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The Power of Print in Laminated Card Manufacturing

ICMA EuroForum 2014 - 9th / 10th

October

Robin McMillan & John Schneiderhan

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Overview

Current print processes and related inks

Introduction to UV curing process

Features, benefits and impact of UV curing technology

Hidden magnetic stripe cards

Added value security features

Divider pagePrinting Ink Developments

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Major advances have been made in UV ink technology through a greater understanding of the basic chemistry and the processes involved

Wider adoption of UV curing ink technology across a growing number of industries

Introduction and Scope

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Inks and associated products used in card production

Screen printing inks– Solid colours )– Metallic shades )– Pearlescent / iridescent effects ) Usually solvent based technology– Transparent shades )– Security effects )

Offset printing inks– Spot colour )– CMYK process inks ) Usually UV curing technology– Security effects )

Digital printing inks– Thermal ) Depends on print technology– Ink Jet ) of the printer

Adhesives– Screen printing ) Usually water based technology– Roller coating )

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Typical Formulation– Pigment– Resin– Solvent– Additives

Surface active agents Plasticisers

Dries by simple evaporation of solvent– Can be in air or forced– Causes printed film to shrink significantly

Release of solvent from wet inkRelease of solvent from wet ink

Evaporation

Solvent Based, Conventional Drying Inks

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An introduction to UV curing

The Electromagnetic Spectrum

Radiation is often used to cure coatings:Microwave, Ultraviolet (UV), Infra-red, Electron Beam (EB)

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UV Curing – Polymerisation, not drying

E.G. Polymerisation of a multifunctional acrylate species

Polymerisation reactionLiquid to solidAlmost instantaneousNo loss of massOther reaction methods exist

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UV curing Inks

Typical Formulation– Pigment Similar to solvent based inks

– Prepolymer In place of resin Inert resins can also be included

– Monomer Usually the solvent of the formulation

– Photoinitiator Additional component to initiate cure

– Additives Surface active agents Plasticisers As solvent based inks

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Printed film properties of UV inks

Wet printed ink film

Cured ink film

UV radiationNo change in massMinimal shrinkageFully dry and resistant film

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Factors Affecting UV Cure

Inte

rrel

ated

UV cure is however effected by a number of factors….

– UV Lamp choice Spectral output UV dose Reflector

– Ink Composition Photoinitiator selection Functionality of system Pigmentation

– Coating Properties Film thickness Substrate

– Oxygen Inhibition

Inte

rrel

ated However, cure

properties are more easily measured and thus controlled, but are more numerous

Divider pageLaminated Card Production

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UV curing inks – Features

Main Features:

– No volatile solvents

– Instant curing

– Little or no shrinkage

– Improved and wider adhesion range

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UV curing screen inks – Impact

– Improved efficiency Less press downtime Lower costs Higher ink mileage Faster print speeds Lower consumable use Reduced space requirement

– Improved quality Higher quality print Colour consistency Superior adhesion Peace of mind

– New opportunities New substrates Greater design freedom

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UV curing screen inks – Impact

– Customer satisfaction Higher quality images Improved colour consistency Greater security Increased print robustness

– Improved competitiveness Reduced costs Increased service capability

– Greener products Reduced VOC Lower energy consumption Less waste generation

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Printing Ink Development SummaryAdvantage Feature How / Why

Reduced Costs Higher ink mileage Lower ink useageLower energy requirement UV driers are cheaper to runTime savings Increased press speedsFewer wash ups / stops Infinite screen stabilityRedcued wash up solvent No mid run wash upsMulti substrate Fewer inks stocks

Improved Sustainability Lower energy requirement UV driers cheaper to runReduced VOC emissions 100% solvent free inksReduction in floor space Smaller driers / footprintsReduction in floor space Immediate stackingFuture substrate ready Suitable for PET and PC substrates

Higher Quality Increased print definition Finer stencils usedNo loss of detail Infinite screen stabilityFiner half tones Finer stencils usedConsistent colour reproduction Consistent ink rheologyHigher degree of process control UV curing more controlable

Security Immediate post processing Reduced number of prints awaiting further processing

Improved ink adhesion More robust prints post curing

Immediate lamination Reduced number of prints awaiting further processing

Future Developments Most research in UV curing systems Future proof facilities

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Key Conclusions

Adoption of UV technology benefits all

– Manufacturers

– Issuers

– Consumers

Future opportunities

Divider pageHidden Magnetic

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Description of the Hidden Magnetic Stripe Card

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Japanese Double Magnetic Stripe Card

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Japanese Double Magnetic Stripe Card

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Printing Construction

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Hyundai Card

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Hidden Magnetic Stripe Card

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Printing Image – Printing Step Test Process

Divider pageEnhanced Security

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Printable Security Levels

Assume 3 levels of printable feature– Contained within the ink

– Printed effects

– Combinations of above

Overt technologies Thermochromic Colour shift Print effects or patterns

Simple covert technologies Colour change UV responsive IR responsive

Bespoke machine readable solutions Magnetic resonance

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Enhanced Security Features

Security Features

Security Features3D Effect Metallic

Infrared (IR)

Color Shift

Ultra Violet (UV)

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Laminated Card Manufacturing Hidden Magnetic Tape

Potential Uses and Markets

Inks and Coatings

Enhanced Security

Questions?

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