The Process

 

1. COPPER PLATING

Our partner engineering company has the capabilities to manufacture steel cylinder bases. The base rotates in a bath or tank filled with a copper sulphate solution. Depending on the special requirements of the gravure cylinder, a mechanical surface treatment completes the preparation of the base. This step normally occurs in parallel with the DTP and repro process.

 

3. CFM/POLISHMASTER

The copper-finished cylinder then goes through a process of polishing and finishing to achieve the required size in preparation for engraving. Our Kasper Walter and recently acquired CFM 1610 plus machine prepares optimal quality copper surface balance to minimize tolerance and achieve evenness of the cylinder.

 

5. CHROME PLATING

The cylinder surface is then chrome plated in a chrome bath or tank, which has the identical appearance to that of a copper bath and finished (polished) immediately after the cylinder has been engraved.

 

7. QUALITY ASSURANCE

There are quality checks and balances in place at the end of each stage in the cylinder manufacturing process with the final step encompassing a thorough inspection of the finished cylinder.

 

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2. DTP/ORIGINATION

From receipt of the artwork usually supplied by a design or advertising studio, the DTP/Repro department will inspect and provide in-house colour separations using a high-end system. The artwork supplied is then converted to a gravure print ready form, for cylinder engraving.

 

 

4. ENGRAVING PROCESS

The cylinder rotates in our Daetwyler Gravostar engraving machine, which can provide both ‘Xtreme Engraving’ and ‘TranScribe’ to process through high quality detail and counter sharpness. This state of the art machine can engrave up to 8000 cells per second.

 

6. CYLINDER PROOFING

A technical content verification of the cylinder is then carried out via a proof press, which mimics and actual gravure printing press.

 

 

8. PACKAGING FOR DELIVERY

The cylinder is then carefully packaged using protective packaging material before it’s placed into a wooden box in preparation for delivery to the customer