with a
remoisturised sponge.
Fig. 10
Apply first coating layer.

3 1. Move the coating applicator up at a constant
speed of 0.2 m/sec.
2
2. Hold coating applicator in one hand and lift
clamping device with the other hand.
3. Swing clamping device to the other position.

4
1 4. Move the coating applicator (with both hands)
to the other position, holding the coating
adaptor.
Fig. 11

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5.6 Checking seam of first layer
Check emulsion increase near seam of first coat

1
1. If area ≤ 3 mm, put screen into dryer.
 After drying go on to figure 13.
2. If area ＞3 mm, wipe excess of emulsion

carefully off using a wet cloth.
Use bladder to apply next 4 coats.
2  After drying go to figure 14.
Note:
For temperature and drying time see table 2 on
Fig. 12 page 13.

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5.6.1 Coating without a bladder
LE
Applying coating layers 2 to 5 without
3 bladder.
 Take screen out of dryer.

2 Turn screen 180 (upside down).
 Put screen in coating adapter, place other
coating adapter on top, and push clamp
device down.
4 1. Apply coating. Move the coating applicator

repeat 4 times
up at a constant speed of 0.2 m/sec.
1
3. Swing clamp device to other position.

Fig. 13
4. Move the coating applicator (with both
hands) to the other position, holding the
coating adapter.
 Put screen into dryer (see table 2).
Go to figure 16.

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5.6.2 Coating with bladder
4
Applying coating layers 2 to 5 with a bladder.
1. Take screen out of dryer. Turn screen 180

(upside down) and put screen over bladder in
the coating adapter.
3 2
2. Inflate bladder with airgun up to approx. 0.4
bar .The bladder just touches the screen’s
inside.
1 3. Put coating adapter at top of screen.
4. Swing clamping device over construction and

clamp it in position.
Fig. 14
repeat 4 times
1. Move the coating applicator up at constant

3 speed of 0.2 m/sec.
2
3. Swing clamping device to other position.

4
4. Move the coating applicator, with both hands,
1 to the other position, holding the coating
adaptor
 Deflate bladder carefully.

 Take screen out and place it in the dryer.
(table 2, page 13)
Fig. 15  Place bladder on other position (in the
coating adapter).

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5.7 Storage of coated screens (only for Kiwo emulsion)
After coating, a screen can be stored or exposed.

storage
 A coated and dried screen can be stored in a
dry and dark area at a temperature of approx.
15-20C. Storage time of a pre-coated screen
is approx. 4 weeks.
 Before exposure, place the stored screen into

the dryer (45C / 110F) for 3 minutes.
Fig. 16

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5.8 Prepare for exposing
 Put screen over bladder.
 Inflate bladder up to 0.25-0.4 bar. There

should be a tight surface contact between the
screen and the bladder.
Fig. 17
 Switch on exposure unit (warming-up takes 5

minutes) and pull screen table to operator.
 Put screen on screen table, batch number on

the left side.
 Check emulsion layer for irregularities.
Fig. 18

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5.9 Mounting film
1. Put a mark in the centre of the seam.

1 4
 If emulsion surface is tacky, apply talcum
2 powder.
3 2. Mount film positive, emulsion side film
towards emulsion side screen, on the screen.
Put the centreline (of film) on the centre mark
(of seam). Line the crossmarks of the film up
with the seam (zero line).
Fig. 19 Fix film positive on screen using Scotch tape.
3. The arrow showing the print direction on the

film should point towards the operator.
4. Allow the screen to rotate one cycle.

(For direction see arrow no. 4)
 Hold film with hand and remove tape

carefully.
1. Place film ends over each other. Line up
centrelines on film. Fix ithe film using Scotch
tape (not too tight; the film still can be
moved).
2 1 2
2. Place bottom marks of film exactly on seam,
3 3 (centreline on mark in centre). Remove tape
and replace it with a tighter one.
3. Fix the film using clear tape. Start taping in

Fig. 20
centre. Place marks exactly over each other
by loosening or tightening the tape. Once the
film has been fixed, increase pressure by
another 0.1 bar.
 If the film is too long, during mounting,

increase air pressure up to 0.5 bar. If film is
still too long, make a new film. If fim is too
short, make a new film as well.
Note: Excessive air pressure ( 0.6 bar) may

damage the screen and may cause severe
injuries.

