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Technical Solutions Handbook

1. Construction amp Verification Write Test A write test involves preparing a dummy form in the color and grade sequence to match the proposed form construction This form should then be imaged by the end user s imaging device The write test will verify the equipment s ability to adequately produce the desired carbonless image on each ply of the form A manual process using a pen to image the form pen check or pencil check is also recommended as a quick check for correct collation sequence and print side during the manufacturing process Intermixing NCR PAPER Brand Carbonless Products Continual improvements in the design and chemistry of all NCR PAPER brand products are made to meet diverse end use requirements E For special purpose applications the uniquely designed features of NCR PAPER Specialties products may be needed E NCR PAPER Specialties products are designed to be compatible with other specific NCR PAPER products consult Technical Services with questions that arise E While all NCR PAPER brand carbonless products are compatible optimal performance is achieved when intermixing of grades is avoided E In situations where intermixing is required please be aware that intermixing can cause performance variability Physical and aesthetic differences may be noticeable and intermixing may cause variation in image intensity image development speed and image clarity E To ensure that your app
2. Digital Duplicators Suggested Tips for Running NCR PAPER brand Carbonless Sheet E Run the digital duplicator at medium to slow speed E On the Ricoh VT6000 3800 and 3600 models remove the feed cradle weights located in the infeed section of E Adjust the original so that the CF smudge mark doesn t the duplicator see fig 2 appear in a critical area E Tighten the side feed guides on any E On the Riso GR model adjust the stripper angle and make or model see fig 3 pressure see fig 1 to high Stronger Figure 1 400 gf O Weak oO 4 250 af o 300 gf lt a Stripper Angle 3 a 27 Adjustment Dial a UL l CN ae g Flatter A Steeper Stri P ay eoe Cam Plate ey Adjusting the pressure of the Stripper Adjusting the angle of the Stripper Figure 2 Figure 3 HE Feed Cradle Weight Torque Limiter Pick up Roller Shaft Paper Feed Roller Core SUCCESS RESOURCES 34 TOOLS FOR BUSINESS technical solutions Xero Form Ii Benefits of Digital Printing care digital equipment has the potential to last considerably longer than its non digital counterparts Throughout the evolution of printing technology the reliability speed cost and quality of the entire printing Another benefit of digital copying is that it speeds up the process has continued to improve However the outputting process by allowing images
3. imaged by pressure The method of applying this medium to paper had to provide uniform coverage and proper adhesion of the colorless dye solution Poor adhesion would result in evaporation of the medium and loss of the dyes causing premature color reaction when the dyecoated side of the sheet is placed next to the reactant coated side After several years of concentrated effort research scientists developed the process of microencapsulation utilizing principles of colloid chemistry This unique process permitted placement of the colorless dye solution into millions of microscopic containers called capsules Micro capsules were the key to development of the new printing system which enabled NCR PAPER the first carbonless paper for business forms to be introduced in 1954 GENERAL INFORMATION technical solutions What is NCR PAPER Brand NCR PAPER brand of carbonless paper is a business forms paper system uniquely coated to transmit an image from writing or mechanical pressure without using carbon paper Normal pressure of inscribing impact on the top sheet automatically reproduces data on subsequent sheets within a properly ordered form set The system can be used for making handwritten typewritten or machine printed copies It s also adaptable to ribbonless imprinting devices An image is created when two separate chemical compounds coated on the sheets are brought together These coatings are colorl
4. needs may vary depending their application Pantone Inc s check standard trademark for color reproduction and color reproduction materials 24 SUCCESS RESOURCES technical solutions Cutting Exercise caution when guillotine cutting pressure sensitive grades of NCR PAPER brand E On CFB unwanted background color will develop on the CF side under the clamp hold down bar if pressure is excessive E After CFB has been cut without unwanted color formation CB can be cut using the same pressure and procedure without damage to the dye capsules E CF grades are not pressure sensitive and may be trimmed using the same procedure as for bond paper Cutting carbonless paper to prevent damage E Reduce the clamp pressure to less than 35 p s i total clamp gauge pressure divided by square inch surface area of the clamped paper This will not cause color development on CFB and will not damage CB coating E Place a piece of open cell medium density sponge rubber 38 to 34 thick under the clamp to cushion the impact of the clamp With some large guillotine cutters it is advisable to prevent the clamp from striking the paper Apply clamp pressure gradually E Block up the clamp with a chipboard stack The stack should be 4 higher than the lift of paper and 12 from the edge of the paper Chipboard may be placed on top of the forms to be cut and will reduce the pressure damage on the lift of forms and eliminate any
5. technical solutions APPLETON What Ide SUCCESS RESOURCES TOOLS FOR BETTER BUSINESS SUCCESS RESOURCES Contents General Information COMEM Sonis aaa a 1 Introduction amp Customer Servite 2 About Appleton Papels c cccccsecccseeceeeseteeeeees 3 4 History of NCR PAPER Brand Carbonless 5 What is NCR PAPER Brand c0000 6 Carbonless Paper System aa 7 Construction amp Verification Packaging amp Handling Packaging amp Handling cccssceessseeeesteeseeees REC GCI Ok eia Storage amp Conditioning Sheet Printing Sheet PrIMINg oseaan aaia aeiia 11 Printing on an A B DICK Press 12 Printing on an AM Multilith Press s 13 Printing INKS sececsesicsessRextesveecwer seas aeveetetssleatenatiees 14 15 Dampening Systems amp Fountain Solution 16 17 Plate Sieen aea na a 18 Blankets nocne pasenes aspedi tae ieSe 19 Scree TIMIS anpa 20 BackprintiN gerisini renias au 2i Dry Offset CF Ink 22 24 CF Ink Color Standard 24 Cutting amp Gluing CUTUNO sasaista A eects 25 Miscellaneous Bindery Operations a 26 Fanapart Edge Paddingd ccccsceessteeeeeeees 27 31 solutions technical Digital Duplicators OVENVIGW a a aa Nei 32 Manufacturers Preparation Characteristics 33 Suggested Tips for RUNNING ccscesessteeeseeeees 34 Xero Form Il Benfits of Digital Print
6. Because you are putting liquid adhesive onto the paper edge some waviness will naturally occur If the adhesive moves into the sheet more than the recommended 1 8 waviness is likely to occur One way to minimize a wavy edge is to apply the adhesive to a fresh cut edge Allow time for the edge to stabilize approximately 1 2 hour The fresh cut edge will assure proper sheet alignment and reduce excessive adhesive penetration 2 What will happen if the multi part form sheets are not in the correct order CB CFB CFB CF Proper sheet order is critical to successful edge padding Remember only coated surfaces accept adhesive and stick together to form sets uncoated surfaces do not accept adhesive and will not stick together 3 Why won t the adhesive penetrate into the stack How can control penetration There are several things to check to make sure the adhesive is going into the stack 1 Check the amount of weight you are using Too much weight will not allow the adhesive to move in between the sheets 2 Be sure to follow the correct procedure shown to apply the adhesive You must cover each area of the stack thoroughly before moving on That is why we recommend going over the same area with 2 4 strokes to be sure the adhesive has penetrated Example Let s say you started at the bottom center and stroked to the edges as recommended but decided that you would apply one pass on the entire stack then go back and apply more
7. Coated Back with dye capsules A Front Side Coated Front with dye co reactant CF Sheet Vv Back Side No Coating A Front Side No coating CB Sheet Vv Back Side Coated Back with dye capsules 3 Part CFB Sh A Front Side Coated Front with dye co reactant Set eet Vv Back Side Coated Back with dye capsules A Front Side Coated Front with dye co reactant CF Sheet Y Back Side No Coating A Front Side No coating CB Sheet Vv Back Side Coated Back with dye capsules 3 Part CFB Sheet A Front Side Coated Front with dye co reactant Set ee Vv Back Side Coated Back with dye capsules A Front Side Coated Front with dye co reactant CF Sheet Y Back Side No Coating Fanapart High Strength Edge Padding Adhesive shown in red is applied to one 1 edge of a stack of printed or copied laser printed carbonless sheets O The edge padding adhesive penetrates the stack only into and along the sheets coated front and back sides causing these sides to swell closer together NOTE The coated sides are always the inside sides of a multi part set so as the adhesive dries only the set itself sticks together The adhesive does not penetrate the stack into or along the sheets no coating sides NOTE The no coating sides are always the sides between two different multi part sets so the two sets don t stick together and easily fan apart break apart when the adhesive dries SUCCESS RESOURCE 28 TOO JSINE
8. Shrink Wrapping A packaging system in which objects are tightly sealed in special plastic films The material is placed in a loosely fitting film sleeve which is then passed through a special oven where heat causes the film to contract and hold the contents firmly Some shrink wraps adversely affect NCR PAPER brand Silk Screen Process of printing through a masked fine silk or wire screen to transfer ink to the image areas on the paper Sizing Material applied to the surface of paper to improve its physical or functional properties Skid A wood base consisting of two large opposite side frames with top cross members which is used to facilitate handling large quantities of paper Skip Coating Areas or streaks on the paper web to which coating was not applied Skip Perforation Perforations that are applied partially to the form width by cam action Slime Spots Translucent spots or holes in paper caused by micro organisms in the papermaking system Slip Sheet Sheets of paper inserted between printed sheets to eliminate ink set Slitting 1 Separation of individual sets from a stack by using a cut down knife drawn along the padded edge of the sheets in the stack 2 Conversion of mill rolls into smaller widths and diameter rolls for use as adding machine rolls tally rolls etc Smoothness The surface finish or lack of roughness of paper Smudge A blue discoloration on the CF coated side of carbonless paper that
9. data ter minals calculators and chart recording equipment Throw Length The theoretical circumference of a printing plate and the length of image it produces It is measured in terms of the cumulative deviation from the theoretical length Tie The uncut area of a perforation Tinting Tinting as it relates to the production of business forms is the process of using an alcohol or water based solution to dye white paper various colors This is an on line process Toning A phenomenon characterized by ink in the nonimage areas on the blanket paper and eventually the plate which stems from ink water logging Tipping A technique for assembling unit set forms in which the individual parts vary in length and location along the stub Tracking A form of set off where ink is transferred from printed areas to clear areas by contact with idler rolls etc Translucent A grade of paper providing more show through or light transmission than bond grades generally used when diazo copies are needed Trapping Ability of ink to accept and hold succeeding colors on multiple color runs Tusche Liquid ink used for corrections on lithographic presses Unit Set Forms Non continuous forms in which the parts are permanently glued in the stub but perforated for ease of separation Varnish Substance used as a vehicle or base in the making of ink Vehicle The fluid ingredients of printing ink that provide flow and act as a carrier
10. from the toner source roll onto the photoreceptor where the document image is created The toner is then transferred to the paper to produce the finished document Because Run Length the components do not contact each other physical wear Source CAP Ventures and image distortion are greatly reduced So with proper Digital O eB gt x lt Xerox and DocuTech are registered trademarks Use does not imply endorsement SUCCESS RESOURCES 35 NESS SUCCESS RESOURCES technical solutions Xero Form Il NCR Paper brand Digital Offerings NCR PAPER brand was the first to notice the need for paper which complements today s digital equipment NCR PAPER brand introduced xerographic carbonless paper in the 1980s and introduced the original Xero Form in 1992 The tradition of innovation continues with the introduction of our newest carbonless paper Xero Form II This new generation of carbonless paper alleviates several shortcomings of traditional carbonless by reducing contamination and odor while improving printability runnability and appearance Xero Form II is the perfect fit for today s broad range of digital and electronic equipment including high speed copiers and laser printers It is a special carbonless grade designed to run easily through copiers and laser printers with bond like performance and is proven to provide the cleanest running sheet of any xerographic carbonle
11. remedies attempted results e Equipment used Type of press inks blankets plates used e Air conditioned Humidity controlled e Were any special adjustments made on the press to the ink or to the paper Describe e Any abnormal or severe forms usage conditions e Any unusual observations or aspects of the complaint E Samples send Unprinted and printed exhibiting the problem 12 qty original size sheets 12 qty finished forms E Other support to send Curled or Wavy Edges Send samples flat Do not roll Damaged Blanket Submit along with sample of the associated paper defect Dimensional Instability Besides adequate form samples include a film positive Blanket Contamination Send sample of contaminant Remove by tape from blanket then fold the tape inward Do not tape to a sheet A photograph may be sent in lieu of samples if the nature of the problem is such that samples would not verify the difficulty such as a loosely rewound roll E Returned Paper Do not return or dispose of any paper except for samples submitted to illustrate the complaint until instructions have been received from Technical Services To avoid transit damage all authorized returns of defective paper should be securely packaged in the original or similar container if possible Return according to instructions given All materials returned should be plainly marked with the appropriate complain
12. wa E The excess toner solvent remaining in the copy sheet migrates to the carbonless paper and attacks the print or coatings E This condition can be minimized by proper adjustment of the drying system and or wringer rolls in the copier and not placing fresh electrostatic copies in immediate contact with carbonless sheets E It is not possible to guarantee complete satisfaction in copying an NCR PAPER brand print because of the many variable and uncontrollable factors When microfilming the image to be filmed should be well defined and intense E Film a copy close to the original in a manifold set E The most important controlling factor in microfilming is the film Two film types ortho and panchromatic are used for microfilming E Generally best results are achieved using panchromatic film with AHU Anti Halation Undercoat E Types of cameras used can affect proficiency of microfilming carbonless images Cameras with longer exposure times usually give better results p NCR PAPER brand Black Print provides high contrast reproduction SUCCESS RESOURCES 51 JESS Instant Replay Il Instant Replay II helps detect pressure damage to CB sheets E It reacts with colorless dye released from damaged capsules causing color development in damaged areas E This helps a printer adjust pressure settings for optimum running of NCR PAPER brand The CB coating on CB and CFB grades is sensitive to pre
13. 1 zZ oc QO pis Lu Lu L Za E Adjust feeder so sheet separators are slightly higher than the bottom of the suction feet e Blower and vacuum settings should be set slightly higher than the lowest acceptable operating level for good separation with minimum flutter e Place paper in center of feeder with every other suction foot engaged starting at the outside edge E Adjust guides on the register board for minimum side guide push e Set skid rolls to barely touch the trailing edge of the sheet when the sheet is at rest against the front guides E Adjust ejector rolls and rings to minimize delivery problems caused by paper curl e Offset upcurl by placing ejector rolls outside ejector rings downcurl with ejector rolls inside ejector rings e Chain delivery systems provide more positive control during paper delivery at all speeds e Generally chain delivery is preferred over chute delivery when optimum press results are desired Ejector rolls inside rings Ejector rolls are set inside ejector rings to compensate for downward curl in stock and to minimize delivery problems 11 technical solutions Printing on an A B Dick Press 350 360 369 Fan and load paper on a stiff board in the center Air should be adjusted to float the top 3 or 4 sheets of the press e Air and vacuum may have to be adjusted as press e Check to assure the printing side is up speed increases e Rear and side paper gu
