1

Inks and varnishes are one of the few key raw materials used by the printer; they play a
crucial role in the printing process.

Inks
You may think that ink is just ink
and that its the plates, press
and skill of the printer that
make all the difference when it
comes to print quality. Not so!
The properties of ink including
colour, the strength of that
colour,
tack,
drying
characteristics and the length
of the filaments that it forms
when it flows, have a big
influence on the final result.

Back-to-basics. Part 7. Inks & varnishes

2
Ink is comprised of 4 basic raw materials that are combined in specific proportions or
formulas. These components serve different purposes.

Pigment the particles or substances that give printing inks their colour. They exist as
an insoluble suspension and absorb and reflect light, giving the appearance of colour
to the human eye.

Resins bind the ink together into a film and also bind it to the printed surface. They
contribute to such properties as gloss and resistance to heat, chemicals and water.

Solvents are used to keep the ink liquid from when it is applied to the printing plate
or cylinder until when it has been transferred to the surface to be printed. At this point
the solvent must separate from the body of the ink to allow the image to dry and bind
to the surface.

Additives - alter the physical properties of the ink to suit different situations.
Back-to-basics. Part 7. Inks & varnishes

3
Printing ink can be broken down into two subclasses: ink for conventional printing and ink
for digital printing.

Conventional printing
Modern printing processes require specific types of ink for specific jobs. There are three
main types:
1. Water-based
2. Solvent
3. UV curable

1. Water-based inks
In water-based inks, the water acts as the main solvent to keep the pigment in liquid form.
A co-solvent may be added for a number of reasons, most commonly, to decrease the
time and heat necessary for curing. For the print to be cured, the water has to have
completely evaporated, allowing the pigment particles to settle into the substrate.

Water-based inks have been used for printing on paper and paperboard for many years.
Printing on these substrates with water is very successful because of the absorbent nature
of the paper fibres. The inks and solvents (water included) are partially absorbed into the
substrate, and partially vaporized into the surrounding air. The use of water inks on other
substrates, such as films and foils, varies and they may require special treatment in order to
have the inks adhere to them.
Advantages of water-based inks:
+

Better for the environment no solvents used in the ink formulation or in press/plate
wash down

Thinner printed layer

More breathable

Inks becomes part of the substrate instead of sitting on top

Back-to-basics. Part 7. Inks & varnishes

4
Disadvantages of water-based inks:
-

Not as vibrant

More time-consuming to work with

Difficult to use - can dry in screens and clog them

More expensive

Less hard wearing and durable

Not resistant to extreme environmental conditions

Less effective on synthetic substrates

Ink manufacturers are working hard to overcome some of these problems and have made
great steps forward in recent years. Due to the number of different machines and materials
however, trials are always recommended to ensure full compatibility before production
commences. The use of water-based inks, which had been declining, is now seeing an
increase in popularity, especially on the Continent. They are being used as a possible
alternative to UV curable inks, where migration can be a problem in food labelling.

2. Solvent inks
A solvent ink is any kind of ink that has a base, but the base is not made with water. There
are many classifications for this type of ink; some are classified as mild or eco-friendly, while
some are categorized as aggressive. Solvent inks require heat in order to dry. The mild inks
take some time to dry and need a lot of heat, whilst the aggressive types are easier to dry
and require less heat.

Solvent inks are toxic and require special handling and ventilation in compliance with
specific regulations relating to the release of Volatile Organic Compounds (VOCs). Their
greatest application is in the printing of products that are to be used outdoors because of
resilience and ability to adhere strongly to non-absorbent materials

Advantages of solvent inks:

+

Fade proof, water proof and scratch resistant

Back-to-basics. Part 7. Inks & varnishes

5
+
+
+
+
+
+
+
+

Available in a wide number of formulations

Can reproduce brilliant colours on an extensive range of flexible and uncoated
media (paper, vinyl, PVC, banners, etc)
Outstanding adhesion
Cost effective
Good opacity
Will not clog screens as it won't dry until cured (requiring 350-degree heat)
Easier to use than water-based inks
Faster curing than water-based inks

Disadvantages of solvent inks;

-

Environmental and health and safety issues to be considered

Less breathable

Solvent flexo inks are used primarily in the flexible packaging industry. Solvent gravure inks
are used to achieve the very highest quality of metallic printing as seen in the beverage
market.
Bio solvent or eco solvent inks are being developed for use in more enclosed print settings
with minimum ventilation. These environmentally friendly inks are made from renewable
resources, namely corn and soybean. They show a high durability to UV light and good
adhesion to vinyl, PVC, and other uncoated substrates. Watch this space!

3. UV curable inks
UV inks are cured with a high-intensity UV light
from either UV lamps or LEDs. The UV radiation acts
as a catalyst and initiates a photochemical
reaction where by cross links are formed, instantly
turning the liquid ink into a dry and durable
coating. This curing process is vital for good print
quality. If insufficient UV radiation is used, the
bonds are weak and ink adhesion poor. If the ink is
over-cured it becomes brittle and shrinks.

UV curable inks are mainly used for indoor

applications, such as shrink sleeves, packaging,
posters, signage and POP displays. They are ideal
for all label applications.

Back-to-basics. Part 7. Inks & varnishes

6
Advantages of UV curable inks:
+
+
+
+
+
+
+

Fast curing therefore increased printing speeds and reduced energy consumption
Versatile across a range of flexible and rigid substrates
Low viscosity of ink + absence of penetration less ink usage
Less environmental impact than solvent based inks
Unintentional curing/drying avoided
Minimal dot gain and ink penetration
Good for sharp lines and edges

Disadvantages of UV curable inks;

-

Uncured UV inks can be irritating to eyes and skin

UV inks stay wet until cured so must be
thoroughly washed off skin and clothing
UV migration issues with food contact
packaging. There are global standards for
migration which must be complied with for
certain types of food packaging. Specialised,
low migration inks are available.

