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Heidelberger Druckmaschinen AG
Print Media Academy
Kurfuersten-Anlage 5260
69115 Heidelberg
Germany
Phone +49 6221 92-00
Fax +49 6221 92-4929
www.print-media-academy.com
Publishing Information
Content current: 2008
Printed in: 09/2009
Photographs: Heidelberger Druckmaschinen AG
Platemaking: Suprasetter
Printing: Speedmaster
Finishing: Stahlfolder, Stitchmaster
Fonts: HeidelbergGothicMl
Printed in Germany
Trademarks
Heidelberg, Print Media Academy, and the Print
Media Academy Logo are registered trademarks
of Heidelberger Druckmaschinen AG in Germany
and other countries.
Technical and other changes reserved. All information
is presented without warranty.
All liability for errors of information is barred.

00.993.0199/01 en

4
7,5

Print Media Academy

4,5
8
5

Profi Tip
Rollers in Inking and Dampening Systems

Foreword

dear reader,
In our current Profi Tip we focus on the inking and dampening
systems of your Heidelberg presses. We will give you some information on the critical importance of the rollers for the quality and
efficiency of your print processes. The articles explain the principles
of the manufacture and use of rollers and we answer the question of
how they have to be inserted, adjusted and maintained. Using this
knowledge you can make cost savings and will obtain an impressive
consistency of print quality. On top of that, you will increase roller
service life as well as print shop productivity. We are sure you will
find this of great interest.
Sincerely yours, Bernd Schopp

Notes

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Contents

4
5
7
8
9
10
11
12
13
15
17
18
19
20
21
22
23
24

Roller Manufacture
Shore Hardness
Roller Maintenance
Glazing
Inking/Dampening System Adjustment
Press Strip Adjustment
Alcolor Dampening System
Alcolor Dampening System Adjustment
Pre-/Post-Dampening with Alcolor
IPA-Free Ecocolor Dampening System
Quickmaster QM 46-2
Printmaster GTO with Direct Film Dampening System
Printmaster PM 52/Speedmaster SM 52
Printmaster PM 74 with Ecocolor
Speedmaster SM 74 with Alcolor
Speedmaster CD 74
Speedmaster SM 102/Speedmaster CD 102
Speedmaster XL 105 Hycolor Inking and Dampening System

Roller Manufacture
Synthetic rubber is used in roller
manufacture: a complex mix of
natural rubber and various chemicals that obtain their stability and
elasticity through the vulcanization
process. It is the raw rubber that
gives the rubbery material its basic
characteristics. The vulcanization
agents are added to this for the
subsequent vulcanization process.
Plasticizers (fluid oils) play a major role as they along with the extenders
and the vulcanization agents determine the subsequent degree of hardness
of the material. The more plasticizers are added, the softer the rubber
after the vulcanization process.
If possible, do not expose rollers to direct natural or artificial light.
The special paper that the rollers come delivered in prevents light
penetrating and therefore helps retain the rubbers characteristics.
For this reason, do not remove the paper before inserting the roller in the
printing press.
Always put the roller with its pivots on a frame support: Putting it
down directly onto the rubber can result in permanent deformations
(pressure marks).
Store rubber rollers in a cool and dry place.
Under certain circumstances ozone causes microscopic scratches on
the rubber surface. For this reason do not store rollers in the vicinity of
motors or other electrical devices.

Shore Hardness
In line with their task of transferring ink, inking rollers must be adjusted
to be oil-friendly (or oleophilic). In an inking system with conventional inks,
rollers of Shore A hardness between 30 and 35 are used. For UV inks,
rollers with Shore A hardness of 25 and between 40 and 45 are used.
Dampening rollers should be water-friendly (hydrophilic). For alcohol
dampening systems, Shore A hardness of between 25 and 30 is suitable.
In direct dampening systems, hard rubber rollers are used.
The Shore hardness of a roller
determined with a Shore meter
designates the resistance against
penetration of a needle taking the
form of either a conic section
(Shore A) or a point (Shore D),
pressed with a defined force (1 kp)
for a period of three seconds
against the rubber surface. Soft
rollers are measured with Shore A,
and hard rollers with Shore D. The
general hardness tolerances according to DIN/EN are +/ 5 Shore A.

