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TFP. Innovation and Ecology.

Available products from TFP.

01.CORRUGATED BOARD

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Basic corrugated cardboard is produced through joining 3 layers of paper on a corrugating machine. The interior undulating layer of paper is the so-called fluting. Corrugation is formed through passing the fluting through corrugating rolls (rolls with longitudinal grooved structure). They form the undulating pattern. The flat layer of paper is attached to the undulating layer from the top and bottom, with starch glue. When the web has dried, corrugated board can be cut into finished sheets.

02.STANDARD BOXES

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Standard boxes are also called American boxes. The production process is as follows: a sheet of cardboard with longitudinal creases is fed to the machine, which is followed by printing (up to 3 colours), cutting the flaps, and glue overlap. At the next stage, the box will be folded to glue together the extreme sides and form a complete box.

03.DIE-CUT BOXES

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Die-cut boxes are so-called patterned packages. They are available in a vast diversity of shapes. They are produced on flat-bed die cutters or rotary die cutters, using a blanking tool. Depending on the blade used on blanking die, a smooth cut, a crease or perforation can be obtained, helpful for folding the flaps, opening the box, or tearing off some of its elements.

04.PREPRINT

Preprint is a flexo printing technology on rolled paper. Paper is printed before a roll is actually installed in a corrugating unit. Printed paper is glued to corrugated fluting as the upper layer of corrugated board. During further processing, finished sheets are processed on die cutters.

05.FLEXO PRINTING

Flexo printing is a process of direct convex printing. The printing element is a print matrix called a photopolymer. The substrate for printing is corrugated cardboard. Generally, photopolymer is a large stamp, transferring ink from an anilox roll to the corrugated board surface. The inks used in our process are water-based inks, setting through absorption by substrate and water evaporation (in a drying module).

06.OFFSET PRINTING

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Offset printing is an indirect flat printing process. The stencil is a flat aluminum panel. Printing and non-printing elements are flat and flush with each other. Ink is transferred from the stencil to a rubber piece and only then to the paper. Inks used in this process are oil-based, fixing through absorption by substrate and oxidation.

07.DIRECT PRINT

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dirEct print is just offset printing with a key difference being that corrugated board is the substrate (E or F wave). Therefore, we get offset print quality on a sheet of corrugated board. This process is faster and cheaper than the one used previously (lamination of a sheet of paper onto corrugated board).

Innovative technologies

Flexo HD.

To achieve the desired quality of print on our packages, we now offer the most elevated flexo printing standard, which is Flexo HD. Frequencies achieved in this technique approximate offset print quality. Photopolymers prepared with 57 lpc (ca. 145 lpi) reproduce a halftone dot with unmatched precision. Flat and stable dot surface transfers inks with unbelievable accuracy. Due to balanced choice of frequency for clichés and transfer of ink fed from anilox roll, dot size increase is minimised. Photos and graphics with tonal gradations are represented accurately and subtly. We achieve reproduction of as much as 1% colour value.

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FSC Photopolymer Printing Plates

To handle the challenge of printing on poorer quality substrates, TFP now offers a solution to improve printing quality on packages using light-weight coating papers used in production of corrugated board. Photopolymers with lower hardness ratings transfer ink to substrate with much better precision, penetrating all pits and roughness of the upper layer of corrugated board. This solution can be applied mainly to vector surfaces where accurate ink transfer is required on large uniform colour elements.

dirEct print.

Is there a technology that enables production of offset printing results on corrugated board packages? There is a relatively complex process of offset printing of sheets, followed by laminating printed sheets on corrugated board. But is there something less time-consuming? Of course there is. Since 2010, TFP has been offering a printing technology under a working name of "dirEct print". With this technique, we achieve offset quality prints directly on microwave (wave E, wave F). We save time and energy through getting rid of lamination, i.e. gluing sheets onto corrugated board.

X-Rite. Print Quality Control System.

We have implemented a new solution to enhance our package printing quality control. The printer has the most advanced SpectroEye measuring instruments from X-Rite at its disposal. After setting the machine and printing a few copies, the operator will control the print through measuring appropriate control fields on the printed copy. Using the ColorMaster software, the printer will get a colour reading, translated into the numerical system, in just a few seconds. Comparing the result in his computer with the colour standard, it receives feedback on how close the print is to the standard. The system will also prompt it how to mix ink components to adjust the desired shade of ink.

Anilox roll washing machine.

With the diversity of assignments, we need to be highly flexible. Therefore, our resources comprise anilox rolls with various ink transfer parameters. In order to be able to use them fully in production, we must prepare them for printing at any time. Print quality depends mainly on the quality of rolls. To avoid a situation when one of the rolls is unfit for use due to contamination, TFP has purchased an anilox roll washing machine.

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