14. Blankets can swell due to a reaction with capsule oils and or blanket cleaning solvents As this swelling occurs excessive pressure may be exerted to the stock damaging more capsules It may be necessary to change the type of blanket used to one which is resistant to oils A number of blanket companies have developed such blankets Blanket swell can be identified by you both visually and by running your hand over the blanket If the printing image feels embossed or like braille it is likely blanket swell has occurred The capsule damage indicator spray Instant Replay II can help identify this condition 19 technical solutions Screen Tints Printing inks when applied to either the CB CF or SC 85 Line 110 Line 133 Line surface with heavy coverage such as in a screen or solid can reduce intensity of NCR PAPER brand carbonless imaging in that area This is objectionable only where the printed area is also a writing area The reduced intensity 10 occurs because some printing inks can cause a physical blocking between coatings Certain inks will cause more difficulty than others For example gloss inks that dry with a hard continuous film cause a carbonless image with reduced intensity 20 To minimize intensity reduction of NCR PAPER brand carbonless imaging E Maintain a very thin film of ink Heavily pigmented inks applied to the paper in the smallest practical amount will generally give best results 30 E Ge
15. E Order Information E Product Availability Product Inquiries E Pricing National Accounts Printer Converter 800 922 1729 FAX 800 922 1712 Merchant East 800 533 9421 FAX 800 872 4141 Merchant West 800 922 1727 FAX 800 922 1709 Visit Our Web Site www appletonideas com ncrpaper CARBONLES NOR PAPER NCR PAPER is a registered trademark licensed to Appleton GENERAL OFFICES P O Box 359 Appleton WI 54912 Optima and UTOPIA are trademarks of Appleton Papers Inc PL 300N CS 09 05 www appletonideas com ncrpaper
16. If the suggestions presented in this section are not effective in correcting the problems described or if problems not included in this list are encountered please contact Technical Services for additional recommendations E In problems relating to ink where we recommend additives it is advisable that the ink manufacturer be consulted before making alterations to assure that it will not harm the performance of the ink E It has been our experience that when manufacturers are informed of the use of the ink they can provide inks that do not require further modification E For additional general information we recommend the GATF publications Web Offset Press Operating and Web Offset Press Troubles E Specific information relative to inks blankets presses etc is generally available from each manufacturer CAUSE CONDITION GENERAL SPECIFIC RECOMMENDATION Backaway from Ink Ink rolls up Agitate with ink knife or add agitator fountain roller Ink Ink is too short and Add varnish consult ink manufacturer heavy bodied except desensitizing ink Blanket swelling Paper Damaged CB coating Reduce impression pressure and maintain minimum pressures during processing Press Extraneous oil Watch for excessive oil applied during routine equipment maintenance Blanket Blanket wash Consult manufacturer Ink Ink blanket compatibility Consult manufacturer Blinding Plate Improper preparation Make new plate followin
17. adhesive with another pass By the time you returned for the second pass the adhesive that was applied first would already be swelling the fibers and the second application would not be able to move into the stack 3 Check the amount of adhesive your brush is carrying and the condition of the brush Brushes that do not hold their shape are worn out or have dried adhesive in them will not hold enough adhesive Make sure your brushes are in good shape and have been cleaned properly 4 Do I have to use a brush Can use a spray applicator We recommend using a brush because you need a little bit of pressure to move the adhesive into the stack A spray applicator does not provide this pressure A brush is also neater and will ensure total coverage 5 What kind of brush should use What should clean it with and how often Most commercial paint brushes will work with Fanapart Adhesive The actual type of brush is not as important as the care and cleaning It is very important to wash your brush out thoroughly after use If adhesive is left in the brush it will harden and reduce the amount of adhesive the brush will carry If you would like to only wash up once a day you should always keep the brush covered so the adhesive will not start to dry You can do this by covering the brush bristles with aluminum foil Wash the brush with a commercial liquid soap Do not use a soap that contains abrasive grains These will become lodged
18. after receipt of shipment Merchant West 800 922 1727 e Submit a copy of signed Packing List indicating FAX 800 922 1709 discrepancy to Technical Services Department e Submit claim to Appleton Papers Customer Service Department 825 E Wisconsin Ave P O Box 359 Appleton WI 54912 SUCCESS RESOURCES 53 t echnical solutions Complaint Procedure In order that we may best provide you with expedient service and complete answers to any inquiries or com plaints we request certain documentation and samples Most questions or complaints are resolved in principle on the same day they are received by Technical Services E All complaints should be forwarded to Appleton Papers Technical Services Department 825 E Wisconsin Ave P O Box 359 Appleton WI 54912 West 800 922 1723 Central 800 981 9681 East 800 922 1724 Fax 920 991 7341 E The following information is necessary to expedite handling of your complaint e Your company name and address e Your merchant s name and address e Paper identification grade weight color size amount pounds rolls or sheets E Order Identification send the following e Labels e Set number Stencilled on cutsize cartons and on each ream e Set number Marked on folio size cartons adjacent to label E Complaint Information List all significant details concerning nature of the complaint e Description of the problem What happened
19. an offset press Mottle Irregular and unwanted variation in color or gloss caused by uneven absorbency of the substrate Mullen Tester A machine for testing the bursting strength of paper NCR PAPER Brand Carbonless paper in which microcapsules of colorless transfer material and colorless receiving material coated on adjacent paper surfaces enable reproduction of the image printed or written on the original through successive parts without the use of carbon This is accomplished when pressure ruptures microcapsules and transfers the colorless dye solution to the receiving sur face where a chemical reaction occurs causing a colored image to develop OCR Optical Character Recognition Use of an electronic device to recognize marks printed or written on documents and convert them into machine language The process relies on differences in contrast between marks or characters and the surface of the paper Offset A printing process in which ink is transferred indirectly from the plate to the paper by means of a blanket Opacity The resistance of paper to transmission of light or show through gt a lt v Wa oO O SUCCESS RESOURCES technical solutions Glossary Oscillating Rollers Rollers that move back and forth sidewise as they rotate to distribute ink to the form rollers Packing Sheets of paper or plastic used to raise surface of plates or blankets to correct printing height Padding Th
20. and found to be receptive to ink jet inks E Coated surfaces such as the CF side of CFB and CF are less likely to receive ink jet ink without smearing or feathering eS e ies C2 a c N S amp S Lud zz 2 pamm Lu Wa E Trials are recommended before producing forms using ink jet as a printing method Mark Sense E Mark sense forms require very exacting specifications E OCR papers are required E The raw stock surface of OCR CBs are used in some applications E Pretesting is necessary because Mark Sense readers vary in their ability to accept different papers and are often set up for only approved papers E Consult the reader manufacturer s specifications and Appleton Papers Technical Service before producing forms 47 technical solutions Optical Character Recognition OCR Optical Scanning forms with machine readable language are used to eliminate the manual entry of information E Optical Character Recognition OCR is only one type of optical scanning among many E The quality of optical reader equipment has improved to the point where special papers are not as critical as in the past E OCR grades are specifically designed to have the proper physical and functional properties such as shade and reflectance needed to maximize performance with optical readers Because of the difference in scanners it is impossible to say whether any paper is acceptable unless you k
21. being used for the first time should be checked by Technical Services to assure they are compatible 26 technical solutions Fanapart Edge Padding How to Consistently Create Perfect Multi Part Form Sets with NCR Paper Brand Carbonless Sheets Unit Sets Snap Sets Unit Sets Offset Press Offset Press Copier or Laser Printer E m z E Individual unit sets easily separate Individual snap sets easily separate Individual unit sets easily separate from an edge padded stack from an edge padded stack from an edge padded stack D 5 D D 5 W The individual plies of each unit Individual plies can be snapped The individual plies of each unit set can be peeled off out leaving the stub plies intact set can be peeled off NCR PAPER brand carbonless is pro LaserSnap is produced for trouble free Xero Form is produced for ultimate duced for trouble free runnability on runnability on offset presses such as runnability and productivity on copiers offset presses such as this A B Dick this A B Dick such as this Xerox DocuLink 5690 SUCCESS RESOURCES 27 technical solutions Fanapart Edge Padding Edge Padding Mechanism How It Works Printed Stack To Be Edge Padded i A Front Side No coating CB Sheet Vv Back Side Coated Back with dye capsules 3 Part CFB Sh A Front Side Coated Front with dye co reactant Set eet Vv Back Side
22. damage e API not the carrier will process transit damage e Indicate type and extent of damage be specific on claims when the above steps are followed Carrier Delivery Receipt E Next compare piece count on Delivery Receipt with e Sign the Carrier Delivery Receipt and ask carrier piece count of material received If discrepancy driver to also sign If driver refuses so indicate i D f e Indicate discrepancy be specific on Delivery Receipt e Take photos of the load when possible before unloading e Sign the Delivery Receipt and ask carrier driver to sign If driver refuses so indicate e Accept damaged paper and set aside for inspection by carrier or API Field Technical Service Rep e Submit claim to Appleton Papers e Take photos again of the damaged paper when Technical Services Department possible after unloading E You should also receive a Packing List with the e Phone Appleton Papers Customer shipment if you do not please contact Service Department at Appleton Papers E Immediately compare individual items received with each item listed on packing list Discrepancies must be reported in ten days If a discrepancy National Accounts Printer Converter 800 922 1729 FAX 800 922 1712 e Indicate discrepancy be specific on Packing List Merchant East e Sign the Packing List 800 533 9421 e Phone claim to Appleton Papers Technical FAX 800 872 4141 Services Department within ten days
23. draw E Be sure the shear stick which receives the knife is even with the table and in good condition Place a protective sheet of chipboard under the lift to prevent marking of the bottom sheets in a lift E Gang cutting more than one lift of forms cut at the same time can be a convenient way to distribute clamp pressure and prevent capsule damage If there is any capsular damage it will become more apparent in time E The initial lift should be observed shortly after cutting to see if there is any indication of unwanted color indicating capsule damage E If there is no coloration on the CFB immediately after it is cut the final developed color if any should be slight and unobjectionable The cut edge on CFB will show a small amount of coloration This can be minimized by E Using a sharp cutter knife and E Preventing draw i e movement of the paper under the clamp Experience has proven that the reduced clamp pressure required to cut carbonless paper is still sufficient to prevent draw which can affect sheet dimension and give undesirable edge coloration If the printed live area of a job is positioned on an oversized sheet it may be possible to clamp on the part of the sheet to be discarded eliminating any possibility of damage to the printed area Sponge rubber pad is attached to bottom of the clamp bar Chipboard stack prevents clamp damage to lift of paper Proper trimming method
24. for the pigment Viscosity An ink s resistance to flow Wash Marks Streaks in ink patterns on the paper from excessive dampening solution Washup Removal of ink from ink mill and fountain Watermark An identifying mark or pattern made by a dandy roll as the paper is formed Water Penetration A test that indicates the degree of sizing in a paper Web Detector Sensing device that trips off the impression and ink when the web breaks Web Guides Use of electric eyes air resistance or touch to control lateral position of paper flow Web Press Rotary presses that print a continuous roll web of paper Wire Side Side of paper in contact with wire during manufacture Yield An expression for square inches of paper per pound of weight Zigzag Fold The process of folding continuous form web lengths into packs gt a lt v Wa oO O 68 SUCCESS RESOURCES technical solutions Customer Service Technical Services Dept E Complaints E Technical information E Packaging amp Handling E Application Information Appleton Papers Inc Technical Services Dept 825 E Wisconsin Ave P O Box 359 Appleton WI 54912 West 800 922 1723 Central 800 981 9681 East 800 922 1724 FAX 920 991 7341 General Offices Appleton Papers Inc 825 E Wisconsin Ave P O Box 359 Appleton WI 54912 920 734 9841 APPLETC2N What 1997 Appleton Papers Inc Customer Service Department
25. is ink receptive while the non image area is water receptive Long Ink that has good flow properties in the fountain Machine Coated Paper that has been coated on the papermaking machine Magnetic Ink Ink containing a magnetic oxide pigment Makeready Press preparation necessary for printing a job Manifolding Form A multiple part form designed for good writing and print through properties Marginal Word Phrase Letter or Numeral Identifying marks printed on form parts to designate distribution or flow after decollation MICR Magnetic Ink Character Recognition A system of electronically reading information encoded on documents printed in magnetic ink with a special type font Micro Picking Similar to picking except that the particles pulled from the surface are too small to be readily visible Micropiling Micropiling is a variation of piling characteristic of but not limited to CB surface printing It appears as minute particles of build up within the boundaries of the printed image Its damaging effect is limited to image quality Misting Misting is a fine spray of ink droplets thrown off from the rollers in a fast running press This is more likely to occur with a low viscosity ink Moisture The amount of water present in paper Moisture Welts Weather Wrinkles Small raised areas on the outside of rolls caused by absorption of moisture from the air Molleton Cloth used to cover dampening rollers on
26. oO 1 SUCCESS RESOURCES technical solutions Glossary Blocking Undesirable sticking of successive plies or sheets Blockout The use of printed solids or patterns on specific areas of parts of a form set to prevent disclosure of information Body Viscosity or consistency of an ink or vehicle Body Gum Thick varnish used to stiffen inks Bond Paper Chemical wood or rag content papers with basis weights 17 X 22 up to 24 26 NCR PAPER brand used for forms letterheads and general business purposes Breaker Bar A metal bar over which a web of paper is drawn at a sharp angle to reduce curl Bridge The uncut area in a perforation Brightness A measure of whiteness of paper Bulk A bookmaking term for thickness of paper expressed in number of pages per inch under a given pressure Burster Mechanical device used to separate continuous forms into individual sets Bursting Strength Resistance of paper to rupture under pressure indicated in pounds per square inch on a Mullen Tester Caliper Thickness of a sheet of paper expressed in thousandths of an inch Capsules In CB and SC type coatings the micro droplets of colorless dye solution are surrounded by a protective coating These microcapsules are ruptured by pressure above 35 pounds per square inch which releases the dye solution in contact with the CF surface causing the print to develop Capsule Damage CB coating which has been s
27. sheet e Rear and side paper guides should lightly e Pushing the sheet excessively to the register point touch the lift may cause it to buckle and wrinkle as it passes 2 Paper height should be between 16 and 14 below trough the press the sheet separators Reduced impression pressure and quick release e Blower tubes should be adjusted to evenly float 6 compressible type blankets are recommended to sheets just below the separator fingers minimize capsule damage e This will also reduce any tendency for the paper to stick to the blanket e Results can be checked by spraying a CB surface with Instant Replay II CB Damage Indicator 3 In feed wheels should be positioned equally from the sheet edges the suction feet should be located about 1 from the edges 3 zZ aa Qa Lu Lu a WN 6 Use quality inks that dry by oxidation and have lower tack in the 10 12 range on a GATF Inkometer to reduce the possibility of setoff and coating buildup on the blanket Run with the minimum amount of fountain solution necessary for quality printing t Multilith is a registered trademark Use does not imply endorsement 13 SUCCESS RESOURCES N technical solutions Printing Inks The standard inks available for forms printing are generally comprised of a pigment a vehicle and certain additives NCR PAPER brand can be printed with most quality inks normally used by the printer to produce business forms