Shore hardness can be easily measured and gives the printer information
on the condition of the rollers. Rollers tend to become harder with use,
as they are exposed to inks, dampening agents and detergents, as well as
the atmosphere. Additional hardening of 5 Shore in the first months of
use should be regarded as normal. Accelerated hardening in use can be a
sign that the rollers are gradually shrinking. If you adjust a roller that has
been subject to hardening and shrinkage to its original gap width, it may
well be that its original transfer characteristics will be reproduced. At the
same time, however, the gap width is closer than previously. This leads
to higher pressure and higher temperatures and thereby to higher wear
on the roller.
Increased hardness can also indicate that a hard film of paper coating
and dampening agents has become deposited on the roller surface. This
film should be regularly removed to prevent the roller hardening and
glazing with use.
the clean and satin-like surface of a roller is even more
important than its hardness.

Roller Maintenance
For optimum maintenance of rollers, the roller manufacturers recommend
a universal group A-III-agent that can be mixed with water. Alternatively,
high solids alkyd resins or biological detergent may be used. Long service
life of the rollers can only be achieved with proper handling and maintenance
(On UV printing, the service-life is, as a rule, shorter).

Ageing cracks

Ozone cracks

Cracking due to chemicals

T he choice of detergent plays an essential role in roller service life.

Highly volatile cleaners remove the plasticizer from the rubber, which
leads to shrinkage and hardening. Other possible consequences of
using unsuitable detergents are swollen rollers or corroded hoses, seals,
machinery paintwork and blankets. Suitable detergents are certified by
FOGRA and may be selected from the relevant list (cf. www.fogra.org)
V
 arious applications (standard inks, UV, hybrid) each require specific
roller materials and these in turn require detergents that are specially
suited to them
A
 long with print chemicals that affect the roller directly, external factors
such as UV light, damp and room temperature may result in premature
ageing of the rubber

Glazing

Clean roller with porous surface

Glazed roller with calcification on the surface

Over time, rollers pick up particles from the ink, the paper coating and the
dampening agent which block their pores. This contamination results in a
smooth shiny surface. Inappropriate detergents and hard water contribute
to this effect. Transfer of ink and dampening solution is noticeably inhibited
as a result.
By using a special decalcifying agent, scaling can be removed and the rollers
regenerated. It is recommended you discuss with the roller manufacturer
which agents have the least long-term effects on the rubber.

Inking/Dampening System Adjustment

Carry

out adjustment work on rollers once they have run warm, or else
calculate in an increase of the adjustment strips.
A
 s a rule, set the damping form roller and inking form roller nearer to
the distributor than to the printing plate but not so near that a pressure
strip in the form of a cigar occurs with the plate. This would indicate that
the roller is being bent towards the cylinder channel.
Only adjust the rollers according to manufacturer specifications.
A
 lways adjust from minus to plus, so as to eliminate thread play on
adjustment.
O
 n Vario set the ink form roller nearer to the distributor, so that it is
decelerated by the dampener oscillator roller.
W
 hen setting the ink form roller to the plate, high pressure is momentarily
exerted (impact), which generates a stronger press strip. For precise
adjustment of the print plate, first ink up and set down the rollers after
waiting for around 10 seconds.
P
 recise roller adjustment is best carried out via the press strip. For this,
coat the rollers equally with a light-colored ink (yellow). After the ink has
distributed and a waiting time of around 10 seconds, with a piece of paper squeeze off the press strip generated.
A
 lways measure between the dot fringes as these are more evident with
increased ink.
Always set the rollers parallel to each other (tolerance 0.5 mm).

Operating end

Drive end

Press Strip Adjustment

Heidelberg provides an adjusting gauge which allows precise measurement
of the press strips (this can be ordered over the Internet at www.heidelberg-
selection.com or via the relevant distributor, part no. G2.024.001). A paper
template print of the press strip makes measuring easier and can be used
for documentation purposes.
By making a professional adjustment, the printer ensures the right pressure
between the rollers. This then ensures ink distribution and a consistent
supply of dampening agent.

10

Alcolor Dampening System

12 | Damping form roller
13 | Intermediate roller
14 | Tipping roller
15 | Application roller
E | Dampener oscillator roller

13

15
12
14
E

Print quality starts with the interaction of the inking and dampening system:
Consistently good results assume a stable ink-water balance. Precise
adjustment ensures thin and equal distribution of the dampening agent film
on the printing plate. This reduces sheet drying time, allowing the sheets
to get to the print finishing process sooner. A responsible printer checks the
adjustments every three months and adjusts in line with the operating manual.
The dampening agent ideally has a water hardness of 8 to 12 on the
German scale (dH) and a pH value of 4.8 to 5.5. The usual dampening agent
temperature is deemed to be between 10C and 15C. To prevent the occurrence of print problems, it is recommended that the dampening agent be
renewed every 14 days.