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5.10 Exposing and developing
 Push screen table backward.
 Enter the correct exposure time (units). See

exposure time table in Section 8.
 Close cover. Exposure unit starts

automatically.
 After exposing remove film positive.
Fig. 21  Take bladder out with care.
1. Place exposed screen into the

1
developing/stripping unit.
Press the developing button.
2. Take screen out after 1 developing cycle.
Fig. 22

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5.11 Checking image
 Put screen onto the inspection stand.
 Turn light switch on.
 Check if emulsion is washed out properly and

correct carefully with spray gun.
Fig. 23
 Rinse off screen with water.
 Dry top endring with cloth.
Fig. 24
For Kiwo emulsion:

 Put screen into dryer at 45C / 113F for 30
minutes.
For SCR 63 emulsion:

 Put screen into dryer at 30C / 86F for 30
minutes.
 Polymerise the emulsion required at a

temperature of 180C / 356F for 2 hours.
Fig. 25

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5.12 Touching up
 If necessary touch up the image. (see table 1,

no 6)
 Put screen into dryer.
Fig. 26
 After drying, screen is ready for printing.
 If the screen is not used immediately, store it

into a dry and clean environment.
Fig. 27

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6 Re-using a screen
6.1 Stripping image (only Kiwo emulsion)
 When a new image on the screen is required,

the screen can be reclaimed to re-use the
mesh.
 Be sure that the screen is completely clean.
 Immerse screen in stripping agent. (see table

1, no. 7)
 After 10 minutes take the screen out.
Note:
Do not allow the stripping agent to dry on the
stencil. Stripping will not be possible anymore.
Fig. 28
1 1. Put (still wet) screen in developing/stripping

unit.
Press the stripping button.
2. Take screen out after stripping one cycle.

 If a ghost-image appears, remove it using the
ghost-image remover
Fig. 29

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6.2 Remove ghost image
 Apply ghost-image remover using a brush.

(see table 1, no 8)
 Do not touch glue and endring with the ghost-

image remover. Keep screen horizontally.
 After at least 10 minutes, ghost image

remover can be removed with developing/
stripping unit.
Fig. 30
1. Put screen into developing/stripping unit.

 Press stripping button.
2. Take screen out after 1 stripping cycle.

 Check screen on the inspection stand if all
emulsion / ghost-image is washed out.
If not: leave ghost image remover prolonged

on the screen.
Fig. 31
 Rinse off screen with water.
 Dry top endring.
Fig. 32
 Put screen into dryer for 30 minutes.
 Screen is ready for a new coating (go to

figure 9),
or the screen can be stored in a dry and
clean cabinet.
Fig. 33
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7 Washing after printing
 After printing allow the ink to drip out of the RotaMesh screen.
If possible use a rubber spatula to pre-clean the screen..
Washing machine
o Wash the RotaMesh screen using the washing machine during one cycle of 5 minutes in
the washing machine using appropriate washing agent (Dowanol pma, Flexowash or
SPGPrints’s SCR902)
o Rotate the RotaMesh screen and wash again during one cycle of 5 minutes.
Next wash the screen in a container by rinsing the surfacet with isopropanol (IPA) to remove the
aggressive cleaning agent from both the RotaMesh’s surface and the endring glue.
Alternatively use 3 containers
1. Pre-washing (removing most ink)
2. Washing (cleaning)
Wash the RotaMesh screen in a tank using a soft brush and a suitable cleaning agent,
such as Dowanol pma, Flexowash or SPGPrints’s SCR902.
3. Final rinsing using isopropanol
Next rinse the screen’s surface by using isopropanol (IPA) to remove the aggressive cleaning
agent from both the RotaMesh’s surface and the endring glue.
Exposing a RotaMesh screen longer than 20 mins to washing agent will dissolve the
endring glue and attack the emulsion. The adhesion between screen and endring will
deteriorate.
 Finally, clean both inside and outside of the screen and the endrings with a lint free cloth. In
particular dry the connection between the inside of the endrings and the RotaMesh screen to
prevent chemical attack of the endring glue by the cleaning agent.
 After inspection the cleaned RotaMesh screen can be stored or reclaimed.
Remarks
 Refresh the cleaning agents regularly
 Never touch the emulsion on the RotaMesh screen with water

