Fountain Solution

pH, Conductivity
and
Offset Printing
EuGene Van Roy
1
Pressroom Chemistry 2/26/02
Introduction
! At heart, lithography is a chemical process with
potential for many variables which may affect
production and the quality of offset printing.
! Of the many facets of offset printing perhaps
none is as prone to variation as fountain solution,
but while the cause and nature of these variations
may seem complicated, controlling them is
relatively simple.
2
pH, Conductivity and Offset Printing 1

Agenda
! What is the purpose of fountain solution?
! How important is the water source?
! What is pH, and determining pH?
! What is conductivity and how do we
measure conductivity?
! Problems caused by incorrectly mixed
fountain solution?
3
Overview
! In 1796, Alois Senefelder applied an oil
type ink on stone, and found that water
adhered to the non-image area only.
With trial and time, more sophisticated
methods were developed. This was done
by using chemicals in the water, in
conjunction with metal plates which have
oleophilic (ink receptive) and hydrophilic
(water receptive) surfaces.
4

Overview
! In Senefelder’s day he
went to the well, got a
bucket of water, and
was ready to go. If
things were only that
simple. We will look
at how we can make
the complex variables
of fountain solution
simple.
5
What is the purpose of

Fountain Solution?
6

Fountain Solution
! The dampening of the offset plate is one
of the most critical factors in quality offset
printing.
! A solution of a fountain concentrate mixed
with water is created that performs several
essential functions on press.
! The most important of these is the wetting
and desensitizing of the non-image area of
the plate.
7
Fountain Solution
! Fountain solution lubricates the plate and
blanket, helping to reduce image wear and
prolong plate life.
! Fountain solution cools and helps to
maintain the working properties of ink.
! Fountain solution aids in proper blanket
release, which reduces piling on the
blanket.
8

Fountain Solution
! The pH and conductivity of the fountain
solution are of major importance if the
fountain solution is to properly fulfill it’s
function of preventing plate non-image
areas from accepting ink.
! Mixing solution should be done on a daily
basis for small duplicators, and tested daily
on large presses with holding tanks.
! The fresher, the better!
9
Fountain Solution Components

! Most fountain solutions are made up of
five basic ingredients and water.
"Acid.
"A wetting agent (surfactants).
"Plate conditioners (chemical salts).
"Gum arabic.
"A buffering agent.
10

! Acid.
"Usually a mild acid, which helps reduce

the pH and keeps the image area
sensitive to ink and the non-image area
more sensitive to water.
11

! A wetting agent.
"Sometimes referred to as surfactants,
these are used to lower the surface
tension of the water allowing it to
maintain the wetting ability of the
fountain solution in the non-image areas,
while allowing you to run less water.
Common agents used are: Isopropyl
Alcohol, Glycerin, and various Glycols.
12

! Plate conditioners (chemical salts).
"These are used to minimize the
corrosive action of the acid on the
surface of an aluminum or metal plate.
This is designed to increase the print
quality and to extend the life of the
plates. Most solutions also contain anti-
foaming and anti-fungus ingredients.
13

! Gum arabic.
"Gum arabic has already been added
to most fountain solution concentrates
made today. It’s function is to adhere to
the plate’s non-image area and protect
it from accepting ink. Gum also serves
to protect the plate from humidity and
chemical attack during press stops.
14

! A buffering agent.
"A substance capable of neutralizing acids and
bases in solutions and thereby maintaining the
acidity or alkalinity level of the solution.
"Keeps the pH constant or within a certain
range regardless of how much acid is added.
"Neutralizes the effects of paper, inks, gases,
and humidity.
15

! Alcohol in dampening solutions.
"Alcohol is added to the fountain solution as

a surfactant. It makes the water wetter. By
reducing the surface tension of the water
the water will spread out to a thinner film.
16

! Alcohol in dampening solutions.
"Isopropyl alcohol is a volatile organic

compound. As a VOC alcohol pollutes our
pressroom and our environment. It is
recommended to use alcohol substitutes.
17
How important
is the
Water
source?