11

Alcolor Dampening System Adjustment

Basic adjustment of the dampening
system should be performed with a
clean roller using two thin paper strips
(approximately 0.05 mm thick). The
wide paper strip covers the rubber roller,
while the narrow strip acts as a feeler
gauge. This means that the greater
resistance of the rubber roller is not felt.
The narrow strip slips between the wide
paper strip and the smooth distributor roller. There is an exact description
of the method in the operating instructions.
If the Alcolor dampening system is adjusted or checked with ink, be aware
that when the strip is formed an unintended rolling movement occurs from
the application roller to the damping form roller. This makes the press strip
wider. If there is a suitable waiting time (approximately 30 seconds), the
inner strip can be properly assessed.

15
12

12 | Damping form roller

15 | Application roller

12

Pre-/Post-Dampening with Alcolor

Using automatic pre-dampening, the Alcolor dampening system ensures there
is adequate dampening agent film on the printing plate. When printing is
interrupted (washing, stopper etc.) the dampening system is automatically
switched off by the plate as part of a post-dampening phase. The duration
of the automatic pre- and post-dampening phases can be set by the
machine control system and is thereby adapted to the many different materials in use and the conditions that exist around the world. Good adjustment
ensures an optimum amount of dampening agent when printing starts and
after printing has been interrupted.

The pre- and post-dampening phase with Alcolor

Mode

Standard
settings

Revolutions

Adjustment
range max.
revolutions

Adjustment
range min.
revolutions

Pre-dampening phase 1

18

Pre-dampening phase 2

18

Post-dampening phase 1

15

15

50

Post-dampening phase 2

45

45

100

to avoid excess dampening agent on the printing plate, the

pre- and post-dampening phases should be set to the minimum.

13

100%

3 revolutions of
pre-dampening at
maximum rpm.

Machine start-up

Pre-dampening

14
Post-dampening 1

Print production

Dampening off

Printing process continues after post-dampening phase 2 return to pre-dampening phase 1

(3 pre-dampening revolutions)

Post-dampening 2

Alcolor runs for 45 revolutions

at 75% of the set rpm

Printing process continues during post-dampening phase 2

return to pre-dampening phase 2 (2 pre-dampening revolutions)

Printing process continues during

post-dampening phase 1 without
pre-dampening in production

Alcolor runs for

15 revolutions with
set rpm

Alcolor runs with

a set rpm

Feeder stop

IPA-Free Ecocolor Dampening System

100% IPA-free printing with the Ecocolor dampening system reduces
emissions, improves the print shop atmosphere and at the same time
saves alcohol costs. Ecocolor ensures quick and stable ink/water
balance. Dampening agent control is via a potentiometer. Dampening
agent temperature is set to 18 to 20C.
22 | Damping form roller
23 | Intermediate roller
24 | Tipping roller
25 | Application roller
26 | Transfer roller, large
27 | Transfer roller, small
E1 | Dampener oscillator roller
25
23
27
26

22

24

E1

15

On IPA-free printing, the degreasing action of the alcohol in the dampening

agent is not present. This means that oily detergent residues may remain
on the rollers, and these can inhibit dampening agent transfer. This is why
absolutely faultless washing procedures are needed. The basic cleaning
agent must under no circumstances contain aromatic compounds, as these
may damage the rollers. You should ask your ink supplier about a suitable
cleaning agent.
clean the rollers by hand after each wash. to do this, run the
press to wash speed, switch the intermediate roller on the
press to connect by double-clicking (it flashes). then, using a
spray bottle, spray a water/alcohol mixture (80%/20%) onto
the rollers. set wash-up blades via the service menu and let
them wipe. clean the tipping roller and applicator r
oller with
alcohol (on the front surfaces as well).

