Flexographic Ink Recovery System Reducing Fluid Consumption
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Solution Overview
Problem
Existing installations for changing ink in flexographic printing machines consume excessive cleaning fluid due to inefficient ink residue removal from the chambered doctor blade, leading to high water usage and residual ink contamination.
Innovation Solution
A cleaning device with a blade cleaner, ink recovery system, prewash system, and air nozzle system that recovers ink from the chambered doctor blade, uses polluted wash fluid as prewash, and employs a bi-directional pump to minimize clean fluid consumption by utilizing compressed air and a recovery tank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large number of runs of the cleaning device are performed over the chambered doctor blade to achieve acceptable cleaning, then cleaning effectiveness is improved, but cleaning fluid consumption increases very high
Solution Approach 1:
The patent implements a recovery tank that collects cleaning fluid after it has been used to wash the chambered doctor blade. This recovered fluid is then reused in subsequent cleaning operations, thereby reducing the need to continuously supply fresh cleaning fluid while maintaining effective cleaning performance across multiple runs.
Solution Approach 2:
The patent introduces a prewashing phase where the chambered doctor blade is initially cleaned with a prewash device before the main washing operation. This preliminary action removes a significant portion of ink residues beforehand, making the subsequent main washing more efficient and reducing the total amount of cleaning fluid required for achieving acceptable cleaning.
2Ease of operation
If manual cleaning methods are used for printing members, then cleaning flexibility is maintained, but cleaning efficiency and thoroughness are insufficient
Solution Approach 1:
The patent designs an automated cleaning device that performs the cleaning operations without manual intervention. The device automatically positions the washing members, controls the cleaning fluid flow, and executes the cleaning sequence, thereby eliminating the need for manual cleaning while achieving thorough and consistent cleaning results.
Solution Approach 2:
The patent utilizes hydraulic or pneumatic mechanisms to actuate the washing members and control the cleaning fluid delivery system. This enables automated, precise, and forceful application of cleaning fluid and washing actions, significantly improving cleaning efficiency compared to manual methods while maintaining operational flexibility through programmable control.
3Reliability
If the ink pump is used to circulate water through the inking circuit for cleaning, then all inking members are cleaned, but residual ink in the piping remains and large quantities of water are consumed
Solution Approach 1:
The patent extracts and removes residual ink from the inking circuit piping using a dedicated recovery tank and pumping system. Instead of simply circulating water through the entire circuit, the system specifically targets and extracts ink residues from the piping and chambered doctor blade, separating the ink removal function from the general cleaning operation to reduce water consumption.
Solution Approach 2:
The patent implements a recovery system that collects and stores cleaning fluid and removed ink residues in a recovery tank. This recovered fluid is then reused in subsequent cleaning operations, dramatically reducing the total consumption of fresh water while ensuring complete cleaning of all inking members including the piping system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Significantly reduces cleaning fluid consumption by recovering and reusing polluted wash fluid for prewashing, ensuring thorough ink residue removal and efficient ink change processes.
Implementation Method 1
an air nozzle system (100) to clean out ink with compressed air
Implementation Method 2
by circulating water through the piping of the inking circuit and through the chambered doctor blade, using the ink pump
Data Source
AI summary
A method and an installation operable for cleaning an inking blade acting against a chambered printing cylinder of a flexographic printing machine. A cleaning device includes a blade cleaner, a recovery device for ink removed from the blade, a first prewash cleaning system, a subsequent regular wash system and an air nozzle system to clean out ink. The ink is recovered before the washing. The ink washed out is recovered and this polluted wash fluid is used in a subsequent cleaning as a prewash.