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8 Re-use of endrings
Provided that the screen is worn out or damaged

and is not acceptable anymore, it can be cut out
1
to reclaim both endrings.
1. Remove gearwheels from endrings.
Fig. 34 2. Separate screen material and endrings, using

a knife or a pair of scissors.
 For safety reasons, keep the glued parts of
the screen material on the endring.
3. Immerse the endrings in the endring glue-

stripping agent. (see table 1, no. 10)
Keep the container closed..
3
 Once the glue has softened, take the screen

material off and remove the remaining glue.
 Endrings are ready to be re-used (figure 2).
Fig. 35

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9 Exposure time table for Kiwo RS and SCR63

emulsion
EXPOSURE TIME TABLE FOR KIWO AZOCOL POLYPLUS RS
IF IMAGE : DETAILED APPLY EXPOSURE : -10%

AVERAGE
COARSE +10%
Repeat size RM 405 RM 305 RM RM RM RM 75/40%

in inch TACTILE
215/125 75/32% 75/40%
EXPOSURE TIME EXPOSURE TIME EXPOSURE TIME EXPOSURE TIME EXPOSURE TIME EXPOSURE TIME
(UNITS) (UNITS) (UNITS) (UNITS) (UNITS) (UNITS)
12 385 450 585 945 1015 4500

12 4/8 400 470 610 985 1055 4690
13 415 490 630 1025 1100 4875
13 4/8 430 505 655 1065 1140 5065
14 445 525 680 1105 1180 5250
14 4/8 465 545 705 1145 1225 5440
15 480 565 730 1185 1265 5625
15 4/8 495 580 755 1225 1310 5815
16 510 600 780 1260 1350 6000
16 4/8 525 620 800 1300 1395 6190
17 545 640 825 1340 1435 6375
17 4/8 560 655 850 1380 1480 6565
18 575 675 875 1420 1520 6750
18 4/8 590 695 900 1460 1560 6940
19 605 715 925 1500 1605 7125
19 4/8 625 730 950 1540 1645 7315
20 640 750 970 1580 1690 7500
20 4/8 655 770 995 1615 1730 7690
21 670 790 1020 1655 1775 7875
21 4/8 685 805 1045 1695 1815 8065
22 705 825 1070 1735 1860 8250
22 4/8 720 845 1095 1775 1900 8440
23 735 865 1120 1815 1940 8625
23 4/8 750 880 1140 1855 1985 8815
24 765 900 1165 1895 2025 9000
24 4/8 785 920 1190 1935 2070 9190
25 800 940 1215 1970 2110 9375
25 4/8 815 955 1240 2010 2155 9565
26 830 975 1265 2050 2195 9750
26 4/8 845 995 1290 2090 2240 9940
27 865 1015 1315 2130 2280 10125
27 4/8 880 1030 1335 2170 2320 10315
28 895 1050 1360 2210 2365 10500
28 4/8 910 1070 1385 2250 2405 10690
29 925 1090 1410 2290 2450 10875
29 4/8 940 1105 1435 2325 2490 11065
30 960 1125 1460 2365 2535 11250
30 4/8 975 1145 1485 2405 2575 11440
31 990 1165 1505 2445 2620 11625
31 4/8 1005 1180 1530 2485 2660 11815
32 1020 1200 1555 2525 2700 12000
32 4/8 1040 1220 1580 2565 2745 12190
33 1055 1240 1605 2605 2785 12375
33 4/8 1070 1255 1630 2645 2830 12565
34 1085 1275 1655 2680 2870 12750
34 4/8 1100 1295 1675 2720 2915 12940
35 1120 1315 1700 2760 2955 13125
35 4/8 1135 1330 1725 2800 3000 13315
36 1150 1350 1750 2840 3040 13500

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EXPOSURE TIME TABLE FOR SCR 63
IF REPEAT SIZE IS BETWEEN TWO SUCCESSIVE SIZES,

USE NEAREST TIME TO DETERMINE EXPOSURE TIME
Repeat size RM 405 RM 305 RM 215/125 RM 75/32% RM 75/40%

in inch TACTILE
EXPOSURE TIME EXPOSURE TIME EXPOSURE TIME EXPOSURE TIME EXPOSURE TIME
(UNITS) (UNITS) (UNITS) (UNITS) (UNITS)
12 285 335 435 710 760