28. specific recommendations E The use of a non compatible tack reducer can cause offsetting in the roll ink bleeding through the finished form or failure of the ink to dry 14 SUCCESS RESOURCES technical solutions Printing Inks Ink Stability A subject closely related to tack is ink stability E Ink stability is the ability of the ink to maintain its physical and chemical properties throughout the inking system until it reaches the paper E Changes in the stability can be created by contact with the atmosphere when the film is split or by water logging If the ink laydown is not of the best quality the back cylinder pressure may have to be increased to help create a better image E In doing this however care must be exercised not to create too much pressure on the paper as this could cause damage to the pressure sensitive capsules of CB CFB and Self Contained E If back cylinder pressure is changed use Instant Replay II to check for capsule damage Ink Drying Poor ink drying is the cause of many printing problems When printing coated sheets such as the CB side it is par ticularly important to take precautions to insure proper drying Ink Driers There are two types of driers added to inks internal driers and external or top driers E Internal driers dry from the inside out and top driers dry the surface of the ink When ink drying problems occur your ink supplier can adjust the amount of dr
29. the best printing quality and longest wear They are recommended for halftones and fine screen work and usually provide better registra tion There are three types of metal plates smooth grained and wipe on Smooth Metal Plates Smooth presensitized plates require less printing pressure than grained plates to obtain good printing E Smooth plates also carry and transfer less water to the blanket thereby keeping the blanket drier and less tacky E A close check should be made periodically to be certain not to run too dry because this can contribute to dry blanket piling in the non image areas Plate Life and Performance Properly developed plates are necessary to ensure optimum printing results E Plates must be well desensitized in the non image areas to prevent scumming E Image areas of the plate should be developed to produce a solid 6 or 7 on a gray scale to ensure against premature image breakdown When printing CF plate life is comparable to that obtained with other coated papers The uncoated printing side of CB should perform comparable to a regular forms bond Another determinant of plate life and performance is the fountain solution E An improperly balanced or mixed fountain solution can contribute significantly to reduced plate life E The pH of the fountain solution regulates the amount of gum arabic available to the non image areas of the plate E Each plate manufacturer has set the ideal operating ran
30. to be printed and introduction of the Xerox DocuTech system in 1991 altered directly from computers This also ensures that was a quantum leap forward in printing capabilities quality remains strong and consistent throughout the The DocuTech a high end digital copier gives owners length of every run no matter how short or long the capabilities of a printing press with the functionality and flexibility of a copy machine And it makes tasks An additional factor driving the growth of digital that were once complicated simpler than ever outputting is its overall cost effectiveness Due to its simplified nature which does not require film plates or ink high speed digital outputting is cost competitive across a wide range of run lengths even extremely short runs see chart below And since digital is able to save money even on small runs it s like turning your high speed copier duplicator into a business forms printing Light laser to press Additional benefits are forms on demand and discharge background F i reduced forms inventories How Digital Printing Works Electrophotography Photoreceptd Photoreceptor discharge and cleanin QS gt Fuse Toner l Photoreceptor Opportunities in Digital Printing Transfer charge to move TAO Unlike traditional methods digital equipment works by projecting laser light onto a photo receptor to produce a charged image The toner electrostatically jumps
31. two sheets marked A and B face up Xero Form II works well whether you ve got a friction or vacuum feed tray although vacuum is preferred 3 Produce Check Copies Set the copy quantity to 2 and press the START button Then remove copies from the output tray without disturbing the delivered sequence 4 Determine Print Side If the original image has been copied onto the side marked with the A and B designation the paper s print side must be loaded FACE UP in the feeder tray If the original image has been copied onto the reverse side the paper s print side must be loaded FACE DOWN in the feeder tray The paper s print side is clearly indicated on the label af fixed to each ream 5 Repeat Steps 1 3 Load paper PRINT SIDE UP or DOWN as was just determined 6 Check Sequence If the sheet marked A is on top your copier requires STRAIGHT SEQUENCE Xero Form II sheets If the sheet marked B is on top your copier requires REVERSE SEQUENCE Xero Form II sheets solutions Step 1 2 Step 1 2 Step 1 3 Step 1 5 37 O eB gt x lt SUCCESS RESOURCES Xero Form Il Step 2 Prepare Paper Program Copier and Run Job also applies to laser printers 1 Load and Prepare Paper Fan paper and ensure proper stacking and edge alignment before loading paper into feeder tray Place the stack in the feeder tray you intend to use Pro
32. 000 sq in E Remember you are responsible for applying enough ink to produce an acceptable image for your customer Continued on next page Pencil check 23 technical solutions Dry Offset CF Ink Paper Basestocks NCR PAPER brand Spot Safe CB is specifically designed for printer applied CF Ink applications Printers are free to use the basestock of their choice however some general guidelines are recommended These guidelines are listed primarily to ensure selection of a good basestock for best ink laydown and press run performance for desired carbonless imaging capability E The paper base should be relatively free of excessive pinholes dirt fuzz slime spots wrinkles and other visual defects E The paper should be uniform in basis weight smoothness caliper formation and shade E Rolls must be true and uniformly wound with clean slitter edges free from dust and fiber particles One primary consideration that must be followed when choosing a basestock is the pH or acidity alkalinity of the paper E Upon imaging an acid sized base a latent image may occur E You can write test using a CB sheet on your basestock to be printed E An alkaline sized base will reduce this reaction However due to the CB dye oils in the mated sheet there will always be a slight image in the non inked areas of an acid sized base E Because of the chance for latent imaging in acid sized bases we cannot guaran
33. 16 6875 17 463 age carry the decimal point two 23 64 3594 9 128 7 10 7000 17 780 places to the right Thus 63 64 or 4 11 3636 9 236 45 64 7031 17 859 9844 equals 98 44 57 SUCCESS RESOURCES NESS SUCCESS RESOURCES technical solutions Glossary Absolute Humidity The amount of water vapor present in a specified volume of air Acid A corrosive compound containing hydrogen which reacts with certain metals and alkalis to form salt In solution it turns blue litmus red and is characterized by a sour taste It is used in printing for etching plates and in fountain solution The acidity of a solution is generally expressed as pH Adhesion The strength of bond between paper and coatings Air Shafts Pneumatic expandable mechanisms inserted into roll core to position and hold the roll on the press unwind or rewind shaft Alkali A caustic alkali hydroxide or metallic oxide which reacts with acids to form salt In solution it turns red litmus blue and is characterized by a bitter taste and soapy feel Alkalinity of a solution is generally expressed as pH Anhydrous Alcohol Alcohol that is free from water Anvil Cylinder A hardened metal press or collator roll which backs up the score cutting knives Art Work Black and White Reproduction Art Camera Ready or Finished Art Keyline or Pasteup Mechanical Art Final drawing or good sharp print of illustration or type matter
34. 20 1 9 1711 2 822 5 11 4545 11 546 13 16 8125 20 638 1 8 1250 3 175 15 332 4688 11 906 9 11 8182 20 782 9 64 1406 3 572 31 64 4844 12 303 53 64 8281 21 034 1 7 1429 3 629 1 2 5000 12 700 5 6 8333 21 167 1 6 1667 4 233 33 64 5156 13 097 27 32 8438 21 431 11 64 1719 4 366 17 332 5313 13 494 6 7 8571 21 771 2 11 1818 4 618 6 11 5455 13 855 55 64 8594 21 828 3 16 1875 4 763 35 64 5469 13 891 7 8 8750 22 225 1 5 2000 5 080 5 9 5556 14 111 8 9 8889 22 578 13 64 2031 5 159 9 16 5625 14 288 57 64 8906 22 622 7 32 2188 5 556 4 7 5714 14 514 9 10 9000 22 860 2 9 2222 5 644 37 64 5781 14 684 29 32 9063 23 019 15 64 2344 5 953 7 12 5833 14 817 10 11 9091 23 091 1 4 2500 6 350 19 332 5938 15 081 1112 9167 23 283 17 64 2656 6 747 3 5 6000 15 240 59 64 9219 23 416 3 11 2727 6 927 39 64 6094 15 478 15 16 9375 23 813 9 32 2813 7 144 5 8 6250 15 875 61 64 9531 24 209 2 7 2857 7 257 7 11 6364 16 164 31 32 9688 24 606 19 64 2969 7 541 41 64 6406 16 272 63 64 9844 25 003 3 10 3000 7 620 21 32 6563 16 669 1 1 0000 25 400 5 16 3125 7 937 2 3 6667 16 933 1 3 3333 8 467 43 64 6719 17 066 To convert a decimal to percent 11 332 3438 8 731 11
35. 4 iN SAMM aunas 00155 sq in Ton ICM A E A 0 3937 in 1 SQ Kee n ENE 1550 sq in 097 MT 1 short ton 2 000 Ib WM iviecvercitisedisveneseecsres 3 9370 in 1 SQM OF Ca eeeeeeeeeeeeeeee 10 7639 sq ft 1 016MT 1 long ton 2 240 lb 39 37 in or 1 1960 sq yd Hundredweight cwt 32 81 ft Vd RE 119 599 sq yd 45 359 kg 1 short cwt 100 Ib 1hm 328 ft 1 in or 109 yd 13 in Mhassar 2 4711 acres 50 802 kg 1 long cwt 112 Ib Vkit 3280 ft 10 in or 6214 mi ASQ Kiiara 3861 sq mi 6 4516 SO GMan 1 sq in 0929 SQ 1 E tenn aise 1 sq ft 8361 SOM ansiano 1 sq yd 4047 SQ Mnri 1 acre 2 5900 sq km 1 sq mi or 640 acres technical solutions Metric Conversion Guide S e z Z S Fraction Decimal and Metric Equivalents Le MM MM MM 3 1 64 0156 397 3 8 3750 9 525 5 7 7143 18 143 1 32 0313 794 25 64 3906 9 922 23 32 7188 18 256 3 64 0469 1 191 2 5 4000 10 160 8 11 7273 18 473 1 16 0625 1 588 13 332 4063 10 319 47 164 7344 18 653 5 64 0781 1 984 5 12 4167 10 583 3 4 7500 19 050 1 12 0833 2 117 27 64 4219 10 716 49 64 7656 19 447 1 11 0909 2 309 3 7 4286 10 886 7 9 7778 19 756 3 32 0938 2 381 7 16 4375 11 112 25 32 7813 19 844 1 10 1000 2 540 4 9 4444 11 289 51 64 7969 20 241 7 64 1094 2 778 29 64 4531 11 509 4 5 8000 20 3
36. Cutting Excessive paper Reduce clamp pressure to 35 pounds per clamp pressure square inch or less of paper covered by clamp Operate clamp manually to ensure gradual contact with paper See Section 3 Collating and Binding for detailed instructions Chalking Ink Vehicle absorbed Add binding base or body gum consult ink before ink is set manufacturer Ink Wrong ink Consult ink manufacturer Color varies Dampening Dampening feed varies Keep system clean maintain uniform level Dampening Erratic dampening Keep system clean eliminate drafts Dust lint or fuzz Paper Loose dust or paper fibers See Picking buildup 41 Za Oo D oe am 7a Lu aa eS ars SUCCESS RESOURCES technical solutions Troubleshooting Tips CAUSE CONDITION GENERAL SPECIFIC RECOMMENDATION Filling in of screens Press Too much ink Decrease ink flow from fountain Press Impression pressure Check impression to ensure 002 to 003 nip Ink Ink too soft Add binding base or body gum consult ink manufacturer Ink Too much drier Consult ink manufacturer for correct formula Check printing pressures Flaky solids Dampening Too much dampening Decrease dampening water flow Ghost image Press Embossing amp Back Trap See Piling Ink not drying Horizontal streaks Press Loose slipping blanket Tighten blanket Ink fails to dry Dampening Solution too acid Check pH Ink Improper formulation Consu
37. IRS have approved NCR PAPER brand for applications requiring permanency E An NCR PAPER brand image is also feather or bleed free unlike carbon paper images But certain unusual external or chemical factors have been identified that can adversely affect stability of the NCR PAPER brand carbonless images Substances to be avoided and which usually are not factors under normal office and storage conditions include E Contact with certain vinyls and plastics E Contact with or exposure to fresh copies from wet toner copy machines or stencil masters and solvents E Prolonged exposure to ultraviolet light sources such as direct sunlight and fluorescent lighting E Repeated direct contact with hand creams skin oils or related ointments E Storage with unapproved carbon papers E Unapproved label protection tapes E Unapproved shrink film Coated front surfaces may turn yellow with age E This yellowing characteristic may be accelerated with time high temperature certain types of light and some industrial fumes such as exhaust fumes from internal combustion engines E This effect is referred to as resin yellowing Very cold temperatures will slow the development of an image E The image will still develop to maximum intensity at room temperature 50 technical solutions Copying amp Microfilming Photocopies of carbonless images on sheets of NCR PAPER brand are readily reproducible on a wide variety of o
38. Ink Pigments The pigment is finely ground solid particles suspended in the vehicle that impart color E Pigments also contribute to many other properties of the ink such as specific gravity opacity or transparency and permanency to light heat and chemicals E They usually determine the resistance of a print to bleed in water oil alcohol acid or alkali Ink Vehicles A vehicle is the liquid portion of an ink that carries the pigment and binds it to the paper after the ink has dried E Varnish obtained from linseed oil soya oil and other blends of agra oils are the most widely used vehicle in business forms inks today E Other common oils such as cottonseed oil castor oil and fish oil are also used as ink vehicles E A combination of certain synthetic resins with a vehicle will produce many specially desired properties Ink Additives Ingredients such as driers waxes lubricants gums starches and wetting agents are used to impart special characteristics E Driers for example act as catalysts to speed the oxidation and drying of the varnish E Lubricants will reduce the tack of the ink and cause it to set quickly E Additions must be carefully controlled in the pressroom since each pigment vehicle combination will behave differently H It is advisable that the ink manufacturer be consulted before altering the ink Ink Feed The inking system for each offset printing unit consists of an ink fountain fo
39. Make sure to jog the stack correctly We also do not recommend using Fanapart on other carbonless products Each manufacturer formulates e DON T RUSH Moving too quickly when applying the their adhesive for their own product Best results are adhesive may result in some areas not being seen when the adhesive and paper are matched covered well enough Do it right the first time 9 have a job that has ink right up to the edge of the e USE A GOOD BRUSH Using the proper technique and sheet and it won t pad What s wrong a brush in good condition will result in a reliable pad A layer of ink on the paper coating will not permit Remember a brush is a lot less expensive than the adhesive to penetrate correctly Try to redesign a re run the job so that the printed image does not bleed off the edge to be padded 5 o 5 L SUCCESS RESOURCES 31 technical solutions Digital Duplicators Overview Digital duplicators are computerized versions of the old mimeograph machine except they are faster m h a cleaner and more efficient Today s digital a way 4 duplicator incorporates a scanner and thermal 4 3 head and has the ability to print up to a 600 dpi resolution Digital duplicators fill the gap between copiers and offset printing for businesses or organizations with high copy volume and a limited budget d E Appeal Digital duplicators are emerging as an affordable alternative for quick print
40. SS technical solutions Fanapart Edge Padding os Brush e Jog stack of paper by hand or machine Sheets must e Saturate the bristles with enough Fanapart High smoothly align along the edge to be padded Strength Padding Adhesive for several strokes Start with a dry clean 11 2 to 2 brush e With a fully loaded brush apply adhesive to the entire edge to be padded Start from the bottom center of the stack stroking several times outward to the edges and work up e Repeat strokes in same area to ensure 1 8 adhesive penetration into the stack Do not apply one light coat to the entire area then apply a second coat oO 5 G So UO Place e Place stack on flat surface or in padding rack Edge to be padded should not overhang support base e Place weight distribution board on stack flush with edge to be padded Board must be as wide or wider than edge to be padded Dry amp Fan Apart e Let stand for 30 minutes before packaging 24 hours recommended before using e When dry fan forms to separate sets Weight e Place weight on board to bring sheets into contact with each other Use enough weight to restrict paper separation to about 1 8 when thumb is firmly run down corner SUCCESS RESOURCES 29 BUSINESS technical solutions Fanapart Edge Padding Frequently Asked Questions 1 How can I reduce wavy edges
