2. 1. What is ink?
2. How are you wasting ink, solvent and plastic
3. Sensitivity and its importance
4. Automatic Control-Sensors & Controllers
5. What is Good Control
6. Manual vs. Automatic Control
7. Real Savings!
8. 7 Other events that impact viscosity.
What you will learn
10. Opportunity to waste!
Here you have extra ink on the surface which a Zahn Cup will
not see the change in viscosity that is causing the extra
thickness.
22. When measuring manually there is a natural margin of error
which can be +/- 1 second.
For this presentation lets assume 2 things:
1. The margin of error is only +/- .5 second
2. All calculations will be done starting at 120 cSt (since this is
a common range for ink)
Using this information we will calculate and compare the
sensitivity of the Zahn Cup #3, Zahn Cup #4 and the Shell Cup #4.
To do this we will mark where each cup intersects with 120 cSt.
Then we will see where each cup intersects if we go +.5 seconds
and -.5 seconds. This will produce the % margin of error for each
cup listed above.
Let’s Talk Numbers
23. This data is assuming a +/- .5 second margin of human error
112 130
130-112= 18
18/120=15% ERROR
Let’s Talk Numbers
cSt
Seconds
24. This data is assuming a +/- .5 second margin of human error
112 130
130-112= 18
18/120=15% ERROR
112 128
128-112= 16
16/120=13% ERROR
Let’s Talk Numbers
cSt
Seconds
25. This data is assuming a +/- .5 second margin of human error
112 130
130-112= 18
18/120=15% ERROR
112 128
128-112= 16
16/120=13% ERROR
118 122
122-118=4
4/120=3% ERROR
Let’s Talk Numbers
cSt
Seconds
28. Automatic Control Claim
Let‟s see what this looks like…
• Claim they can measure to
within +/- 1 Zahn cup
second.
Other Viscosity
Control
Companies
• Can measure to .1 TOF
which is the equivalent to
+/- 1.1 cSt
30. Automatic Control
cSt
Seconds
Now of course you
can‟t see how well
Norcross is controlling
using a Zahn Cup.
Thus customers often
say the other
viscometer is good
enough.
31. This is data from an actual gravure press in China.
Customer Examples
32. Real Customer Savings
This customer reduced their ink consumption by 20%
by simply using Norcross automatic viscosity control.
33. Real Customer Savings
Solvent consumption down 30%
Varnish consumption down 30%
ROI = 2 Months!
Without Viscosity Control With Viscosity Control
34. *This is why the NSF/ NCR is being started.
*If you can‟t measure changes then you will
think you are doing good when you are not!
*We need to break the mindset that a Zahn cup
is „good enough‟ simply because it has been
around “forever.”
*The charts show the waste, we know we can
control so well the Zahn cup cannot see our
saw tooth wave of control.
*Customers must use better cups!
35. *But Bob, “they have always used that and the
operators will never agree to having two cups to
pick from.”
*Why two cups? Because if you have really good cups
and a wide range of Zahn cup viscosity then you will
need two good cups to cover one Zahn cup.
*But you only use one cup on a given job.
*But Bob, “they just won‟t do it.”
*They will if their customers (i.e. the packaging
buyer) knows that there is waste, pollution and
money to be saved.