12 4/8 300 350 455 740 790
13 310 365 475 770 825
13 4/8 325 380 490 800 855
14 335 395 510 830 885
14 4/8 345 405 530 860 920
15 360 420 545 890 950
15 4/8 370 435 565 915 980
16 380 450 580 945 1015
16 4/8 395 465 600 975 1045
17 405 475 620 1005 1075
17 4/8 420 490 635 1035 1110
18 430 505 655 1065 1140
18 4/8 440 520 675 1095 1170
19 455 535 690 1125 1205
19 4/8 465 545 710 1155 1235
20 480 560 730 1185 1265
20 4/8 490 575 745 1215 1300
21 500 590 765 1245 1330
21 4/8 515 605 780 1270 1360
22 525 615 800 1300 1395
22 4/8 540 630 820 1330 1425
23 550 645 835 1360 1455
23 4/8 560 660 855 1390 1490
24 575 675 875 1420 1520
24 4/8 585 685 890 1450 1550
25 595 700 910 1480 1585
25 4/8 610 715 930 1510 1615
26 620 730 945 1540 1645
26 4/8 635 745 965 1570 1680
27 645 760 985 1600 1710
27 4/8 655 770 1000 1625 1740
28 670 785 1020 1655 1775
28 4/8 680 800 1035 1685 1805
29 695 815 1055 1715 1835
29 4/8 705 830 1075 1745 1870
30 715 840 1090 1775 1900
30 4/8 730 855 1110 1805 1930
31 740 870 1130 1835 1965
31 4/8 755 885 1145 1865 1995
32 765 900 1165 1895 2025
32 4/8 775 910 1185 1925 2060
33 790 925 1200 1955 2090
33 4/8 800 940 1220 1980 2120
34 810 955 1235 2010 2155
34 4/8 825 970 1255 2040 2185
35 835 980 1275 2070 2215
35 4/8 850 995 1290 2100 2250
36 860 1010 1310 2130 2280

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10 Preparing the coating applicator for general print

applications
Before one can use a new coating applicator he has to check the form and surface of the applicator edges.
Both edges should be smooth and just very little rounded (R=0.2). The form of the edge is important. A
sharp edge gives thinner layers, a more rounded edge will apply thicker layers.
Preparing:
Move your fingers over the edge surface to feel any irregulations. When needed use very wet sandpaper to
change the form and smoothness. Start with a 600 grit, and finish with 1200 grit.
Sand as less as possible; use no force.
Edges
Sandpaper waterproof 600 and 1200. Use water.

For flat sanding use the 600 grit, to make the edges
round (very little) use 1200 grit.
Bend the sandpaper

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11 Preparing the coating applicator for RotaMesh 75 and

215
Before one can use a new coating applicator he has to check the form and surface of the applicator edges.
Both edges should be sharp. The form of the edge is important for the dip coating process.
Use waterproof sandpaper grit 600 and 1200. Keep the sandpaper wet.
A VITON applicator can be recognized by a gap at the outside of the rubber coating ring.
This coating applicator can also be used for 215 and 75 mesh manual coating.
A sharp edge gives thinner layers, a more rounded edge will apply thicker layers.
Sharp edges
Wrong
Do not make lateral movements, turn the
pipe, while you move it over the rubber.
See picture below.
First wrap pipe with sandpaper grit 600, than use grit 1200 to finish. In
this way you can make the edges sharp. Sand as less as possible, use
no force.

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12 Problem solving guide
Problem Cause Solution
Mounting endrings
Crease in screen Endrings not parallel Mount endrings properly
Calibrate endring glue equipment

Screen handling Handle screen with care
Degreasing / drying
Water spots / streaks Insufficiently dried endrings Carefully dry endring’s in- and outside
after degreasing
Coating
Too much emulsion Coating applicator not horizontal Keep applicator horizontal
alongside of seam Inconsistent coating speed Apply emulsion at 30 cm/min
Viscosity too high Decrease viscosity
Assembly not perfectly cylindrical Wipe off excess of emulsion, insert
bladder and continue coating
Poor emulsion distribution Coating applicator not horizontal Keep applicator horizontal
Inconsistent coating speed Apply emulsion at 30 cm/min
Insufficient emulsion in coating applicator. Take corrective action
Streaks // coat direction Coating rubber worn-out/damaged. Replace coating rubber

Dried emulsion on coating rubber/adapter ring. Clean coating rubber /
adapter ring
Viscosity too high Decrease viscosity
Development
Poor was-out Emulsion aged Take fresh emulsion.