41. The buffer will control the pH to the level it is designed to handle until the buffer is exhausted At that point the fountain solution is no longer able to tolerate outside chemicals and the pH will start to change Too acid conditions can cause the following problems E Toning due to etching of the plate E Ink drying is retarded E Ink will emulsify E Ink rollers will not accept ink stripping E Plate wear is accelerated E Plate will not accept ink or have low contrast blinding E Ink color changes may occur if too acid a condition exists Too alkaline conditions can cause the following problems E Plate wear E Toning tinting of plate 16 technical solutions Dampening Systems amp Fountain Solution Conductivity Conductivity is the ability of a solution to conduct an electrical charge Conductivity is a measure of the amount of available ions present in the solution The more available the higher the conductivity Conductivity is measured in micromhos by a meter In the printing process a workable conductivity range is determined by the requirements of the plate being used the base water used the inks and the type of dampening system There are both good and bad dissolved ingredients ions which are measured when a conductivity reading is taken The good components are from the fountain solution and are used to clean the plate The bad components are contaminates which are collected in the prin
42. anapart Adhesive Use a clean dry brush minimum 1 is recommended and apply a liberal coat of Fanapart High Strength Padding Adhesive starting at the bottom center brushing horizontally out to the edges and moving up gradually Do not oversaturate the paper Then rinse the brush in water and re seal the adhesive container Step 3 1 3 Allow Fanapart Adhesive to Dry Let the stack stand undisturbed for 20 to 30 minutes to ensure proper adhesion and Fanapart performance 4 Fan the Form Sets Apart Remove the weight and distribution sd aie board from the stack Starting at the bottom of the stack fan the sets apart Lightly run your thumb along the corners of the padded edge to fan the sets apart perfectly The forms are now ready to use or be stored for later use Step 3 4 Additional information can be found in your handy Xero Form Il Sequence Guide O eB gt x lt SUCCESS RESOURCES 39 technical solutions Troubleshooting Tips This section consists of a list of conditions that may occur when processing NCR PAPER brand along with recommended corrective action E The recommendations are listed in the order that our experience indicates should be followed for the fastest solution of the problem E Those conditions common to all paper grades which are normally solved through the operators general knowledge and experience have not been included in this listing E
43. ay at pump gas receipts Thermal solutions technical GENERAL INFORMATION label products are sold to companies who apply pressure sensitive coating and then distribute to label manufacturers Thermal tag ticket and chart grades are sold to specialty printing companies who convert them to finished products such as entertainment tickets tags coupons and medical charts Coated Free Sheet Appleton Papers sells its UTOPIA family of coated free sheet papers to merchants printers and converters who use it to produce annual reports upscale magazines catalogs advertising and promotional materials and other commercial printing as well as to manufacture labels envelopes and books Specialty Coated Products Appleton Papers Specialty Coated Products are sold to merchants printers and converters and are used in a wide variety of niche market applications Facilities Headquartered in Appleton WI the company has 30 sales offices throughout North America Appleton Papers operates a pulp and paper mill and coated free sheet complex at Combined Locks WI a pulp and paper mill at Roaring Spring PA a paper mill with integrated recycling operations at West Carrollton OH a paper mill focused on coated free sheet production at Newton Falls NY coating and converting plants at Appleton and Harrisburg PA and a carbonless capsule plant at Portage WI Distribution centers are located in Appleton WI Harrisburg PA Floren
44. ce KY Kansas City KS Portland OR Los Angeles CA Albany NY Davenport IA Atlanta GA and Peterborough ON APPLETC2N What Ideas Can Do ste Headquarters O Manufacturing Facilities A Distribution Centers SUCCESS RESOURCES NESS About Appleton Papers Company Promise Our 4 300 employees are dedicated to meeting or exceeding customer expectations in all aspects of every transaction with Appleton Papers We call this Customer Focused Quality We believe customers define quality for Appleton Papers and one way we support that belief is by offering an Unconditional Satisfaction Guarantee for all our carbonless and thermal paper products and related services Visit our web site for more information www appletonpapers com Leadership Through Customer Focused Quality Appleton Papers quality improve ment process is known as Customer Focused Quality Customer Focused Quality is defined as meeting or exceeding customer expectations in technical all aspects of every transaction with Appleton Papers The CFQ process focuses on both internal and external customers It is based on the principle that every employee serves a customer Knowing your customers identifying their expectations measuring the effective ness of your actions and implementing methods to achieve continuous improvement are the fundamental elements of the CFQ process Appleton Papers guarantees your satisfaction If you are dissa
45. check the amount of CF Ink laydown compare the sprayed area to the CF Ink Color Standard see page 24 E The blue color of the CF Ink area should meet or exceed be darker than the color shade of the CF Ink Color Standard Checking CF Ink with CF Indicator Spray Densitometer check for CF Ink E A check of color hue on a reflection densitometer using the blue color setting can also differentiate CF Ink laydown amounts E Questions regarding the use of a densitometer for this purpose should be addressed to Appleton Papers Inc Technical Services Image Development To check that the amount of CF Ink that has been applied is sufficient the following method is recommended a zZ oc Az Lu Lu L Za E Obtain sheets of the NCR PAPER brand CB surface that will be used to image the CF Ink surface when the form is collated E Place the CB surface in contact with the CF Ink surface and write on the form so that an image will develop on the CF Ink surface E Evaluate the image to determine if it is an acceptable image for your customer Note the ability of CF Ink surface to make an image will decline slightly once the CF Ink has dried completely E Make sure that the image that you initially obtain is slightly better than you need When acceptable image levels are obtained the following conditions are usually met e CF Ink film thickness 3 to 4 mil laydown e One Ib CF Ink covers approximately 300
46. d them in order for further processing or use See Fanapart Emulsification A condition when the offset ink and fountain solution mix 61 SUCCESS RESOURCES technical solutions Glossary Endorsability The writing upon the CB portion of a carbonless sheet such as endorsing a check Fine point pens can give inconsistent results due to coating accumulation at the point Etch Offset Lithography A dilute acid that is mixed with the dampening fountain water to increase water acceptability in the non printing areas of the plate Etch Photoengraving To image a plate by chemical or electrotype action Fanapart A system of edge padding using a special adhesive that enables a lift of glued forms to be quickly and easily separated into individual sets by fanning Fanfold The process of folding a web width of paper into a form set with a subsequent zigzag fold to make packs of completed forms Feathering A form of bleeding in which fine lines of color radiate from the imaged areas Feeder A mechanical device on a printing press that separates and delivers the sheets into the press Felt Side The top side of the sheet from a fourdrinier paper machine Flaky Solids Printed solid ink areas on paper that have the appearance that the ink has flaked or peeled off Flat Side The ends of a paper roll Flow The tendency of an ink to level out in an ink fountain Flying Paster A mechanism that allows
47. der E Appleton Papers makes no guarantee of the readability of bar code carbonless images NCR PAPER brand grades have been used successfully for these types of applications testing recommended MOCR OCR E Appleton Papers produces specialty grades for MICR applications E Appleton Papers MICR MOCR grades meet eAMB Estandares Papa El Processo de Cheques Mexican Standard ISO 1004 eAPACS CBS1 Standard E Appleton Papers also produces grades for OCR applications E Our OCR CB grades are sold for specialty medical insurance retail and other applications where OCR is being used with machine readable fonts E OCR scanners are increasingly flexible so other grades may work but only OCR qualified grades are recommended E Appleton Papers strongly recommends that MOCR OCR forms are trialed in all equipment used in the applications 46 SUCCESS RESOURCES technical solutions Specialty Applications CMC7 E CMC7 is used for checks in Europe South America and some regions of Asia E CMC7 is a hybrid between MICR and bar coding Ink Jet E Ink jet printers are being used to apply specialty fonts and graphics to NCR PAPER brand carbonless E This equipment includes small desk top ink jet printers and large ink jet printing presses E The large presses are most often used for applying variable data to preprinted forms for direct mail applications E The raw stock surface of some CB grades has been tested
48. e adequate coverage or effectiveness of the desensitized area Ink Fluid or viscous material of various colors used in printing The ingredients are determined by the printing process type of paper and the end use requirements Instant Replay CF material in an aerosol spray can that is used to detect CB damage Intaglio A direct process printing from an ink filled recessed image plate Jog The process of aligning sheets of paper for further processing Jump Perforation Perforations applied partially to the form length by cross perforating cylinders Knurled Wheel A rough surfaced wheel used on collators to break through the paper coating exposing fibers in the stub or margin to give improved adhesive performance Ledger Chemical wood or rag content papers in the 24 to 36 17 X 22 range used for bookkeeping and machine applications because of their superior physical properties Legibility Clarity or definition of print Letterpress A direct process printing from relief type or plates Letterset Dry offset printing from plates with a relief image 63 technical solutions Glossary Lift A stack of paper Line Hole Punching Equally spaced holes punched in one or both margins of continuous forms to facilitate feeding in forms handling equipment Lithography The process of printing from a planographic surface Plate that has been sensitized and selectively developed so that the image area
49. e air voids in the compressible blanket will act as tiny springs that contract under pressure then regain their original form rapidly when the pressure is removed E Lateral flow Smee SS Ua which is the displacement of a blanket on both sides of the pressure point is found only with non compressible blankets Lateral Flow Non compressible blanket E Lateral flow can cause blanket bounce or blanket chatter at the printing nip and ultimately damage the CB capsules E Lateral flow is reduced by using compressible blankets E Compressible blankets usually have a more even caliper across the web which reduces concentrated pressure points and produces more uniform ink coverage and better release General Information Here are some helpful hints pertaining to blankets when running NCR PAPER brand D zZ oc Az Lu Lu TL Za E Sponge the blanket with water after every washup so the blanket surface does not lose its ink receptivity by becoming glazed or hard This will keep the printed impression from gradually losing its sharpness E To avoid horizontal streaks in the printing make sure the blanket is kept tight A loose blanket tends to follow the plate and slip on the blanket cylinder Remember the greater the plate to blanket pressure the worse the slippage E Check the squeeze between blanket and plate frequently to make certain it is within the accepted tolerance of 002 to 003 Press
50. e process of gluing multiple sheets along the edge to hold them together Pallet A wood base consisting of two large opposing side frames with top and bottom cross members that is used to facili tate handling of paper rolls Pallet Pak A type of packaging for pressure sensitive grades in which the wrapped rolls are placed on a pallet and enclosed in a corrugated carton Paper Clamp The pressure actuated bar on a guillotine that holds the lift of paper down to prevent draw Pencil Check Test before printing to assure that correct side will be printed Perfecting Press A press capable of printing both sides of the paper in one pass Perforate Placing alternating in line cuts and ties in paper for subsequent separation pH The degree of acidity or alkalinity in a solution pH 7 is neutral above is alkaline below is acidic Picking Picking is characterized by coating and or fiber being pulled off in the Z direction of the paper This can be caused by too high of an ink tack too fast of press speed poor internal bonding of paper fibers or insufficient binder in the coating In commercial printing picking can also occur between two or more layers of ink Picture Framing Slitter or coating dust that accumulates on the blanket outlining the edge of the sheet Pigment Microscopic particles added to printing inks to give color body and opacity Piling Piling is the result of ink in water emulsification mixing wi
51. e task of manually converting information into machine readable language 48 SUCCESS RESOURCES technical solutions Magnetic Ink Character Recognition MICR Development The American Bankers Association ABA approved the MICR standard in 1958 This system was developed because the manual procedures used for processing the growing flow of paper documents in the 1950 s was becoming inadequate E Encoding with the E13B font referred to as MICR numbers makes checks deposit tickets or forms machine readable E Generally speaking checks are encoded with three sets of MICR numbers routing customer account and the amount E A rigid set of standards have been developed for MICR by ANSI including size and location of characters number of digits allowed within a field of information the sequence of these fields and proper ink densities MICR Ink Toner and Transfer Ribbon E MICR pigments used to maaa E print the E13B font 0759 PSP 2 contain iron oxide are E iron oxide is electronic 0 759048 S5eaRO0Ot ally excited forming a F magnetic field which can be read by specially designed equipment E Each MICR character emits its unique signal which can be interpreted by the reader to designate the individual character E There are three widely used methods for applying MICR pigments to documents eMagnetic ink is a specially formulated ink with iron oxide in it eMagnetic toner is used in co
52. ecial adhesive is applied to one edge of the stack in order to create the multi ply forms Appleton Papers Fanapart High Strength Padding Adhesive delivers consistent reliable edge padding It s easy to use and dries faster than other padding adhesives You can use it with all NCR PAPER brand carbonless sheet products And it only adheres to the carbonless coated surfaces CB and CF it will not adhere between the back of the CF sheet the last ply of one form and the top of the CB sheet the first ply of the next form Unit sets non continuous form sets with a glued edge and snap sets non continuous form sets with a laser scored construction are available in 8 1 2 x 11 8 1 2 x 11 1 2 and 9 x 11 standard sizes Other sizes are available Please note that all of our options produce dark sharp images down to the last ply 36 SUCCESS RESOURCES technical Xero Form Il How to Use Xero Form Il In addition to its unmatched features Xero Form II is also incredibly easy to use To easily create your own form sets simply use the following guide Step 1 Determine Straight Reverse Sequence Requirement and Print Side applies to both copiers and laser printers 1 Mark Plain Paper Sheets Mark 2 sheets of plain xerographic bond paper A and B 2 Load and Prepare Copier Place the original you wish to copy face down on the copier platen and position it properly then load the
53. ers Copies can be made for a fraction of the cost typically around one third cent per copy of a photocopy E Quality With higher 600 dpi resolutions fine lines and shading meet the quality of digital copiers or high speed laser printers E Applications Digital duplicators are Riso GR3750 perfect for print jobs between 25 and 5 000 copies Many models are capable of delivering up to 8 000 10 000 impressions an hour and cost less to purchase than copiers with E Operation Digital duplicators take about 30 seconds comparable speed to produce the first copy and about 5 minutes to produce 500 sheets They can be interfaced with PC E Ink A high density water base ink held in a cartridge or Macintosh computers No technical training or is placed inside the print cylinder This ink cartridge special skill is required to operate a digital duplicator technology keeps hands clean and facilitates quick ink changeovers without wash up E Maintenance Digital duplicators are less service intensive than copiers E Feeding system Friction on most digital duplicators Riso is a registered trademark Use does not imply endorsement 32 SUCCESS RESOURCES NESS technical solutions Digital Duplicators Manufacturers Characteristics Issues Riso Inc Ricoh and Duplo are the leading E Print resolution is poor on older digital duplicator manufacturers of digital duplicators models Today s models have improved p