16

17

4
6

4+1

2+1

2
C

4+1

2+1

DW 1

3+1
2+1

3+1

2 + 1 setting 6

2+1

Quickmaster QM 46-2

3+1

DW 2

3+1

3 2

4+1

2 + 1 setting 6

2+1

| 50 mm

| 45 mm

2. Ink form roller

3. Ink form roller

| 54,7 mm

1. Ink form roller

Damping form roller | 63 mm

Roller diameter

2+1

18

4+1

2+1

3+1

_ 0,5
3+

4+1
3

10

3 +_ 0,5

| 45 mm
| 47 mm
| 51 mm

3. Ink form roller

4. Ink form roller

| 49 mm

2. Ink form roller

1. Ink form roller

Damping form roller | 55 mm

Roller diameter

5 +_ 0,5

_ 0,5
3,5 +

3 +_ 0,5

4+1

4+1

3+1

Printmaster GTO with Direct Film Dampening System

19

4+1

12

_ 0,5
3+

4,5 +_ 0,5

4 +_ 0,5

3,5 +_ 0,5

10

15
17

16

Squeeze off
the water film

5 +1

3,5 +_ 0,5

3,5 +_ 0,5 spring

4+1

14

11

13

4 +_ 0,5

Printmaster PM 52/Speedmaster SM 52

| 54 mm
| 68 mm

4. Ink form roller

| 61 mm

2. Ink form roller

3. Ink form roller

| 64,5 mm

1. Ink form roller

Damping form roller | 68 mm

Roller diameter

20

2+1

4+1

4+1

_ 0,5
4,5 +

_ 0,5
4+

3,5 +_ 0,5

4
8

22

23

4,5 +_ 0,5

11

26

27

3 +_ 0,5

24

25

3 +_ 0,5

10

4 +_ 0,5

Printmaster PM 74 with Ecocolor

4 +_ 0,5

| 55 mm
| 70 mm

4. Ink form roller

| 60 mm

2. Ink form roller

3. Ink form roller

| 65 mm

1. Ink form roller

Damping form roller | 75 mm

Roller diameter

21

2+1

4+1

4+1

4-1

4 - 0,5

3,5 +_ 0,5

11

12

13

14
Squeeze off
the water film

15

4+1

2,5 +_ 0,5

10

4 +_ 0,5

Speedmaster SM 74 with Alcolor

| 55 mm
| 70 mm

4. Ink form roller

| 60 mm

2. Ink form roller

3. Ink form roller

| 65 mm

1. Ink form roller

Damping form roller | 48 mm

Roller diameter

22

4+1

2+1

4+1

3,5 0,5

4+1

6+1

Speedmaster CD 74

10

Wasserfilm
abquetschen

5+1

2,5 + 0,5

4 0,5

| 72 mm
| 66 mm

4. Ink form roller

| 60 mm

2. Ink form roller

3. Ink form roller

| 78 mm

1. Ink form roller

Damping form roller | 70 mm

Roller diameter

23

4+1

13

4-1

6
3

6+1

5-1

14

15

4 +_ 0,5

10

4+1

12

5+1

2,5 + 1

3 + 1 spring

4+1

ZW

11

5+1

Squeeze off
the water film

| 66 mm
| 80 mm

4. Ink form roller

| 72 mm

| 60 mm

3. Ink form roller

2. Ink form roller

1. Ink form roller

Damping form roller | 78 mm

Roller diameter

Speedmaster SM 102/Speedmaster CD 102

24

5 +_ 0,5

4 +_ 0,5

_ 0,5
5+

7 +_ 0,5

14

5 +_ 0,5

6 + 1,5

5 +_ 0,5
6 +_ 0,5

7 +_ 1,5

4 +_ 0,5

11

15

17

16

10
6 +_ 1,5

Squeeze off
the water film

8 +_ 0,5

4 +_ 0,5

5 +_ 0,5

12

13

4 +_ 0,5

| 102 mm

| 74 mm

4. Ink form roller

| 86 mm

3. Ink form roller

| 80 mm

2. Ink form roller

1. Ink form roller

Damping form roller | 92 mm

Roller diameter

Speedmaster XL 105 Hycolor Inking and Dampening System

In-Depth Knowledge: From Training on

Machines to Management Seminars
The latest technologies and up-to-date management expertise from the print
media industry these are the two focal points at the core of the comprehensive array of trainings and seminars provided by the Print Media Academy, which is represented in 18 locations in Germany and across the world.
We provide in-depth knowledge enabling you to master the increasingly
rapid change process in the industry. Vocational outlines, software, machines
and, especially, client requirements are all subject to a permanent and
ongoing transformation. In the Print Media Academy you will acquire the
competencies that you need for your success: From training on machines
to management seminars, you will not just update and improve your
professional knowledge, but also become qualified in soft factors such as
the capacity for teamwork, team leadership and company management.
Why not order our current seminar catalogue?
25

