Speed Without Compromise.
High-speed printing pushes every component to the limit β ink transfer, drying, adhesion, and color consistency. StarColor delivers low-viscosity, fast-drying, and highly stable ink systems engineered for speeds up to 400 m/min on flexo and UV presses.
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High-speed printing challenges and their impact
Ink misting / fly
Ink droplets fly off the anilox or plate at high speeds, causing hickeys and contamination.
Inconsistent ink transfer
Poor flow and leveling at high speed leads to banding, voids and density variation.
Drying lag / smearing
Ink not dry before rewinding or stacking β smearing and blocking occur.
π¬ Root cause diagnosis: speed-related factors
π Ink Rheology
- Viscosity too high β poor flow at speed
- Low shear-thinning behavior
- Insufficient tack or thixotropy
- Pigment settling in circulation
βοΈ Press & Anilox
- Anilox volume too high β thick film
- Anilox cell geometry not optimized
- Insufficient impression pressure
- Worn doctor blades
π‘οΈ Drying System
- Air flow insufficient for speed
- Dryer temperature too low
- Short dryer length vs. speed
- Poor air knife positioning
β¬οΈ Free on-site speed trial and ink rheology analysis β we optimize your entire system.
β StarColor high-speed ink systems
Every component β resin, solvent/water balance, pigment dispersion, and additive package β is optimized for high-speed performance. Our inks maintain stability, transfer, and drying even at maximum press speeds.
| Ink System | Recommended Series | High-speed features |
|---|---|---|
| Water-based flexo (high speed) | SC1000-HS series | Low viscosity, fast evaporation, excellent transfer, up to 400 m/min |
| Water-based flexo (ultra-high) | SC1000 series | Ultra-low viscosity, shear-thinning, anti-misting, up to 300 m/min |
| Water-based gravure | SC3100 series | Fast solvent release, high solid content, stable at 200 m/min |
| UV flexo (high speed) | UV7000 series | Rapid cure response, low viscosity, low migration, up to 200 m/min |
| UV offset (high speed) | UV7200 series | Excellent flow, fast setting, stable at 15,000 sheets/hour |
π High-speed printing diagnostics
π Rheology measurement
We measure viscosity at different shear rates to predict ink behavior at high speed. Low high-shear viscosity = good transfer and leveling.
π¨ Mist test
Simulated high-speed rotating disc test to quantify ink misting tendency. Our HS series shows <30% misting vs. 70% for standard inks.
β±οΈ Drying speed profile
We analyze solvent/water evaporation rate at different speeds and temperatures to match ink with your dryer capacity.
π We offer free on-site speed trials and rheology analysis β we'll help you unlock the full speed potential of your press.
β‘ Case Study: Flexible Packaging Converter β Speed Bottleneck at 350 m/min
The Challenge
A mid-sized flexible packaging converter in Guangdong, China was operating an 8-color CI flexo press but was limited to 350 m/min β far below the machine's rated maximum of 500 m/min. The bottleneck was caused by two interrelated issues:
- Ink misting β At speeds above 350 m/min, ink droplets would aerosolize and contaminate the print, causing hickeys and quality defects
- Drying limitations β The existing ink couldn't dry fast enough at higher speeds, leading to smearing and blocking on the rewind
The company was running 24/7 shifts to meet demand, and the speed limitation was constraining capacity β forcing them to turn away new business.
The Diagnosis
StarColor conducted a comprehensive full press audit covering every variable affecting speed:
| Audit Area | Finding |
|---|---|
| Anilox Roller | 6.0 BCM volume β excessive film thickness increasing drying load |
| Ink Rheology | High viscosity at operating shear rate β poor flow at speed |
| Dryer Profile | Air flow and temperature insufficient for water-based ink at higher speeds |
Additionally, the standard ink used lacked the shear-thinning properties needed for high-speed transfer.
The Solution
StarColor implemented three key changes:
| Action | Rationale |
|---|---|
| Switched to HS-3000 Series | Ultra-low viscosity with shear-thinning rheology; anti-misting formulation; fast evaporation co-solvent system |
| Reduced anilox volume: 6.0 β 4.5 BCM | Thinner film = less drying load; improved ink release at high speed |
| Optimized dryer temperature profile | Increased air flow and temperature for faster water evaporation |
The Results
| Metric | Before | After |
|---|---|---|
| Press speed | 350 m/min | 520 m/min (+48%) |
| Ink misting | Present | Zero |
| Color consistency (ΞE) | 1.5 β 2.3 | <0.8 |
| Annual capacity | Base | +40% |
Business Impact:
β
$300,000+ additional annual revenue from capacity increase
β
Converter won 3 new FMCG accounts with the additional capacity
β
Payback period: 4 months on investment (ink, anilox, dryer optimization)
β
Reduced energy cost per meter due to higher throughput
"We had accepted 350 m/min as our limit for years. StarColor's audit showed us what was actually possible. The HS-3000 series runs clean at 520 m/min β no misting, no drying issues, just consistent quality."
β Plant Manager, Guangdong Flexible Packaging Converter
π High-speed printing best practices checklist
Maximize your press speed without compromising quality:
- Measure ink viscosity at operational shear rate β not just Zahn cup static viscosity
- Check anilox volume β high volume increases film thickness and drying load
- Verify dryer air flow (m/s) and temperature β both need to increase with speed
- Use anti-misting additives or high-speed formulated inks
- Maintain constant ink circulation and temperature control
- Run a speed ramp test β identify the speed where defects appear and optimize from there
Frequently asked questions β High-Speed Printing
β What is the maximum speed your inks can achieve?
Our HS-3000 series is validated up to 400 m/min on CI flexo presses. UV-HS series reaches up to 400 m/min. We can also custom-formulate for specific press configurations.
β How do you prevent ink misting at high speeds?
We optimize resin molecular weight, solvent balance, and add anti-misting agents. Our HS series inks show <30% misting compared to standard inks.
β Will high-speed inks work with my existing anilox?
In most cases, yes. However, we recommend an anilox audit β higher speeds often benefit from lower anilox volumes and specific cell geometries. We provide free anilox consultation.
β Can StarColor send engineers to my factory?
Yes. Our technical team visits your plant to measure all parameters β press, dryer, anilox, ink β and provides a complete optimization report with actionable recommendations.
Inks engineered for maximum speed β and quality.
Request a free speed audit, rheology analysis, or on-site trial β we'll help you unlock your press's full potential.