54. ess The colored image produced by the union is nonsmearing Three different types of carbonless paper CB CFB and CF are used to create a three ply business form set please refer to the enlarged photos with supporting text below CB meaning Coated Back is the original or top sheet of a multi part form This sheet is microscopic capsules dry to the touch but containing a solution of colorless dyes and oils These materials are permanently sealed within plastic like capsules until the capsules are broken by pressure CFB coating or Coated Front p and Back constitutes the intermediate sheets of a multi part form The front side has the CF coating the reverse side has the CB coating Several intermediate sheets can be used to provide pa the desired number of 5 copies m TES CF or Coated Front is the receiver part and generally the last ply of a multi part form The front side of this receiving sheet is coated with a resin coating which reacts with the colorless dyes released from the broken capsules to develop a color on the CF surface in the identical pattern of the imaging pressure CF Coating Encapsulation Process Although there are several variations the basic process of microencapsulation is as follows Colorless dyes are dissolved in oils and mixed with aqueous solutions to form large dye oil drops By a homogenization process the large drops are reduced to microsco
55. examination prior to final printing Punching A method of making holes by means of a two part die Ream Five hundred sheets of paper of a specific size Register Alignment of forms images or ink colors relative to each other Relative Humidity RH The amount of water vapor present in the atmosphere expressed as a percentage of the maximum that could be present at the same temperature Resin Yellowing The term used to describe yellow discoloration on CF surfaces This occurs over time as the resin in the CF reacts with the atmosphere Certain storage conditions can cause greater amounts of the discoloration Reverse Stacking A technique used when guillotining assembled forms having varying length plies to eliminate the need for building up the thick end of the lift Ridges Raised streaks running in the grain direction in rolls or skids of paper resulting from localized higher caliper or lower compressibility of the paper Rope Wrinkles A distortion having a rope like appearance running in the grain direction in rolls or skids of paper resulting from localized lower caliper or stretching These normally disappear during running and do not cause wrinkles or misregister Rotary Collation Assembling sets in the proper sequence from rolls printed on a roll to roll press Round Side The cylindrical or curved side of a paper roll Rubber Plate Relief molded rubber plate used for direct transfer of ink to paper Sa
56. f receipt E Forms produced containing CF ink printed parts should be used within two years of production Ink Storage E Normal climatic conditions will not affect CF ink If stored or received in adverse conditions bring ink to pressroom temperatures before use Do not store above 140 fahrenheit Precautions E Do not use any additives with CF ink Any additions will change the performance of the ink and result in a decline of functionality E CF ink applied on a bond weight CB sheet may cause unwanted color development E Forms produced with CF ink printed plies cannot be fanapart edge padded E Certain substances have been identified which can adversely react to NCR PAPER brand CF surfaces and CF Ink These include unapproved carbons shrink wraps wet toner copiers etc E Incompatible paper basestocks may result in imaging outside of the non inked areas See page 24 for further information Press Instructions Dry Offset Applications Only Full Printing Tower Preparation E Color wash rollers residual ink will contaminate CF ink E Roller stripe settings should be set to meet manufacturer s specifications Proper CF Ink settings should be 1 8 inch to the plate Stripes must be uniform across the printed web to ensure proper laydown Improper roll settings may cause piling E Plate and blanket cylinders should be packed to ensure proper printing nip squeeze Idler Rolls E Must be free turning E Mus
57. fety CB An NCR PAPER brand grade in which the CB coating is applied to the back side of safety paper Safety Paper A special patterned grade for checks or documents made to reveal any attempts at chemical or physical erasure or alteration SC Self Contained A self imaging grade of NCR PAPER brand in which both dye and reactant coatings are applied to the front side of the sheet SC CB Self Contained CB A self imaging grade of NCR PAPER brand that has CB coating on the back surface allowing it to be used with transfer grades of NCR PAPER brand Score To impress or indent paper to facilitate folding Scumming Scumming is an imbalance in the printing process causing the non image area of the plate to accept ink Not to be confused with toning which differs in appearance and is ink water oriented scumming is not easily cleaned up and can result from one or more of the following situations Incompatibility between ink and fountain solution Plate wear Poorly desensitized plate Poorly formulated ink Improperly set rollers Paper contaminants Setoff Offset Undesirable transfer of ink to a contacting surface Shelf Life Shelf life is the length of time printed forms are stored under normal conditions before they are imaged for use gt a lt v Wa oO 1 66 SUCCESS RESOURCES technical solutions Glossary Short An ink that does not flow freely in the fountain
58. ffice copy machines E Blue Print image gives satisfactory results in most situations E Black Print image provides optimum results E When possible construct a dummy set Write or type on it as in its end use Copy and evaluate E Little or no difficulty should be encountered on any diffusion dye transfer electrostatic or dual spectrum machines E NCR PAPER brand images cannot be copied on thermal infrared systems for these systems copy pigmented images only Some office copiers have difficulty copying gray and blue images but it s usually possible to get good results if the following suggestions are considered E The primary variable is the copier Keep it well maintained and properly adjusted E Copy quality depends upon good print definition and intensity of the original E For best results copy a ply closest to the original in a form set for the image sharpness should be better than a ply further down in the form E If possible avoid copying goldenrod or pink colored sheets on xerographic machines E On electrostatic copiers particularly those that use zinc oxide coated papers paper colors that detract from copiability are blue green and goldenrod Occasionally some background discoloration and print bleeding occurs when NCR PAPER brand documents are placed in contact with copies from an electrostatic copier having a liquid toner system T a SS D Ca 5 O Lu Z Lui Oo
59. g manufacturer s processing recommendations and develop to a solid 6 on gray scale Dampening Too much acid Check pH Dampening Too much gum Reduce gum in dampening system Check for swollen blanket Press Plate blanket pressure Check impression to ensure 002 to 003 nip Ink Improper formulation Consult ink manufacturer Continued on next page Low tack inks recommended for coated papers will occasionally cause this condition if they are not properly formulated 40 SUCCESS RESOURCES technical solutions Troubleshooting Tips CAUSE CONDITION GENERAL SPECIFIC RECOMMENDATION CB Damage Paper Transit damage Inspect all incoming shipments for damage from mishandling or dropping contact carriers for improved handling and damage claim Paper Excessive truck Reduce clamp pressure to minimum amount clamp pressure needed to lift material for transporting Use pressure relief valve on clamp trucks Press Excessive impression Reduce impression pressure pressure Press Localized damage Avoid excessive impression pressure and raised metal plates Press Crash imprinting Keep transfer area clear of solid or heavy density imprint Press Perforating Replace perforating jacket when excessive area abrasion is created Collator Localized damage All feed and guide mechanisms or any points where the paper is contacted by the equipment should be set to the minimum pressure consistent with satisfactory performance Shear
60. ges for pH and conductivity for their plates the fountain solution should be filled to match these recommendations 18 technical solutions Blankets Blankets have a direct effect on the quality of your printing The best assurance for quality blankets is to buy from a reputable firm E An offset blanket is wrapped around the cylinder and held with sufficient tension or adhesive to prevent slippage during printing E The most commonly used offset blankets consist of several plies of long fiber cotton fabric calendered together with a special rubber cement and then coated with a rubber compound on one side E The thickness of the individual rubber layers vary according to press specifications and requirements E The exact thickness is not as important as thickness uniformity Variations in thickness of up to 001 are normally acceptable E A clean properly cared for blanket should be used at all times However if the blanket becomes tacky an application of blanket powder available from blanket suppliers or talcum powder is helpful in preventing the web from sticking to the blanket Compressible Blankets To minimize capsule damage the use of compressible blankets is recommended E The compressible blanket contains tiny air pockets into which the blanket fibers and rubber can be displaced under pressure Pressure Vertical Compression Compressible blanket E The material that forms the walls of thes
61. h Calculation To calculate the length of paper on a roll we recommend using the following formula L D2 d X 06545 C Where L length feet D outside diameter of roll inches d outside diameter of core inches C caliper inches technical solutions Calculating the length of paper 0037 in caliper on a 16 O D roll with a 4 O D core would be accomplished as follows L 162 42 X 06545 0037 L 256 16 X 06545 0037 L 240 X 06545 L 4245 Feet Metric Conversion Guide Area Weight amp Mass Length Sq centimeter sq cm Milligram mg Gram 1 000 Millimeter mm Meter 1 000 VAERE E 0001 centare ca Centigram cg Gram 100 Centimeter cm 2 Meter 100 or 1 ca 10 000 Decigram dQ eee Gram 10 Decimeter dm 008 Meter 10 Basic Unit Centare ca Basic Unit Gram g Basic Unit Meter m which is 1 square Meter sq m Kilogram kg Gram x 1 000 Decameter dkm 0 Meter x 10 Are A viccs sccstvadei caicoscescazigant 1 ca x 100 Metric Ton MT 00 2 204 6 lb Hectometer hm Meter x 100 Hectare h 1 ca x 10 000 TG raa AAE E 0353 oz Kilometer km Meter x 1 000 Sq kilometer sq km 1 kg or 1 000 g sossen 35 274 oz Myriameter mym Meter x 10 000 a wnees 1 ca x 1 000 000 or 2 2046 lb VIN eranan 0039
62. ible with the ink and plate A fountain solution which is too acid or too alkaline will retard in drying It is important that a Pe write test be done see page 8 on the coatings is utilized This test should pick up any image intensity reduction caused by the ink For backprinting use light face type or screened images u if heavy ink coverage a zZ oc Az pis Lu Lu TL Za 21 SUCCESS RESOURCES technical solutions Dry Offset CF Ink Introduction CF Ink is a CF coating applied in an area to produce the CF ply of chemical carbonless forms CF Ink can be applied to the paper base of your choice see page 24 This ply can then be used in conjunction with NCR PAPER brand of carbonless paper CB coated back and CFB coated front and back E CF Ink must be applied by the dry offset or letterpress printing process as the last color down using a full offset tower inking system or equivalent rubber tower E CF Ink can be applied on the maximum size solid your press will print without form roller starvation mechanical ghosting E Should starvation occur consult press manual or press manufacturer E CF Ink is compatible with both Blue Print and Black Print grades of CB and CFB NCR PAPER brand E Questions or inquiries regarding the CF Ink product itself can be directed to Technical Services Storage and Handling Information Shelf Life E CF ink should be used within six months o
63. ides should lightly G set buckle at 12 to 14 touch the lift 6 Set bump at lowest setting to ensure good print quality 2 Set the paper lift height to a point where the suction and minimum capsule damage feet just barely pick up the top sheet of paper e Begin with the pile height adjuster set between D Quick release compressible type blankets are No 2 and 4 recommended to minimize capsule damage and reduce any tendency for the paper to stick to the blanket e Results can be checked by spraying a CB surface with Instant Replay II CB Damage Indicator 3 Place paperweight bar in one of the two forward notches which will help control the amount of air separating the sheets e In some situations your press may perform better 8 Keep ink flow to the minimum necessary using the lightweight paper kit Part No 1 3507 e Use quality inks that dry by oxidation and have lower ink tack in the 10 12 range on a GATF Inkometer to reduce the possibility of setoff and coating buildup on the blanket Run with a minimum amount of fountain solution necessary to keep plate clean and for quality printing t A B Dick is a registered trademark Use does not imply endorsement 12 NESS SUCCESS RESOURCES technical solutions Printing on an AM Multilith Press 1250 1850 2650 Fan and load paper in the center of the feed table The side register guide should barely tap the side of e Check to assure printing side is up the
64. iers to match your needs E It is not recommended that driers be added by the printer unless specified by the ink manufacturer E There is a point when too much ink drier will extend drying times Fountain Solution Fountain solutions can retard drying in inks E If the pH of the fountain solution is too acid for the ink generally 4 5 or more acid or if the ink is contaminated it will stay open longer This could lead to offsetting tracking and other problems E Other ink drying problems created by an improper fountain solution are ink emulsification and over wetting of the paper so it will not accept ink as well D zZ ae ee Lu Lu Za Ink Film Too dense an ink film will create drying problems E Higher pigmented inks will allow the printer to get good color without laying down too much ink E The thinner the ink film the faster it will dry Precautions and Tips Although it is generally true that standard inks used with conventional printing processes are suitable for NCR PAPER brand observation of the following guidelines can help avoid problems related to carbonless paper and ink E An ink of reduced tack will minimize coating pick or loose material pick up E Certain formulations of inks may develop a halo as the ink components separate A simple change in ink formulation should correct the problem The ink manufacturer involved should be contacted regarding the recommended change E I
65. in 1907 Appleton Papers has earned a reputation as an innovative producer of high value added paper products The company is the world s leading producer of carbonless and thermal papers and a premier producer of a broad range of coated papers used in a variety of commercial printing and specialty applications Setting Appleton Papers apart in such competitive markets is the company s expertise in coating its aggressive investment program in manufacturing technology and its unique approaches to customer service and logistics Driving all these programs and processes are the people of Appleton Papers and their single minded commitment to meet or exceed customer expectations in everything they do Markets We Serve Carbonless Appleton Papers sells NCR PAPER brand carbonless paper directly to converters and business forms printers who print carbonless forms and to paper merchants who stock and sell carbonless paper to printers Companies and individuals who use printed business forms and carbonless paper for transactions are the end users of carbonless paper Thermal Appleton Papers sells its OPTIMA brand of thermal paper to converters who in turn sell facsimile paper to resellers such as office supply stores office superstores warehouse clubs mail order catalogs equipment dealers merchants and original equipment manufacturers OEM s Thermal papers are also increasingly used for point of transaction automated teller ATM and p
66. in the bristles and interfere with adhesive application After the brush is washed we recommend wrapping the end in a paper towel This is done so that the brush dries properly and maintains its shape This will allow it to hold more adhesive NOTE Always cover the adhesive container when not in use Leaving the cover off will change the adhesive s ability to penetrate correctly Water and fluids will evaporate changing the adhesive s viscosity 6 Why can t I edge pad on two sides We do not recommend applying adhesive to more than one side because it may cause unwanted sheet separation and wrinkles If you must edge pad two sides to satisfy your customer we recommend that you perform a fresh cut on the edges to assure complete alignment of all the sheets in the stack 7 Can put a sheet of bond paper into my carbonless form set No The bond sheet does not have the proper coating for edge padding Remember form sets separate at uncoated surfaces If an uncoated bond sheet is in the set that is where it will separate 30 technical solutions Fanapart Edge Padding 8 Can we use other manufacturers adhesive on NCR Helpful Hints PAPER brand carbonless Can we use Fanapart Adhesive on other carbonless e JOGGING IS CRITICAL Proper alignment of the sheets products No We do not recommend using other is the difference between a good padding job and a manufacturers adhesive on NCR PAPER products bad one
67. ing ccccsecseeeseesens 35 NCR Paper brand Digital Offerings 006 36 How to Use Xero Form Il ccccccccceeeeeeessseseeeeeeees 37 39 Troubleshooting Tips Troubleshooting TIPS iaria 40 45 Miscellaneous Information Specialty ApplicatiOMS srira 46 47 Optical Character Recognition cceseeeeeee 48 Magnetic Ink Character Recognition 49 Shelf Life amp StOrage ccccccescessseesseesessteeeseeeeees 50 Copying amp MitrofilM Ng issii 51 Instant Replay Ul cecececsseeeeseeeeeesseeessteeeseeeeess Receiving API Products Complaint ProceCure cccsccceessecesseeeeeesteeeeeees Weight Size amp Metric Conversion Guide 55 57 Glossary Glossary anaiona ea aA A A aE 58 68 Customer Servite saisai iaaa 70 GENERAL INFORMATION SUCCESS RESOURCES technical solutions Introduction Our goal is to help your company be more productive and profitable and maintain a technical edge As with all our Success Resources programs Technical Solutions is a result of Appleton Papers uncompromising dedication to customer satisfaction and our commitment to the industry Technical Solutions wil help you E Enhance printing quality for more satisfied cus tomers E Increase productivity for improved output rates E Reduce waste to make your business more profitable E Improve employee skills to be more efficient Technical Solution
