REHAU Tackles Plate Block Errors with Innovative Polymer Solutions, Boosting Printing Efficiency

LEESBURG, VA – October 26, 2023 – REHAU INDUSTRIES LLC, a leading global provider of polymer solutions, is making waves in the printing industry with its advancements in combating plate block errors – a common, frustrating problem impacting print quality and productivity. Based right here in Leesburg, Virginia, REHAU (reachable at 313-892-5864) has been quietly developing and deploying solutions that are helping printers minimize downtime, reduce waste, and ultimately, deliver superior finished products. Let's face it – plate block errors are a headache. Those little imperfections, caused by plates sticking together during the printing process, can lead to smudges, streaks, and a whole lot of rejected prints. It’s not just about the wasted materials, it’s the wasted time, the upset customers, and the dent in profitability. For years, printers have been trying everything – different coatings, modified air settings, even changing the way they handle plates. But REHAU believes they’ve cracked the code with a unique approach using specifically engineered polymers. “We’ve been listening to the concerns of printers for a long time,” explains a REHAU product engineer. “They’re dealing with increasingly complex printing demands – faster presses, thinner materials, and the need for consistently high-quality results. Plate block is often overlooked as a significant bottleneck, but it really adds up. We asked ourselves: ‘What if we could address the cause of the sticking, not just the symptoms?’” REHAU’s solution isn't a new coating or a tweaked air system. It's about the plate material itself. They've developed a proprietary polymer formulation that’s incorporated into the plate manufacturing process. This formulation modifies the surface characteristics of the plate, dramatically reducing the adhesion forces that cause plates to stick together. “Think of it like this,” says the engineer. “Regular plates, under pressure and with ink present, can develop a temporary bond. Our polymer formulation creates a microscopic ‘release layer’ that prevents that bond from forming. The plates still grip the ink perfectly, but they don't grip each other.” How Does it Work in Practice? Printers who have tested REHAU’s plate formulation report significant improvements in several key areas: Reduced Plate Blocking: This is the big one. Testing shows a dramatic decrease in the frequency of plates sticking together, minimizing production stoppages. Some printers are reporting reductions of up to 80% in plate blocking incidents. Faster Changeovers: When plates do occasionally stick, they separate much more easily, cutting down on the time and effort required for changeovers. This translates directly to increased uptime and higher throughput. Less Waste: Fewer blocked plates mean fewer rejected prints and less wasted material. This has a positive impact on both the bottom line and the environment. Improved Print Quality: By minimizing the risk of smudges and streaks caused by plate blocking, REHAU’s solution contributes to consistently high-quality print results. Compatibility: REHAU’s polymer formulation is designed to be compatible with most existing printing equipment and processes. It can be incorporated into the plate manufacturing process without requiring significant modifications. Beyond the Basics: What Makes REHAU Different? REHAU isn’t just a materials supplier; they’re a full-service partner. They bring decades of experience in polymer science and engineering to the table, along with a deep understanding of the challenges facing the printing industry. Here’s what sets them apart: Custom Formulation: REHAU doesn’t offer a one-size-fits-all solution. They work closely with plate manufacturers to tailor the polymer formulation to their specific needs and requirements. Rigorous Testing: REHAU’s plates undergo extensive testing to ensure they meet the highest standards of quality and performance. This includes tests for adhesion, ink transfer, and durability. Technical Support: REHAU provides comprehensive technical support to its customers, from initial consultation to ongoing assistance. Commitment to Innovation: REHAU is constantly investing in research and development to create new and improved polymer solutions for the printing industry. Looking Ahead REHAU sees plate block errors as just one piece of the puzzle when it comes to optimizing printing efficiency. They’re also exploring other innovative polymer solutions that address challenges such as ink transfer, plate wear, and substrate adhesion. “We believe that polymer science has the potential to revolutionize the printing industry,” says a company spokesperson. “We’re committed to working with our customers to develop cutting-edge solutions that help them achieve their goals.” For more information about REHAU’s plate block solutions, contact them directly at 313-892-5864 or visit their facility at 1501 EDWARDS FERRY RD NE, LEESBURG, VA, 20176-6680. They’re eager to discuss how their innovative polymer technology can help you improve your printing process and boost your bottom line.