UV curable ink technology is on the move. Developers have made heavy investments into
its development and continue to come out with new inks and substrates optimised for UVcuring. Look out for more advances in the near future.

Digital printing (HP Indigo)

The ink or toner that is used in a digital press is fundamentally
different to that used in conventional machines; its chemistry is
far more complex and it comes in a sealed canister not a pot! In
the digital world the ink represents a key part of the technology
and must be compatible with all elements of the press.
The ink or toner consists of small colour powder particles,
suspended in imaging oil. During the printing process, the toner is
electrostatically charged to adhere to the printer drum which is
charged with opposite polarity. After transferring to the paper,
the toner is fused in place by a heating element forming a very thin and smooth plastic
layer on the surface.

Back-to-basics. Part 7. Inks & varnishes

7
Toner formulations, particle size and melting point vary from manufacturer to manufacturer.
A great deal of research has gone into trying to achieve small, uniform particle size, key to
achieving accurate colour reproduction and print quality.

Varnishes
A varnish is a transparent, liquid coating applied to a printed surface to add a clear glossy,
matte, satin, or neutral finish.
Varnishing can be carried out online (the varnish is applied directly after the ink is put on
the paper), or offline by a separate machine, sometime after printing. The liquid varnish
hardens after application by a variety of processes depending on its formulation.
Adding varnish to print has several advantages;
+
+
+

Can reduce or accentuate particular areas on the printed page

Increases colour absorption and speeds up the drying process
The ink is locked in under a protective coat increased durability

There are a number of varnishes available. Here are the major types.
Gloss varnish
A gloss varnish is often used to heighten the impact of
photographs or particular design elements, as the
coating reflects back the light and makes colours
appear richer and more vivid. A gloss coating can add
impact to your print, especially in sales or promotional
material, where optimum presentation of images is
paramount.
The percentage of gloss can actually be measured in
accordance with DIN 67530 which is based on the reflection
of light corresponding to specific angles.

Matt varnish
A matt varnish diffuses the reflection of light to give the
printed surface a non-glossy, smooth look. This type of
varnish can soften the appearance of a printed image.
Small text on a label is easier to read on a surface coated with matt vanish as the coating
scatters the light, reducing glare.
Silk/Satin varnish
This represents the middle ground between the two above, being neither as glossy as a
true gloss, nor as subtle as a matt.

Back-to-basics. Part 7. Inks & varnishes

8
Flood varnish
This is when a varnish is applied all over the printed surface. A gloss varnish seal is the most
common type of all-over varnish, (perhaps because this finish really does give a very high
gloss effect, more so than with a laminate in many cases) although silk and matt are also
available.
Spot varnish
A spot varnish is applied to a chosen spot or area on the printed piece. This has the effect
of drawing attention to a specific part of the design and can add interest to the label. It is
particularly effective when applied as a gloss spot varnish on top of a matt flood varnish.
This achieves maximum contrast between the highly reflective shiny coating and the lightabsorbing matt finish.
Textured/Tactile varnish
Textured varnish is a glossy varnish that overlays a slightly
rippled, tactile finish to the page. It can be used as a spot
varnish to enhance the impact of particular page elements
and is an interesting and eye-catching alternative to
standard gloss varnishes. Tactile varnish can be applied as
braille using silkscreen technology.
Other varnishes
There are other more creative varnishes on the market today. Sparkly varnishes include
metallic flakes to catch the eye. Tinted varnishes add gloss and colour. Scratch-and-sniff
technology takes a fragrance and encapsulates it in minute gelatin or plastic spheres
which are then incorporated into a varnish the number of fragrances available is
impressive!

AJS Labels inks and varnishes

We spend a lot of time trialling and developing the best ink technology for AJS and our
customers;
UV flexo inks for vibrant top quality print
In-house ink mixing technology
Working with top ink and varnish suppliers on the very latest formulations
Skilled and experienced printers
Please get in touch on 01903 738 205 if you would like to discuss any of this blog with our
technical team.

Back-to-basics. Part 7. Inks & varnishes

What is next?
Next time we take a whistle-stop tour of the main label printing processes.

Source:
1.
2.
3.
4.
5.

http://www.chimigraf.com/productos.php?&idioma=eng&id=4&gr=p&res=4&cat=f
http://www.flexoexchange.com/gorilla/uvink1.html
http://www.outputmagazine.com/tags/qotw/
http://www.packprintworld.com/news/features/uv-flexo-for-food-packaging
http://www.flintgrp.com/en/products/Packaging-and-Narrowweb/Narrowweb/NorthAmerica/Flexography/index.php
6. http://72.52.184.8/~radtecho/pdfs/PrinterGuideUVNWFlexo.pdf
7. http://www.webmartuk.com/print_brain/misc/what-do-print-finishing-companies-do-a-guide-to-varnishes-fordesigners-and-marketers/
8. http://www.digitaloutput.net/content/ContentCT.asp?P=542
9. http://nzic.org.nz/ChemProcesses/polymers/10E.pdf
10. http://www.fespa.com/news/industry-news/do-you-know-your-water-based-inks-from-your-uv-inks.html LATEX INKS
11. http://printerinkcartridges.printcountry.com/printcountry-articles/wide-format-printers/a-beginners-guide-to-solventinks-for-large-format-printing
12. http://www.packaging-gateway.com/contractor_images/zellergmelin/1.jpg
13. http://www.imaging.org/ist/resources/tutorials/inkjet.cfm
14. http://www.globalspec.com/learnmore/optics_optical_components/light_sources/process_uv_lamps_systems

Back-to-basics. Part 7. Inks & varnishes