68. ing is typically sold to a wastepaper dealer who may require the waste to be segregated While some paper waste is unavoidable when producing business forms Appleton Papers is dedicated to helping our customers minimize waste and improve production efficiencies For consultation regarding waste reduction and production improvements please contact our Technical Services Department 5 E q ey p All NCR PAPER brand carbonless products are recyclable SUCCESS RESOURCES 9 JESS Storage amp Conditioning Storage Storage and conditioning can effect paper performance on press E NCR PAPER brand of carbonless paper is manufactured to be in equilibrium at 71 degrees F and 45 RH E For ideal pressroom performance the printing plant should be controlled to match these temperatures and RH values E It is very important that the relative humidity RH be maintained above 35 RH during the heating season air drying to reduce abnormal static and paper stretch problems technical solutions E As a matter of good inventory practice NCR PAPER brand should be used on a first in first out basis Conditioning Proper conditioning of paper will alleviate some of the problems caused by fluctuating RH but nothing short of humidity control in the pressroom itself can eliminate them E Unless the temperature and relative humidity are the same in the paper storage area and pressroom wrapped reams should be stored in
69. ish consult ink manufacturer Ink Too much ink Adjust ink water balance pH should be between 4 0 and 5 0 Ink Too much drier Consult ink manufacturer Dampening Dirty or worn covers Wash dampener or ductor roll covers Dampening Greasing Clean fountain and distribution roller re etch Dampening Dampening roller Reset rollers check for trueness consider pressure enclosed system eliminating plate dampening rollers Dampening Emulsifying sensitizing Use stiffer ink eliminate wetting agent coating agent consult manufacturers Dampening Water streaks Adjust ductor distributor roller contact Dampening Insufficient acid or gum Check pH Press Form roll pressure Readjust form roll pressure Plate Plate wear Wash plate more frequently to remove foreign particles Plate Oxidation Dry plate quickly Keep storage areas as dry as possible Slur or double image Press Loose blanket Replace or tighten blanket Press Wear or malfunction Have press serviceman check press out Sticking Blanket Blanket wash too strong Change blanket wash consult blanket and chemical manufacturers Paper Poor coating adhesive Contact Technical Services Department balance Tinting Dampening Fountain solution too acid Check pH Dampening Ink water balance Washup readjust ink and water Ink Ink is too soft Add binding base body gum or varnish consult ink manufacturer Plate Plate processed wrong Make new plate Wash marks Dampening Excessive water Decrease dampening wa
70. k Ink too heavy Add varnish consult ink manufacturer is not absorbed Dampening Fountain solution too acid Check pH Press Delivery stacked too high Remove completed sheets more often Press Operator mishandles Educate personnel to offset problem Press Static Attach static eliminator Picking Ink Ink too tacky Use ink in the tack range of 10 12 or add reducer consult ink manufacturer Blanket Tackiness Use quick release blankets For temporary relief treat with blanket lacquer or hardener Dampening Insufficient dampening Increase dampening water flow Dampening Water alcohol balance Check alcohol bring content to between 20 to 30 Press Reduce operating speed Press Reduce impression pressure Press Water alcohol balance Install vacuum sheet cleaner Paper Poor coating adhesion Contact Technical Services Department A number or our customers indicate that Jet Speed Pomade from Sleight amp Hellmuth Inc effectively lowers the tack range of inks however RESOURCES other reducers are also available that give satisfactory performance Contact your ink supplier 43 JESS Za Oo O e am 7a Lu aa Se a SUCCESS RESOURCES technical solutions Troubleshooting Tips CAUSE CONDITION GENERAL SPECIFIC RECOMMENDATION Piling Ink Paper dust or lint Add reducer check ink manufacturer non image area Press Check impression to ensure 002 to 003 nip Da
71. lication requirements will be met when intermixing we recommend the use of the Write Test procedures described above to verify performance Intermixing Other Carbonless Products With NCR PAPER Brand The specific chemical composition used to produce carbonless paper varies between manufacturers E Should intermixing occur these differences may adversely affect such properties as image intensity dimensional stability and Fanapart edge padding E Intermixing of various brands of carbonless paper is not recommended technical solutions Packaging amp Handling mA P RNNG 6 Carbonless gear Z sensitive t Te Handle wit T W 7 g 3 Characteristics E These points should be considered in all operations z a E There are two important characteristics of the emulsion E The CF grades are not sensitive to pressure and can be grades CB CFB Self Contained of NCR PAPER brand handled the same a5 bond or ledger paper as long ee that set them apart from conventional forms papers it sa in a a any of the emulsion e They are sensitive to pressure grades SUCA As AOI e They are coated papers Recycling Carbonless Paper Recyclability All NCR PAPER brand carbonless products are recyclable Recyclability is one of the primary advantages that NCR PAPER brand has over carbon paper Carbon paper is not recyclable in the normal wastepaper stream NCR PAPER brand wastepaper from forms manufactur
72. lt ink manufacturer Ink rollers stripping Dampening Fountain solution too acid Check pH Dampening Too much water Reduce dampening water flow Press Desensitized rollers Pumice and etch ink rollers as recommended by manufacturer Press Rollers glazed Deglaze rollers Loss of sharpness Press Printing pressure Check blanket height with a packing gauge and solidity Blanket Swelling Check blanket for correct solvent or oil resistance Obtain faster evaporating wash that is compatible with blanket being used consult manufacturer Paper Blanket swelling or piling See Blanket Swelling and Piling Ink Wrong ink Make sure ink and blanket are compatible Blanket Glazing Scrub with pumice powder and sponge the blanket with water after each washing or use a commercial glaze remover Continued on next page 42 technical solutions Troubleshooting Tips CAUSE CONDITION GENERAL SPECIFIC RECOMMENDATION Mottling Ink Ink too heavy or thin Reduce or build as needed consult ink manufacturer Ink Improper tack Add body gum consult ink manufacturer Press Impression pressure Check impression to ensure 002 to 003 nip Ink Wrong ink Consult ink manufacturer Paper Galvanized Cal Crush Consult Technical Services Department Offsetting Press Too much ink on paper Reduce ink flow from fountain Ink Not enough drier Add cobalt drier consult ink manufacturer Ink Wrong ink Check ink manufacturer or their reference charts In
73. mpening Increase dampening water flow Dampening Increase ink flow from fountain Press Reduce operating speed Press Install vacuum sheet cleaner Piling image area Dampening Ink water balance Same as non image area except reduce ink flow from fountain Paper Micro picking or Increase ink and or dampening water ghost image Dampening Ink water balance Check alcohol content bring content to between 20 and 25 Dampening Increase dampening water flow Blanket Use good quality quick release blanket Press Check blanket height to ensure 002 to 003 impression nip Plate Image Wear Dampening Too much gum Re etch plate reduce gum in dampening system Dampening Too much acid Check for roller stripping check pH Plate Wear Press Form roll pressure Readjust form roll pressure Dampening Fountain solution too acid Check pH Press Too little ink Increase ink flow from fountain Check plate and blanket packing Ink Too much drier Reduce drier consult ink manufacturer Plate Plate processed wrong Make new plate Paper Loose coating particles Contact Technical Services Department Continued on next page When plates are made we recommend adding a gray scale as a quality control A solid step 6 generally gives the best performance 44 SUCCESS RESOURCES technical solutions Troubleshooting Tips CAUSE CONDITION GENERAL SPECIFIC RECOMMENDATION Scumming Ink Ink is too soft Add binding base body gum or varn
74. nerally use an 85 to 133 line screen at 10 20 density for best results LIL Sie E Use ink colors other than blues or blacks that may be close to the hue of the carbonless image color 20 SUCCESS RESOURCES TOOLS NESS technical solutions Backprinting Backprinting can be used to show additional information on the back CB side of the sheet For example the terms and conditions of a contract could be backprinted To ensure good printing without damage to the CB capsules certain precautions should be taken Copy E Whenever possible screen copy to reduce coverage Whenever possible avoid large solid areas logotypes or trademarks with heavy coverage Printing Method E Use Instant Replay II spray to detect capsule damage The release of capsule oils will mix with the inks creating a chemical reaction They will also retard the drying of the ink which leads to set off and tracking Inks E In order to ensure good drying only use an ink formulated specifically for carbonless backers an ink that dries by oxidation evaporation E Use a minimum ink film thickness Whenever higher pigmented inks are used the ink film can be run thinner and yet have adequate coverage E Inks with a high soy content have been found to react with carbonless coatings Lower soy contents other agra based inks and petroleum ink give best results Fountain Solutions E Maintain a pH and conductivity compat
75. nimize blocking and extensive discoloration around the holes Perforating Machines Except for occasional capsule damage caused by guide wheels we have not had any indications of problems on this type equipment E For optimum performance we recommend using an angled conveyor delivery to the perforating head Indexing Damage resembling paper clamp pressure on a cutter can result from die pressure on some indexing machines E Care should be taken so that the die throat does not compress the forms Forms Packaging We recommend good quality corrugated cartons 200 minimum bursting strength for packaging finished forms E The box should be firmly packed to keep the forms from shifting E If possible the boxes should be matched to the size of the forms being packaged E Contents should be firm but not over packed as pressure damage can result E A piece of corrugated board should be placed inside the carton at both top and bottom for additional protection Shrink Wrap Packaging Many of our customers have had very good results with shrink wrapping packages of forms E This provides a low cost convenient and attractive means of packaging that gives good protection to the contents E Best results are obtained when chipboard is used at the top and bottom of the stack of forms for added protection E Some plastics contain ingredients that can have an adverse effect on the carbonless coatings so any shrink films
76. nk drying Cockle A puckered appearance in paper caused by uneven drying Collating Gathering and assembling into order parts of multiple part forms Collator A device for assembling multiple part forms Color Development Chemical change that occurs when the colorless dye in the CB coating reacts with the CF coating and gives a colored image Combers Wheels that buckle the top sheet in the feed pile to start the sheet separation Compatible Dissimilar materials that do not affect or are not affected by contact with the others Compatible Carbon Carbon paper that can be incorporated into an NCR PAPER brand form set without affecting the functional properties of the system Consecutive Number Sequential numbering Copy Any material hand drawn typewritten manuscript pictures art work etc to be set and reproduced Crash Printing A method of printing precollated form sets using hard type and heavy impression pressure to image all parts except the original which receives the ink Crimp Lock Joining of continuous webs of paper and or carbon by pressing several punched tabs on each ply through the bottom ply Crop Remove outer area or edge of copy by masking or cutting Cross Direction Perpendicular to the machine or grain direction of a sheet or web of paper Crushed Core Collapsed core due to handling or transit damage Curl The tendency of paper to not lie flat There are two kinds structu
77. nks that dry by oxidation evaporation should be used for backprinting printing on the CB side of the sheet E The ink stripe on the ink form roller should be of the manufacturer s recommended width and uniform across the roller This ensures uniform ink laydown color density and coverage 15 SUCCESS RESOURCES technical solutions Dampening Systems amp Fountain Solution Dampening Systems Although there are no specific precautions in the area of plate dampening when printing on NCR PAPER brand a higher degree of quality is realized when E Dampening rollers have a uniform pressure from end to end E All rollers are set to manufacturer s specifications Fountain Solution There are no special requirements for printing NCR PAPER brand carbonless Fountain solution plays a key role in quality and performance using a wet offset printing process The choice of fountain solution is the first step in a properly balanced water system A good solution should meet the following criteria to get the best results E It should be pH buffered to match the recommended pH level of the plate and the ink you are using H It should be formulated to match the hardness of the water with which you mix your solution pH Buffer Most fountain solutions are designed to buffer out at a preset pH level and hold that level The buffer acts like a sponge to absorb any chemical which is a different pH either more acid or more alkaline
78. now the type of scanner being used E Selection of the correct paper will depend on the scanner being used and the specific physical and functional requirements of that reader and other equipment in the system E Required values of paper properties such as brightness stiffness shade reflectance opacity vary from reader to reader E If specific paper specifications are not available trials are recommended TUVW E j NCR PAPER brand OCR and MOCR grades are designed to meet multiple scanner requirements while functioning correctly as a carbonless sheet MOCR grades for example meet both MICR and OCR requirements It is recommended that optical reading be restricted to the original document and not the copies unless extensive testing has been performed E The lighter weights and the colors other than white associated with the back plies of a form usually make these plies difficult to scan E The carbonless image produced by multiple plies may not have the contrast values needed to scan properly E In cases where the properties of CB do not meet the specifications of selected equipment or the equipment manufacturer does not recommend carbonless OCR bond for the original with Self Contained for the copies makes a viable alternative Technical Service will attempt to answer specific questions regarding specific applications Optical character recognition is one form of optical scanning Optical scanning eliminates th
79. occurs when it is in contact with CB coating under excessive pressure Some of the conditions leading to this are storing CFB rolls on their side failure to follow recommended cutting procedures heavy impression on press followed by tight rewind and prolonged storage before collation Self Contained type NCR PAPER brand is also subject to this condition Smudge Frictional A blue discoloration on the CF coated side of carbonless paper that occurs when it is brought in tight sliding contact with CB coating such as would occur on rewinding a CFB roll or multiple ply tally rolls SC paper is also subject to this condition Sponge Rubber Pad attached to bottom of clamp bar to alleviate clamp bar smudges ST Carbonless paper for stock forms applications Also called Economy Stiffness The resistance to bending of paper Suckers Vacuum feet used on press for lifting paper and moving it forward in the press feeder system Tablock A type of flexible fastening used on continuous forms Tack The resistance of an ink film to splitting Tag A smooth heavy grade of paper used where durability and strength are prime requirements Tear A measure of paper strength 67 SUCCESS RESOURCES technical solutions Glossary Telescoping A condition occurring with loosely wound rolls where pressure on the flat side causes the opposite side to bulge out Thermal Paper Heat sensitive products used on facsimile labels
80. of Sequence Place the original you wish to copy on the copier platen and position it appropriately Run only 2 or 3 sets and check to ensure that the proper sequence is being used For 2 two part sets program 4 copies for 2 three part sets program 6 copies etc To ensure the proper sequence mark the top sheet to be certain the mark is imaged through all plies of each set Program the Copier Enter the number of copies needed determined by multiplying the number of sets desired by 2 if using two part Xero Form II 3 if using three part etc Programming may vary with different copiers Run the Job Press the copier s START button Once the job is complete remove sheets from the output tray Proceed to pad the Xero Form II sheets into form sets using Appleton Papers Fanapart High Strength Padding Adhesive technical solutions Step 2 1 Step 2 3 38 technical solutions Xero Form Il Step 3 Edge Pad Xero Form II Sheets Into Perfect Carbonless Form Sets 1 Jog and Stack the Sheets Jog the sheets to the edge that is going to be padded and place in a stack Anchor the stack with a weight roughly 1 pound of weight per inch of edge and a board to evenly distribute the weight placed flush with the edge to be padded Check to make sure the weight distribution is such that thumbing the corners of the stack results in paper separation of about 1 8 inch 2 Apply Appleton Papers F