(Potlife 12 weeks)
Emulsion prematurely polymerized by
excessive heat. Dry temperature max. 45°C
prolonged drying Corrective action
unwanted light Corective action
Insufficient density black area film positive. Corrective action

®
Pinholes Improperly degreased

Diazo –powder not dissolved
Air bubbles introduced during stirring
Coating too fast Touch-up pinholes using screen
filler and dry
Insufficient EOM Corrective action and prepare
new screen
Cleanliness screen making room
Exposing insufficiently dried emulsion
Under exposure
Insufficient adhesion Poorly degreased Corrective action

Insufficient EOM
Exposing insufficiently dried emulsion Dry emulsion thoroughly
Under exposure Apply correct exposure time
Poor film positive (clear area D≤ 0,05). Use correct film positive
Emulsion aged Use fresh emulsion
Fine details filling in Film positive turned Corrective action

Poor contact film positive – emulsion Mount according to manual
Insufficient density film positive Density black area ≥ 3,5
Over exposure Reduce exposure time
Details too fine for mesh count Use finer mesh count
Aged emulsion Use fresh emulsion
Pre-coated screen stored prolonged Use new screen
Printing
Endrings separate from mesh Inferior adhesive Use recommended adhesive

Endring and mesh not properly degreased. Corrective action
Adhesive soft after washing prolonged
Adhesive soft by washing agent Apply washing guideline
After washing not rinsed with IPA
Too small gap Corrective action
Damaged seam screen Excessive squeegee pressure Reduce squeegee pressure

Too many support blades Reduce number of support blades
Too big gap Reduce gap
Squeegee blade / support blade not parallel. Remount squeegee blade /
support blade
Poor registration Incorrect length film positive / step-out Corrective action

Incorrect thickness film positive Corrective action
Excessive ambient temperature/humidity. 21°C and 50%
Film positive stretched during mounting procedure. Mount correctly
Incorrect film mounting procedure Mount correctly
Endrings not parallel Calibrate endring glue
equipment

®
Premature stencil breakdown Underexposed stencil Increase exposure time

Insufficient EOM Increase EOM
Solvent / washing agent attack Use recommended solvent / washing
agents
Emulsion - ink compatibility Ccompatible emulsion – ink
combination
Abrasive ink
Ink density inconsistent in print Squeegee blade damaged/wear & tear. Use new squeegee blade
direction Ink tailing from squeegee Decrease ink level in screen
Ink starvation at tailing edge Air bubbles encapsulated due to

EOM too thick Decrease EOM
Print speed too high Decrease print speed
Ink viscosity too high Decrease ink viscosity
Ink starvation at selective part Clogging mesh due to

of image ink drying in Use a coarser mesh
ambient temperature too high Decrease ambient temperature
ink viscosity too high Thin down ink
Mottling solids / Insufficient ink transfer Use corrrect mesh

low ink density Ink not opaque Increase pigmentation
Ink not mixed well Mix ink well
Insufficient squeegee pressure Increase squeegee pressure
Poor stock Take corrective action
Shoulder around image EOM too thick Decrease EOM

Wrong mesh Use correct mesh
Sawtooth EOM too thin Increase EOM

Mesh too coarse Use finer mesh
Image with bulges Rz-value stencil too high Improve Rz- value
Ink viscosity too low Increase ink viscosity
Poor image definition Improper exposure Apply work instructions

Excessive spray during wash-out
Squeegee pressure too low Increase squeegee pressure
Mesh too coarse Use finer mesh
Film positive turned Corrective action
Randomly feathering ink Substrate electrostatically charged Ground usin spring-likewires

due to: ground press as well
Relative humidity too low Increase rel. humidity (> approx 50%)
Production speed too high Reduce speed
Mesh marks Ink viscosity too high Reduce ink viscosity

®
Too small gap Increase gap
Poor over printability First ink layer too thick Use correct mesh
Over cured Reduce curing conditions
st
1 ink layer too many silicones Use silicone-free ink
nd
2 ink layer too thin Use correct mesh
Line / dot gain Stencil deposits too much ink Decrease EOM and/or select other
mesh
Squeegee pressure too high Decrease squeegee pressure
Pinholes in solid area ink Insufficient ink flow Thin down ink / add flow agent
Increase squeegee pressure
Surface tension substrate too low Switch on Corona
Dust / static electricity Cleanliness
Ink density mismatch Different meshes used Use same meshes