Previously published issues from

the Profi Tip series:

Print Media Academy

Pro Tip
Dampening Solutions in Offset Printing

00.993.0199/01 en

Print Media Academy

Pro Tip
Rollers in Inking and Dampening Systems

Dampening
Solutions in
Offset Printing
Feuchtmittel im
Offsetdruck

Rollers in
Inking and
Dampening
Systems
Walzen in Farbund Feuchtwerk

Print Media Academy

Pro Tip
Problem Cases in the Pressroom

Problem Cases
in the Pressroom

Problemflle
im Drucksaal

Print Media Academy

Coating, Drying
and Powdering

Pro Tip
Coating, Drying and Powdering

Lackieren,
Trocknen und
Pudern

At www.print-media-academy.com, you can order all issues published up

until now for free. Please tell us the issue you would like and your address,
and you will receive your personal copy promptly.

26

Foreword

dear reader,
In our current Profi Tip we focus on the inking and dampening
systems of your Heidelberg presses. We will give you some information on the critical importance of the rollers for the quality and
efficiency of your print processes. The articles explain the principles
of the manufacture and use of rollers and we answer the question of
how they have to be inserted, adjusted and maintained. Using this
knowledge you can make cost savings and will obtain an impressive
consistency of print quality. On top of that, you will increase roller
service life as well as print shop productivity. We are sure you will
find this of great interest.
Sincerely yours, Bernd Schopp

Notes

1,5

5,5

2
2,5
3
3,5

6,5

4
7,5
4,5
8
5

Foreword

dear reader,
In our current Profi Tip we focus on the inking and dampening
systems of your Heidelberg presses. We will give you some information on the critical importance of the rollers for the quality and
efficiency of your print processes. The articles explain the principles
of the manufacture and use of rollers and we answer the question of
how they have to be inserted, adjusted and maintained. Using this
knowledge you can make cost savings and will obtain an impressive
consistency of print quality. On top of that, you will increase roller
service life as well as print shop productivity. We are sure you will
find this of great interest.
Sincerely yours, Bernd Schopp

Notes

1,5

5,5

2
2,5
3
3,5

6,5

4
7,5
4,5
8
5

1,5

5,5

2
2,5
3
3,5

6,5

8
Heidelberger Druckmaschinen AG
Print Media Academy
Kurfuersten-Anlage 5260
69115 Heidelberg
Germany
Phone +49 6221 92-00
Fax +49 6221 92-4929
www.print-media-academy.com
Publishing Information
Content current: 2008
Printed in: 09/2009
Photographs: Heidelberger Druckmaschinen AG
Platemaking: Suprasetter
Printing: Speedmaster
Finishing: Stahlfolder, Stitchmaster
Fonts: HeidelbergGothicMl
Printed in Germany
Trademarks
Heidelberg, Print Media Academy, and the Print
Media Academy Logo are registered trademarks
of Heidelberger Druckmaschinen AG in Germany
and other countries.
Technical and other changes reserved. All information
is presented without warranty.
All liability for errors of information is barred.

00.993.0199/01 en

4
7,5

Print Media Academy

4,5
8
5

Profi Tip
Rollers in Inking and Dampening Systems

1,5

5,5

2
2,5
3
3,5

6,5

8
Heidelberger Druckmaschinen AG
Print Media Academy
Kurfuersten-Anlage 5260
69115 Heidelberg
Germany
Phone +49 6221 92-00
Fax +49 6221 92-4929
www.print-media-academy.com
Publishing Information
Content current: 2008
Printed in: 09/2009
Photographs: Heidelberger Druckmaschinen AG
Platemaking: Suprasetter
Printing: Speedmaster
Finishing: Stahlfolder, Stitchmaster
Fonts: HeidelbergGothicMl
Printed in Germany
Trademarks
Heidelberg, Print Media Academy, and the Print
Media Academy Logo are registered trademarks
of Heidelberger Druckmaschinen AG in Germany
and other countries.
Technical and other changes reserved. All information
is presented without warranty.
All liability for errors of information is barred.

00.993.0199/01 en

4
7,5

Print Media Academy

4,5
8
5

Profi Tip
Rollers in Inking and Dampening Systems