81. oration A change in the color of the paper Distributing Rollers Rollers that break down and distribute ink to the form rollers Double Double Bevel A slitter wheel with both sides angled in from the center having sharper angles at the cutting edge to give better resistance to dulling Draw Movement of paper under clamp when guillotine cut causing a difference in length between top and bottom of lift Driers Compounds added to ink to accelerate drying Drilling The use of hollow rotating paper drill bits to make holes in a lift or stack of paper Driography An offset printing process using special planographic plates and inks that do not require dampening to differentiate between image and non image areas Dry Offset A printing process using a relief plate and blanket but no water Ductor Roller Ink or water roller that alternately contacts the fountain and distributing rollers Duplex Paper having different colors and or finishes on opposing sides Dusting Debris coating pick slitter dust fibers and or starch is deposited onto the blanket from the paper during the printing process In severe cases dusting can affect the quality of the printed image Dwell Time The period when two objects are in contact Edge Gumming The process of gluing multiple parts along the edge of the sheets to create a finished form Edge Padding A process of gluing collated form sets or similar sheets along one edge to hol
82. pic dye oil droplets Through a patented chemical process a thin protective wall is deposited and surrounds the individual droplets The walls are then chemically hardened to form microcapsules each capsule having a complete chemical shell CB capsules on a human hair Microcapsules destroyed by writing pressure SUCCESS RESOURCES 6 JESS Carbonless Paper System CB Sheet Carbonless Paper System Pressure CB CFB oS8 688 8222 ee ee CF Dye Capsules Dye Coreactant Broken Dye Capsules Developed Color Paper Self Contained SC Pressure Any Paper sc may WRBABSRALEL ES Se ec heh ehh hen teed he wee Broken Dye Capsulemwww s Paper SUCCESS RESOURCES TOOLS NESS solutions technical GENERAL INFORMATION Basic System Coated Back Coated Front and Back Coated Front In a formset the carbonless plies need to be in the correct sequence of CB CFB CF Should any ply be out of sequence or reversed the desired carbonless image will not be produced Another type of NCR PAPER brand termed Self Contained SC is made with both the capsules and receiver coating on the same side of a single sheet Thus any sheet of paper can be pressure imaged and the Self Contained sheet beneath will reproduce the image Self Contained paper can also be used in the original position for ribbonless imprinter applications SUCCESS RESOURCES technical solutions
83. piers and laser printers eMagnetic ribbon used in impact printers ribbon encoders and post encoding devices to apply MICR pigments in a dry form MICR Quality The quality of MICR printing is critical E Most banks are testing printed samples before check orders can be used by customers E Banks test for format spacing alignment character edge irregularities voids uniformity of ink ribbon and toner extraneous ink debossing or embossing of characters signal strength of characters T a as Cay 5 SS Lu a m Lui Oo D E All these specifications must meet ANSI standards Press Tips When printing magnetic inks it is important to balance the formulation for the type of press being used E Magnetic ink is more sensitive to fountain solution conditions and ink tack than other printing inks because of the higher pigment content E MICR inks do not flow as easily as other inks so they require more monitoring E They also tend to increase in tack on press causing difficulties in character formation E Regular addition of fresh ink to the fountain is recommended MICR ribbons are applied by ribbon encoders and post encoding devices in banks E Although no special ribbon is required to print NCR PAPER brand MICR grades some ribbon brands give better results than others E Testing when choosing the brand of ribbon is important for best results E Regular batch testing of ne
84. ral which is related to the manufacturing and or coating process and roll set wrap which results from the paper being wrapped around the core Structural curl is with or occasionally diagonal to the grain roll set curl is always across the grain Cut A type high engraving line or halftone used in the letter press printing process Cylinder Press A printing press having a flat bed for the type form with the printing being done against a revolving cylinder Dampeners Rollers that transfer the dampening solution to the offset plate gt a lt v Wa oO O 60 SUCCESS RESOURCES technical solutions Glossary Dancer Roll Dancing Idler A weighted roller that rides between the unwind and metering unit The roller is used to take up slack and maintain a uniform web tension Dandy Roll Wire cylinder on papermaking machines that patterns or watermarks the web Decollator Mechanical device used to separate parts of continuous forms while removing waste materials such as carbons Desensitize To restrict the ability of NCR PAPER brand to produce a print Desensitizing Ink Transparent ink applied to CF coating to prevent print development Diecut Removal of form sections by use of cutting rule or special die Dimensional Stability The property of a paper to resist changes in size caused by stresses occurring during processing and or changes in temperature and relative humidity Discol
85. rint resolution E Riso The Riso GR3770 Risograph was the first 600 x 600 dpi digital duplicator The GR3750 with E Registration is poor or 1 16 in on older digital 400 x 400 dpi is shown on the preceding page duplicator models but much better on new models Registration also improves with running at slower E Ricoh Among others distributes its equipment speeds through its Savin and Gestetner divisions and is the OEM for Standard Duplicating digital duplicators E The friction feeding system of the digital duplicator can produce double or misfeeds It also produces a E Duplo Offers a complete line of digital duplicators smudge mark on CF sheets when running and differs from Riso and Ricoh with an air assisted carbonless paper sheet separator E Two color printing is accomplished by changing the Preparation ink cartridge and then running a second pass E Jog the paper into a straight stack E Digital duplicators are better suited for line copy originals than for originals E Fan paper on the edge leading into the digital with heavy solids and halftones duplicator Image Processor Scanner Print Head N O 2 TE m a 2 m Master Disposa Box Digital Duplicators are driven by either PC or Macintosh computers Illustration courtesy of Riso Inc Riso Ricoh and Duplo are registered trademarks Use does not imply endorsement 33 technical solutions
86. ront or leading edge of paper held by the grippers as it passes through the press Gripper Margin Plate Gap Unprinted edge of area of paper it passes through a printing press Gum Arabic Water soluble dried sap from acacia trees used in fountain solution and as protective coating on offset plates Gumming Up Process of applying a gum arabic solution to the surface of an offset plate to prevent oxidation and protect it from damage during washup and make ready Hairline Rule A rule less than one point 72 wide Halftone A method of reproducing a continuous tone picture by using small screened dots on the plate to represent vary ing degrees of light and dark Hickies Doughnut shaped spots in inked areas caused by dirt or other extraneous matter Hold Down Bands Flexible strips at the delivery end of a press or collator to guide the sheets to the stack Idle Rollers Rollers used to break down the ink before it reaches the form rollers Impression Cylinder A press cylinder which presses the paper against the blanket or type to transfer ink to the paper Indexing Diecutting of forms to place tab or shoulder cuts at one or both ends for easy identification DuPont registered trademark Indicator Solution for Ludox Desensitizing ink tracking spray or voids can be detected by using an Indicator Solution for Ludox which turns the CF coating blue when sprayed on nondesensitized areas The spray will not indicat
87. s the image and non image areas are essentially on the same level E The image areas are not raised as in letterpress nor depressed as in gravure printing E The image areas are simply ink receptive areas surrounded by water receptive ink repelling areas E When moistened the water receptive areas refuse to take ink while the image areas repel the water E The printing cycle consists therefore in 1 dampening the plates non image areas 2 inking the imaging areas and 3 transferring the ink from the image areas to the blanket from which the image is offset onto the paper E Water flow should be sufficient to keep the plate clean from and minimize tinting or toning E Excessive amounts of water carried by the plate can lead to ink water emulsification and tinting Types of Plates There are three general types of plates for offset duplicator use and NCR PAPER brand carbonless can be printed with each of them These three types are paper polyester and metal E The type of plate selected often depends upon the desired printing quality and the required plate durability length of run E Paper plates are the most economical Printing quantity is typically limited to 5 000 although some paper plates are capable of 10 000 depending on paper and pressure used Halftone reproduction is not as good as with other plate types E Polyester plates can generally be used for quantities up to 50 000 E Metal plates provide
88. s provide best results 5 oO So oO 5 W 25 SUCCESS RESOURCES technical solutions Miscellaneous Bindery Operations Bracket Cutting This operation because of equipment design should be periodically checked to assure that it is not causing excessive CB damage E To minimize damage on CB CFB and Self Contained type we recommend that the knives be kept sharp and that the height of lifts be reduced Scoring Creasing These operations do not usually cause problems with NCR PAPER brand E They can damage CB CFB and Self Contained type coatings however in most forms applications there is no need to produce a print at the score or crease E Color will develop on Self Contained type paper upon scoring or creasing Tipping Problems have not been experienced with regular equipment using adhesives formulated for this purpose Jogging Care should be taken to assure proper sequencing and orientation of copies E Sets should be pencil checked occasionally to assure proper transfer though all parts of the form E We recommend the use of collating racks or a table with the jogger to reduce costs on this operation E Multiple set collation from racks will result in additional savings over single set collation Round Cornering The plunger ram should be locked to keep it from operating because the pressure may cause damage to the capsules Sharpness of the drills is essential to mi
89. s wil give you E Experienced advice on all aspects of forms production E Innovative troubleshooting information in an easy to understand and use format E Useful material from manufacturers and suppliers about other products you use Technical Solutions is a reference for using Appleton Papers products Information in this binder will be updated and supplemented on a periodic basis If you have any questions comments or suggestions please contact your local Appleton Papers representative Or just complete and send in one of the business reply cards in the back of this binder Customer Service Technical Services Dept E Complaints E Technical information E Packaging amp Handling E Application Information Appleton Papers Inc Technical Services Dept 825 E Wisconsin Ave P O Box 359 Appleton WI 54912 West 800 922 1723 Central 800 981 9681 East 800 922 1724 FAX 920 991 7341 General Offices Appleton Papers Inc 825 E Wisconsin Ave P O Box 359 Appleton WI 54912 920 734 9841 Customer Service Department E Order Information E Product Availability E Product Inquiries E Pricing National Accounts Printer Converter 800 922 1729 FAX 800 922 1712 Merchant East 800 533 9421 FAX 800 872 4141 Merchant West 800 922 1727 FAX 800 922 1709 Visit Our Web Site www appletonideas com About Appleton Papers A Leader in High Value Added Papers Since its founding
90. ss paper It also has heavyweight stiffness excellent toner adhesion intense clear imaging and stiff sheets which feed and deliver with ease Digital Trends pecine Time Source IBFI 1997 In addition to Xero Form Il NCR PAPER brand has a large variety of product options which can be tailored to your business form needs whether your customers print for office managers hospital administrators shipping managers financial officers or others Three types of carbonless paper Coated Back CB Coated Front and Back CFB and Coated Front CF are used to create a multi ply business form These plies need to be in the correct sequence CB CFB CF and with the correct sides facing each other or the desired carbonless image will not be produced PRESSU SE Coated Back CB The top D sheet of a multi part form This sheet is back coated e686 000 with millions of tiny microscopic capsules CFB containing colorless dyes CF Coated Front and Back CFB The intermediate sheet of a multi part form The front has CF coating the reverse has CB coating Several intermediate sheets can be used for the desired number of copies Coated Front CF The receiver part of the form The front side is coated with a receiver coating which reacts with the colorless dyes from the broken CB capsules to develop an image on the CF surface After all the parts of a carbonless form are printed and collated a sp
91. ssure thus can be damaged during handling or processing E Using Instant Replay II helps establish where damage has occurred so corrective steps can minimize or eliminate the condition E CB coating can be damaged on a sheet press by such conditions as excessive impression pressure and improper settings of ejector and infeed wheels E On web presses damage may result from frozen or dragging idler rollers excessive impression pressure excessive rewind tension or from bumping or dropping rolls or even rolling rolls on the floor E Guillotine cutting NCR PAPER brand without minimizing clamp bar pressure may also rupture CB capsules Using Instant Replay II reveals CB damage through variations in color intensity or pattern E Overall damage is indicated by fairly uniform color development in the sprayed area localized damage by color concentrations in specific areas E To illustrate damage effects take samples from the same roll or lift before and after processing Excess impression pressure Excess idler roll pressure technical solutions spray and compare E Some color will develop on undamaged paper E Due to variations in spraying technique and color development one cannot accurately estimate amount of damage by color intensity E Take samples through successive stages of processing spray after each step and note the degree of color E At each point where pressure damage is evident make adj
92. t contain like new roller covering Worn or contaminated covers can promote tracking Ink Preparation E Ink should be at pressroom temperature E Agitate ink in can E Fill fountain Ink Film Adjustment E Set fountain keys for normal ink flow to image area E Set ductor roll dwell to near maximum Run at desired speed to check ink film laydown E See page 23 for measurement of ink laydown Continued on next page 22 SUCCESS RESOURCES technical solutions Dry Offset CF Ink Running Conditions E Maintain full fountain to eliminate skip coating E Check for tracking on idler rollers which can be caused by e Heavy first down colors wet picking e Heavy CF ink film e Worn or contaminated idler roll covers E Check for misting which can be caused by too short of a ductor roll dwell or too heavy of an ink film E Fountain agitator is desirable if not available press operator must periodically manually agitate ink in fountain Registration and Laydown Since CF Ink is a clear ink film it is difficult to identify its location once it is on the paper E Check for registration and CF Ink laydown using CF Indicator spray E The spraying of the CF Indicator on to the sheet being printed will show color development in any areas where CF Ink has been applied E CF Indicator will also show ink tracking voids in the ink laydown and any extraneous ink that has transferred onto the printed sheet E To
93. t reference number E Final Disposition will be promptly given upon verification of the problem 54 technical solutions Weight Calculation Factors To calculate the weight of 1 000 sheets of any sheet size multiply the area length X width of the sheet by the factor T a as Cay 5 SS Lu a p Lui rw D Sheet Basis Weight Factor Sheet Basis Weight Factor A E T rt ase cts A tated dette eat etree T 0749 2A E E E EE 1283 E A E A hes 0802 QO eiea a A EEOSE 1390 DO E A A E O O A A EN 0855 2B E E T O E E 1479 ND seein n E T 0909 FO r AE E AA coe eeaaba ek 1604 bc E AETA T NE A A A ETA 1016 E E E E E A E a cacielean aie 1764 QD E E A A E 1069 BO a RAE aE 1925 QD EE A E T A A E 1176 a E E A E O E 2431 TAO aidea aana ae eae A 3241 Conversion Factors Multiply By To Convert from To 17 X 22 20 X 30 24 X 36 25 X 38 GM SQ MTR 17 X 22 500 gt 1 60 2 31 2 54 3 76 20 X 30 500 gt 62 1 44 1 58 2 34 24 X 36 500 gt 43 69 1 1 1 63 25 X 38 500 gt 39 63 91 1 48 GM SQ MTR gt 266 427 614 676 SQ FT REAM gt 1300 2083 3000 3300 THOUSAND SQ IN REAM gt 187 300 432 475 Example CFB which weighs 17 1 X 22 X 500 can be converted to Book basis 25 X 38 X 500 as follows 17 X 2 54 43 18 thus 17 CFB is equivalent in basis weight to 43 18 Book SUCCESS RESOURCES NESS Roll Lengt
