The SHARPER System™ allows you to run “by the numbers” for optimum results. This system provides a uniform set of criteria for greatly improved communication between flexo color separators, printers and buyers. Jobs go more smoothly so there’s less wasted time and materials, and more customer satisfaction with resulting profitability.

There are seven key elements to this powerful system:

1. Adopt Platinum™ Anilox Technology
   
2. Scientific Anilox Selection
   
3. Adopt Thinner Ink Film Printing
   
4. “Snapshot” Provides Key Information
   
5. Running Targets For Quality Control
   
6. Printing By The Numbers
   
7. Continuous Improvement Plan

Click on the links above to learn more about The SHarper System™.

ELEMENT 1:  Adopt Platinum™ Anilox Technology

Superior Surface Properties
Exclusively from Harper, Platinum™ is a revolutionary innovation that helps keep ink from plugging the cells in the surface of an anilox roll. It’s the result of a new CO2 laser process that reacts with trace elements in our ceramic compounds creating smoother cell walls and cavaties in the surface of an anilox roll. Scanning electron microscopes (SEMs) confirm that the new laser process creates a 60 percent increase in ceramic cauterization - resulting in a cell wall that is much smoother, rounder and more level, as shown in these SEM photos.

Echotopography™ Volume Measurement System
Our Echotopography measurement system uses reflected light to gather height information of microscopic surface patterns with accuracy as fine as 10 nanometers. (There are 1000 nanometers in one micron.)

Previously, we calculated anilox cell volume by using a microscope. However, this method was dependent upon the skill and optical perception of the person using the microscope. Also, the formula used approximates the cell shape but does not describe it precisely. No two people measure exactly the same, and because a micron is so minute, some variance was inevitable. With Echotopography, we can actually map the topography of the anilox cells and measure the exact volume. Our statistical studies show it to be more than twice as accurate as any other anilox measurement technique. The operator, or human factor, is no longer an issue since there is no subjectivity in capturing the surface data digitally.

In general, Echotopography measures volume a little lower than conventional scope volumes. Do not let this throw you. Overall, your rolls will perform better than the rolls specified for scope volumes. We have a volume chart specifically for Platinum™ rolls, and this chart contains Echotopography volumes (ETVs) to assist you. 

The most important benefit you’ll get from Echotopography is scientific predictability. It allows you to predict color on press with the first anilox surface technology guaranteed to work in correlation to the color strength or densities you desire. (See chart below)

ELEMENT 2:  Scientific Anilox Selection

A. In order to get the full benefits available from Platinum™ technology, understanding the basic concepts behind specifying your anilox is critical. 

Your CO2 anilox roll cells typically perform best within the depth-to-opening ratio of 23% to 33%. This will assure you that your cells are releasing ink at their optimum level. However, due to the superior ink release characteristics of Platinum™ anilox rolls, we now offer some volumes in excess of 33%. Additionally, most YAG technology is offered outside of these parameters.

At different depth-to-opening ratios, the cell
takes on different shapes. For example, at 28%
depth-to-opening ratio the cell is a rounded
bowl. At 15%, the bowl shape is not as rounded
as the 28%. Wall thickness at the top of the cell
and inside the cell will vary with the bowl shape.

B. Another important relationship to understand is that of the physical dot size on the plate to the anilox cell opening. If the dot on the plate is smaller than the cell opening, “dot dipping” can occur which leads to excessive dot gain, dot bridging, and dirty or spotty print defects in the highlights. Higher line screen anilox rolls give better support to the small highlight printing dots for higher quality reproduction,
especially in the highlight areas.

When calculating the anilox screen needed to properly support your printing dot, remember the 6:1 ratio of anilox line screen to plate screen (using a 2% dot as the minimum is the best rule of thumb). This ratio will prevent the smallest dot (usually 2%) from entering inside the cell of an anilox, preventing dirty printing in the highlights. The following table can be used as a reference guide to selecting the proper anilox screen count for a particular process plate screen.