Different ink densities Use same ink density
Moiré - film-to-film Interaction between halftone angles. Ccorrective action

- film-to-mesh screen ruling and mesh count Corrective action
- screen-to-substrate substrate texture, mesh and halftone image Corrective action
Poor adhesion Contaminated substrate Clean or replace substrate

Surface tension substrate too low Switch on Corona
Poorly cured too thick ink deposit Reduce ink deposit
Double edged images Gap too small Increase gap

Print speed too fast Decrease print speed
Ink deposit too thick Reduce ink depsit
Reclaiming
Poor reclaimability Stencil under exposed Expose properly

Stencil surface covered with ink Remove ink from stencil surface
Stripping agent contaminated Use fresh stripping agent
dries on stencil Use new mesh
unsuitable Use proper stripping agent

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13 Contact details SPGPrints

®
The facts published herein are correct at the time of publishing and are subject to
future modifications. SPGPrints reserves the right to modify the construction and the
execution of their products at any time without any obligation on their part to modify
any equipment delivered before accordingly.

NWP RotaMesh PP Process En-08-2

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NWP RotaMesh Pre-press process manual

NWP RotaMesh® Pre-press

Version EN 08-3 SPGPrints 1

4 SPGPRINTS RECOMMENDS THE FOLLOWING CHEMICALS ............................................................. 8

5 PRE-PRESS PROCESS GUIDE LINES .................................................................................................... 9

8 RE-USE OF ENDRINGS .......................................................................................................................... 27

9 EXPOSURE TIME TABLE FOR KIWO RS AND SCR63 EMULSION .................................................... 28

10 PREPARING THE COATING APPLICATOR FOR GENERAL PRINT APPLICATIONS ...................... 30

11 PREPARING THE COATING APPLICATOR FOR ROTAMESH 75 AND 215 ...................................... 31

12 PROBLEM SOLVING GUIDE .................................................................................................................. 32

13 CONTACT DETAILS SPGPRINTS .......................................................................................................... 36

Version EN 08-3 SPGPrints 2

1.1 The system that works

 Endring gluing and coating unit

Version EN 08-3 SPGPrints 3

1.2 Process flow for RotaMesh Pre-press system

ENDRING GLUING/COATING DRYING EXPOSING

SCREEN AND PRINTHEAD

Version EN 08-3 SPGPrints 4

2 Warnings / safety precautions

 SPGPrints only accepts responsibility as stated in SPGPrints equipment manuals.

Version EN 08-3 SPGPrints 5

- Gearwheel and screws

- Gearwheel and screws

Version EN 08-3 SPGPrints 6

Version EN 08-3 SPGPrints 7

4 SPGPrints recommends the following chemicals

Product Product name Supplied by Note

2. Glue Araldite 2012 A / 2012 B SPGPrints / 4 minutes potlife

b) Water based ink resistant SCR 52 S SPGPrints For SCR 63 / SCR 61

9. Screen cleaner SCR 40 SPGPrints Removing dried ink.

Slow SCR 230 SPGPrints Process time 24-48 hours

Version EN 08-3 SPGPrints 8

5 Pre-press process guide lines

5.1 Prepare for gluing

 Place balloon in screen and inflate.

 Check endrings for irregularities.

 Degrease shaded parts (fig. 2) of endrings

 Prepare glue and apply glue at endrings and

Version EN 08-3 SPGPrints 9

1. Put endrings in the gluing station, zero cam in

Version EN 08-3 SPGPrints 10

1. Unscrew both clamps.

3. Release handle and take screen out

4. Take out balloon.

Put screen into dryer for:

 Drying time for 2010 A / 2010 B is 40

Version EN 08-3 SPGPrints 11

5.3 Prepare for coating

2. Put the screen into degreasing agent for 10

3. Wipe off any loose glue using a sponge.

4. Dry top endring with cloth.

 Put screen into dryer for approx. 30 minutes.

 Tape both shaded parts of endrings.

Version EN 08-3 SPGPrints 12

5.4 Drying time

Coating layers RM 305 RM 125/215 RM 75

Version EN 08-3 SPGPrints 13