94. tee a specific basestock manufacturer but only recommend those that appear to have less imaging in the non inked areas and acceptable imaging in the inked areas E It may also be noted that the bond manufacturers may periodically change their paper formulations without our knowledge CF Ink performs best on plain bond however special bases such as dry gummed or pressure sensitive papers can be used E It is possible that the special coatings on some basestocks can adversely affect the CF Ink and its imaging capacity E Different basestock characteristics may require some ink film adjustments We suggest submitting samples of the desired basestock before applying CF Ink for a compatibility study E One dozen 8 x 11 paper samples are required for lab testing E Please submit the samples to Appleton Papers Inc Technical Services Department 825 E Wisconsin Ave P O Box 359 Appleton WI 54912 CF Ink Color Standard CF Ink area sprayed with CF Indicator Spray should approximately match the intensity of Pantone 279 Evaluation Instructions E Spray CF Ink area with CF Indicator Spray E Place printed sample side by side with this color standard E If blue color development is lighter than this color standard more ink should be applied E If blue color development is equal to or darker than the color standard the CF Ink surface should be capable of developing an acceptable image Note your customers
95. ter flow 45 Za es O am IVa Lu aa Se 0E SUCCESS RESOURCES technical solutions Specialty Applications NCR PAPER brand carbonless is used for a number of specialty applications bar coding MICR CMC7 ink jet mark sense and OCR E In each instance trial forms should be run and extensive testing done on the equipment on which the form will be used E Appleton Papers recommends this approach for new forms applications or in instances where a printer is duplicating a form which is now being used in a specialty application E Warranties may be limited in experimental applications so it is recommended to contact your Technical Service Representative before producing these specialty applications Bar Code The rawstock surface of CB the CF surface of CFB and the CF surface of CF have been found to accept certain fast drying ribbons designed for bar coding E Specialty inks and specialty mylar ribbons for encoders and ink jets are also being used to apply bar codes to NCR PAPER brand carbonless E Suppliers of these materials and equipment are familiar with printing processes and the paper E Pretesting should be done to prevent misapplication of the papers chosen E The reading of bar coded carbonless images is not recommended E Although a bar coded carbonless image may read in some instances the readability will vary by the type and condition of the rea
96. th particles of dust debris or coating pigment thus interfering with the transfer properties of the ink A crusty build up may occur on the blanket along the trail ing edge of the printed image In extreme cases if unde tected blanket smash will occur Pin Holes Barely visible openings in paper where no fibers were deposited by the machine Plate Offset Light sensitive coated sheet material which after imaging serves as the master for offset printing Plies Individual parts of a multiple copy form Position Sequence The order relative to location in the web in which narrow rolls are slit on the press left center right etc Precollated Sheeted carbonless paper consisting of the required grades weights and colors assembled in reverse or straight sequence to eliminate collation after printing Pressure Sensitive A material that is susceptible to damage by weight friction or impact Print Fade Loss of image due to exposure to certain unusual external or chemical factors Print Intensity Development An increase with time in the strength of color after carbonless paper is imaged 65 SUCCESS RESOURCES technical solutions Glossary Print Intensity The degree of color occurring when carbonless paper CB and CF or SC alone coatings are imaged Print Stability The ability of the image to resist fade and maintain legibility Proof A trial impression or test print made to permit easier
97. the lead end of a new roll of paper to be connected to the trailing end of the previous roll without stopping the press coater or paper machine Formation A pattern in paper caused by variations in the amount of fiber laid down across the web Form Rollers Ink or water rollers that contact the plate or form Fountain Reservoir for ink or water on printing press Fountain Solution Solution carried in the water fountain of an offset printing press Fuzz A residue on paper consisting of loose fibers or lint Gap Space The area unaffected by the use of excessive impression pressure Gathering Assembling into order parts of multiple part forms Ghost Image A term used when two sheets of CB are placed one over the other and pressure or imaging is applied to the top sheet Due to basestock pH and a mild reaction with the broken capsule dye a light image may appear on the bottom ply Grain Direction The direction in which the paper was produced on the paper machine and the majority of the individual fibers lie Also referred to as machine direction Grain Long In cut paper when the grain runs in the long dimension of the sheet Grain Short In cut paper when the grain runs in the short dimension of the sheet gt a lt v Wal amp 62 SUCCESS RESOURCES technical solutions Glossary Grippers Metal fingers that hold paper and carry it through the press Gripper Edge The f
98. the pressroom prior to processing away from heaters or cold walls in accordance with one of the following charts Temperature Conditioning Charts for Paper Volume of Papert Difference in Temperature F of on Skid Paper and Temperature of Room in Case or in Which it is Opened in Roll cubic ft Le Pe Me ee Pail eT BER ERRERR EES voit tT tT TT TT TT aim Hours paper should stand Volume of a Case cubic ft Length inches x width inches x height inches 1 728 EXAMPLE Four cartons of paper stacked 22 wide by 34 long and 12 high 6 cubic feet using the formula com ing off a 30 F truck into a 70 pressroom 40 temperature difference will require 25 hours of conditioning tVolume of a Roll cubic ft 3 14159 x roll radius inches x roll radius inches x roll width 1 728 radius 12 diameter 20k me EP vol LAr tT TIME REQUIRED FOR TEMPERATURE CONDITIONING HOURS wo Arritit tt i i tt 10 20 30 40 50 60 TEMPERATURE DIFFERENCE F Chart source Graphic Arts Technical Foun technical solutions Sheet Printing NCR PAPER brand is a premium coated bond like sheet whose press performance equals or betters that of similar products Preparation of Paper E NCR PAPER brand single sheets and precollated sets including 812 X 11 812 X 14 812 X 11 and 9 X 11 are trimmed grain long
99. ting process These contaminates raise the conductivity in a negative manner and create printing problems What is an ideal conductivity Only you can determine that What works for you is correct But to determine a starting point E Contact your plate and ink suppliers and ask for the ideal pH amp conductivity range for the plate and ink being used E Take a gallon of your water and add 12 ounce of fountain concentrate per gallon mixing well Take the pH and conductivity reading Repeat for 1 oz gallon 112 oz 2 oz etc up to 8 oz E Plot the results on the following graph pH amp Conductivity Graph Conductivity Ideal pH range 1 zZ ae jee Lu Lu WN 0 1 5 2 0 25 3 0 35 40 45 5 0 5 5 6 0 65 ounces per gallon KEY W pH x Conductivity E From the graph you can determine if the fountain solution is properly buffered to match your plate and ink Also you can decide if what the proper number of ounces per gallon is best for your shop Process Control Once the proper fountain solution and the mixture has been determined the next step is to maintain that level and know when to change the solution A regular schedule of changing the solution and cleaning the tanks should be set up SUCCESS RESOURCES 17 NESS SUCCESS RESOURCES technical solutions Plates The lithographic plate is different from other mechanical printing plates E The litho plate is planographic that i
100. tisfied with our products or services for any reason we will help solutions you resolve the problem replace the product or refund its cost Unconditional Satisfaction Guarantee Appleton Papers Guarantee Your Satisfaction No hassles No fine print ot oe No conditions T00L SUCCESS RESOURCES USINESS History of NCR PAPER Brand Carbonless FAMOUS BARE CO RRAN ta 1954 March 26th is the first commercial sale of NCR PAPER brand and the first registered use of the NCR PAPER trademark The development of NCR PAPER brand of carbonless paper dates back to the late 1940s when researchers were asked to develop a technique for printing without using ink rolls or ribbons A key factor in achieving this goal was the development of a technique to chemically convert certain color dyes to a colorless state When these dyes are in a colorless state they will not produce color when placed in contact with ordinary paper clothing or skin However when the dyes are placed in contact with special reaction materials intense colors are formed The next step was to develop a medium for transferring the colorless dye solution to the surface of paper This medium was required to provide intense and complete color development localized only in the areas being NCR PAPER is a registered trademark licensed to Appleton Papers Inc solutions technical no carbon required TRADE MARK
101. to reduce dog earing and improve delivery on presses with chute or chain deliveries E Other size sheets can be trimmed so grain direction will be parallel with paper flow through the press grain long E Fan each edge of the paper before loading it into the feeder Fanning reduces clinging tendencies thereby improving feeding characteristics E To produce a flatter sheet roll edges of slightly curled paper in the opposite direction of the curl Operation of the Press E Use a clean properly cared for blanket at all times e Higher quality printing and improved runnability are generally obtained by using compressible blankets which minimize squeeze at the printing nip e Compressible blankets are generally quick release in nature and produce more uniform ink laydown E Use soft bodied inks with tack in the 10 12 range or below plus a fountain solution with a pH of 4 0 to 5 0 Ejector rolls outside rings gi Bex Setting ejector rolls outside of the ejector rings offsets upward curl in stock and sheet delivery will improve See comparison E Use fountain solution sparingly to minimize curling and picking tendencies which can result from excessive wetting of the coated surface E We recommend that inks be used straight from the can without alteration e If a tack reducer is used be sure that the reducer is compatible with the ink being used e The reducer and amount to be used should be ink supplier recommended
102. ubjected to excessive pressure which caused the microcapsules to break thereby rendering that area incapable of making a satisfactory print CB Coated Back The back coated sheet which serves as the original in a carbonless form set CF Coated Front The front coated sheet which serves as the receiving part of the form CFB Coated Front and Back The front and back coated sheet that serves as the intermediate part s of a carbonless form set C1S Coated one side either CB or CF coatings C2S Coated both sides with the same coating either CB or CF Chain Delivery Endless chain with grippers that accept the sheet from the impression cylinder and transport it to the delivery pile for ink drying and better runability purposes Chalking A condition in a printed image in which the pigment is not properly bound to the paper and can easily be rubbed off as a powder Chucks Mechanisms inserted into roll core to position and hold the roll on the press unwind or rewind shaft SUCCESS RESOURCES technical solutions Glossary Coating Material applied to paper surface to give it special characteristics Coating Pattern Appearance of a coated surface caused by the nature of the coating method of application or drying technique Coating Weight A measure of the amount or weight of coating applied usually expressed in pounds per ream for a given sheet size Cobalt Drier A material that accelerates i
103. untain roller ductor roller three or four oscillating vibrator rollers four or more distributor rollers and two three or four form rollers It is not necessary to make any changes or additions to this basic system when running NCR PAPER brand Ink Tack One of the most important phys Composition Roller ical characteristics of ink in rela tion to NCR PAPER brand is the gt if Ink tack Metal Roller H Ink tack is a measure of the resistance of an ink film to being split Figure 1 Figure 1 Ink tack E The number such as 10 tack ink is a value assigned to represent the force required to split the ink film E If the force required to split the ink film is greater than the force required to pull the coating from the base paper the coating material will be physically picked from the sheet E The coating that is removed from the paper can build up on the blanket plate or elsewhere in the inking system and create major problems E With the wet offset process we recommend the use of a 10 to 12 or lower tack ink based on a GATF inkometer reading at 800 rpm E If using the dry offset process we have found a 5 to 7 tack ink works better E Inks with a higher reading can create problems Care should be taken to assure stripe settings are at manufacturer s specifications E We recommend that ink be used straight from the can However if a reducer is needed we suggest that you contact your ink supplier for
104. ustments to reduce damage When setting up a press compare samples from feed and delivery piles or web press sheet unwind and rewind stations for excessive impression pressure or other improper settings E Take corrective steps E Follow the paper through each pressure area E Adjust and check with Instant Replay II until any damage is minimized Instructions for use of Instant Replay II E Can should be at room temperature E Place samples closely together E Shake can briefly E Hold can upright 10 12 inches from sheets spraying back and forth till sheets appear damp E Allow paper to dry then examine E Compare the pattern with adjacent photos for common CB damage Roll dropped on edge Roll bumped Infeed wheels Roll dropped on floor Excess impression pressure Ejector rolls Clamp bar damage SUCCESS RESOURCES 52 NESS technical solutions Receiving API Products A Carrier Delivery Receipt and a Packing List will E Include with claim accompany each Appleton Papers shipment You will be required to sign the Carrier Delivery Receipt Before signing the Carrier Delivery Receipt please e Amount of damage piece count and description follow these instructions T a as Cay 5 SS Lu a p Lui rw D e Copy of Delivery Receipt e If salvage amount recovered E Immediately inspect for transit damage e Evidence of damage photos E If there is
105. w shipments is advisable in order to ensure maximum productivity and quality that complies with ANSI Standards E Encoder maintenance plays a large role in accurate results The quality of MICR applied by toner on laser printers and copiers is critical E Regular testing of the results is expected by the banks before introducing the check into the Federal Reserve System E Toners supplied by the printer manufacturer are recommended but OEM toners can also give good results E Batch testing is advisable to prevent rejection by the banks 49 SUCCESS RESOURCES technical solutions Shelf Life amp Storage Shelf life is the length of time printed forms are stored under normal conditions before they are imaged for use E A shelf life of two years is assured but storage duration can be greater especially if forms are stored under ideal conditions E Forms that have been stored in files since initial production over 30 years ago are still capable of producing an acceptable image Print stability is the ability of the carbonless image to resist fade and maintain legibility for a prolonged period NCR PAPER brand carbonless images are guaranteed to last for the life of the document when stored under nor mal office conditions E Normal office conditions assume drawer file storage 60 95 degrees fahrenheit and 40 60 relative humidity E Many government agencies and large institutions including the
106. which can be photographed Backaway A condition occurring in the ink fountain when the ink does not adhere to the roller Back Gauge Movable metal bar behind the knife on paper cutters used for squaring the paper Background Color Overall color development resulting from damaged CB in contact with CF Backprinting Applying thin film of ink to CB surface as screened image Ink dries by oxidation and evaporation Baggy Rolls A roll condition caused by tension variations across the web Basis Weight The weight of one ream 500 sheets of paper in a speci fied or standard size for that grade Bearers Bands on each end of the press cylinders which maintain the correct separation between the cylinders Binder A material used in coatings and inks to hold them together and make them adhere to the material on which they are applied Black Light Ultraviolet light used to detect desensitizing ink tracking spray or voids Blanket Vulcanized rubber sheet on a fabric base used to cover the press cylinder It transfers the inked image from the plate to the press sheet in offset printing Blanket Swelling An increase in blanket caliper caused by contact with sub stances that are not compatible with the blanket materi als Bleed A colored halo extending beyond the impression area of a printed line character or imaged area See Feathering Blinding Plate with an image that will not accept ink gt a lt v Wa

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