The engraving process encompasses an electronically-controlled diamond-stylus that cuts or engraves cells into the surface of cylinder. A combination of these cells forms the image. After artwork has been supplied by the customer, the DTP/Origination department transforms the artwork into a format understood by the specialised software used to communicate to the high tech engravers.Each image is converted to halftone-like dots, each having an electronic signal, ranging in intensity from 0:100%, depending on the light density of the image. The image is then converted back into an analogue signal, which then drives the engraving head, regulating the depth to carve the cell on the cylinder. A computerised system controls the engraving head, which moves diagonally across cylinder punching cell holes at between 6000 and 8000 holes per minute. At 100% depth, the diamond-shaped cells interlock with those of the rows on either side of it, creating just a tiny cell wall; therefore at 10% the cell walls are thicker or bigger. The angle of cells can be altered by producing elongated or compressed diamond shaped cells if necessary.
After proper inspection of base shell, for proper size and surface, the cylinder after degreasing process, is immersed in formulated Alkaline Pre-Copper tank, to ensure proper bounding of Hard Copper Plating. High purity copper nuggets in balanced electrolyte chemistry ensures that the plated cylinder achieves optimum hardness (200 to 220Hv) and grain structure for Engraving cells.
A high precision digitally controlled MDC Daetwyler-Switzerland "Duostar machine" with an accuracy of 10 microns per meter is used to achieve accurate and mirror surface that is required for electronic engraving on the cylinder.
Electromechanical engraving uses an electronically-controlled diamond-stylus to cut the the cells into the surface of the gravure cylinder. The original copy is scanned into a computer and digitized. Each scanned and digitized image is converted to halftone-like dots, each having an electronic signal, ranging in intensity from 0:100%, depending upon the darkness or lightness of the image. The image is then converted back into an analog signal which then drives the engraving head , telling it how deep to carve the cell on the cylinder.
Chrome process of engraved cylinder is the next step which gives solidity to engraved copper surface to withstand the aggression of ink & Doctor blade corrosion. The optimum micro cracks ensure easy doctor blade lubrication for long life of cylinders. Our Chrome hardness is 1000 to 1100Hv with 400/cm( Min) Microcracks.
To ensure our cylinders meet high quality standards, our Proofing press has high precision and best in class proofing machine to produce in-house proofing of our cylinders. These machines ensure total registration employing the same inks and substrate which are to be used by the customer. Every proof is approved by customer. Before being supplied to the clients, all our cylinders are efficiently packed in high grade packaging material to avoid any kind of damage during the time of transit.