REHAU Tackles Plate Block Errors with Innovative Polymer Solutions, Boosting Print Quality & Efficiency

Leesburg, VA – October 26, 2023 – REHAU INDUSTRIES LLC, a leading global specialist in polymer solutions, is stepping up to address a persistent headache for the printing industry: plate block errors. These frustrating defects, which manifest as inconsistent ink transfer during flexographic and gravure printing, can lead to wasted materials, production delays, and ultimately, unhappy customers. REHAU believes they’ve got a pretty solid answer, leaning on decades of polymer expertise. For those not deeply involved in the printing process, plate block errors happen when the printing plate – the thing that transfers the image to the material being printed – isn’t perfectly uniform. Little variations in the plate's thickness or density create areas where ink doesn’t transfer cleanly. It shows up as patchy areas, streaks, or even complete image drop-out. It’s a real pain, and printers have been fighting it for ages. “We’ve been talking to printers for a while now, and plate block errors kept coming up as a major issue,” explains a REHAU spokesperson. “They were looking for a material solution, something that would address the root cause rather than just masking the symptoms. That's where we thought, 'Hey, we work with polymers all day long, let's see what we can do.'" REHAU isn’t exactly new to the game. They’ve been around for over 70 years, building a reputation for high-performance polymer solutions in a bunch of different industries – automotive, construction, even medical technology. They’re known for pushing the boundaries of what’s possible with materials. They’re not just selling plastic; they're selling solutions built on deep materials science. Their Leesburg, Virginia facility is a key hub for innovation and custom development. So, what did they come up with for plate block errors? The answer lies in a specialized range of polymer materials engineered with extremely tight tolerances and consistent properties. They aren't naming the exact polymer blend publicly just yet – it's a bit of a trade secret – but they describe it as a highly engineered thermoplastic with exceptional dimensional stability and resilience. “The key is consistency,” explains the spokesperson. “Traditional plate materials can sometimes have slight variations in thickness or density, even within the same batch. Our materials are formulated and processed to minimize those variations, creating a plate that's uniformly resilient and consistent across the entire surface.” Here’s how it works, in plain English: Precise Formulation: REHAU starts with a carefully selected blend of polymers, chosen for their specific properties. Tight Tolerance Manufacturing: They then manufacture the plate material using state-of-the-art equipment and rigorously controlled processes. This ensures that the material meets extremely tight tolerances for thickness, density, and hardness. Enhanced Resilience: The polymer blend is also designed to be highly resilient, meaning it can withstand the stresses of the printing process without deforming or losing its shape. This is crucial for maintaining consistent ink transfer over long print runs. Reduced Downtime: By minimizing plate defects, REHAU’s solution helps printers reduce downtime for plate changes and troubleshooting. That translates directly into increased productivity and lower costs. REHAU isn't positioning this as a "magic bullet." They acknowledge that other factors can contribute to plate block errors – things like ink viscosity, substrate properties, and press settings. But they believe their material can significantly reduce the incidence of these errors, giving printers more control over their process. “We’ve been running trials with several printers, and the results have been really promising,” says the spokesperson. “They’ve seen a noticeable reduction in plate defects, improved print quality, and lower waste rates.” One printer, who asked not to be named, told REHAU representatives, “We were constantly battling plate block errors on a particular flexible packaging job. We tried everything – different inks, different substrates, even different press settings. Nothing seemed to work consistently. Then we tried REHAU’s material, and the problem practically disappeared. It’s been a game-changer for us.” REHAU is offering its plate block error solution in a range of thicknesses and sizes to meet the needs of different printing applications. They’re also providing technical support to help printers optimize their processes and get the most out of the material. Looking ahead, REHAU is continuing to invest in research and development to further improve its plate materials and develop new solutions for the printing industry. They believe that material science will play an increasingly important role in driving innovation and improving print quality. “We’re not just selling a product; we’re partnering with printers to solve their challenges,” says the spokesperson. “We’re committed to providing them with the materials and support they need to succeed in a competitive market.” If you’re a printer struggling with plate block errors, or just looking for ways to improve your print quality, REHAU INDUSTRIES LLC at 1501 EDWARDS FERRY RD NE, LEESBURG, VA, 20176-6680 or by calling 313-892-5864 might just have a solution you've been waiting for. They’re offering samples and consultations to help you see the difference for yourself.