Water
! Since approximately 98% of a working
fountain solution is water, being aware of
your water condition is of vital importance.
! Water can be either hard or soft, acid or

alkaline. In fact, water quality can vary
seasonally, monthly, weekly, or even daily.
19
Water
! Understand that tap water can be a variable

when used in fountain solution because
some minerals and chemicals in the water
may not be compatible with the chemicals
in the fountain solution concentrate.
20

Water
! There are three stable substitutes for tap

water: De-ionized, Distilled, and Reverse
Osmosis water.
21
Water
! De-ionization, or the demineralization
process.
"A complex chemical process that uses two

ion exchange resins to remove minerals
from water. The cost of this method is
considerably less than the cost of producing
distilled water.
22

Water
De-ionization, or
Demineralization
unit
Water
! Distilled water.
"Produced in a laboratory by boiling ordinary
tap water in a water still. The steam that rises
from the boiling water is almost free of the
mineral matter present in the tap water. The
steam is fed through condenser coils where
it is converted into liquid, distilled water.
Some fountain solutions do not work well
with distilled water.
24

Water
Distilled
Water
Unit
Water
! Reverse Osmosis water.
"The best method of water purification. In
this process the water is filtered through a
membrane to remove most of the positive
and negative ions, un-ionized dissolved solids
(sugars), suspended matter, and bacteria
leaving only pure water.
"Sometimes referred to as “RO water”.
26

Water
Reverse
Osmosis
Unit.
Water
! What is Hard Water?
28

Hard Water Is:
"Tap water is rarely pure.
"Ions associated with minerals and inorganic
compounds in water make it “hard”.
"Through formation of oleaginous (oily) soaps,
hard water can play havoc with press
operations (roller stripping, halftone fill-in).
"Water hardness is rated in terms of total
concentration of calcium carbonate ions.
29
Water
! How do we evaluate water hardness?
30

We evaluate water hardness by:
"Water hardness usually is indicated in parts
per million (PPM) (or milligrams pre liter
(mg/l) or grains/gallon) of calcium carbonate.
"Water hardness varies from locality to
locality.
"The best source for determining water
hardness is the local water company.
"Water hardness can be estimated by using a
conductivity meter.
31
We evaluate water hardness by:
32

Water
Softener.
Water
! What is water alkalinity?
34

Water alkalinity is:
"Alkalinity neutralizes acids.
"Tap water with high levels of alkalinity are
most common in areas with limestone deposits.
"Alkalinity is measured and expressed in PPM,
mg/l or grains/gallon.
"In areas with alkaline water, alkalinity is more
important than water hardness because
excessive levels shift pH towards neutral.
35
What is pH?
36

What is pH? (History)
! For those who wonder how the term pH
came by its odd spelling, the Romans
knew pH as “potentia hydrogenii,”
or “potential for Hydrogen,” and thus
the small “p” and capital “H”.
! All the press operator really needs to
know about pH is that it is a measure of
the degree of acidity or alkalinity of
fountain solution.
37
What is the pH Scale?

" The pH scale runs from 0 to 14.0.
" 7.0, the mid-point on the pH scale, is neutral.
" A solution with a pH of less than 7.0 is acid. A
solution with a pH of more than 7.0 is alkaline
(base).
" A whole-number change on the pH scale
represents a tenfold change in pH. Small
differences on the scale, in practical terms,
may be quite large.
38


" Each whole number on the pH scale represents
a tenfold change in acidity or alkalinity.
" A solution at (pH 5.0 is 10 times more acidic
than a pH 6.0) and a solution at (pH 4.0 is 100
times more acidic than a pH 6.0).
" A solution at (pH 9.0 is 10 times more alkaline
than a pH 8.0) and a solution at (pH 10.0 is 100
times more alkaline than a pH 8.0).
40

Determining pH.
41
Determining pH.
" There are two basic methods for checking
pH in the industry: with chemically-coated
indicator papers (strips), and with
electronic pH meters.
" Indicator papers and strips tend to be
inaccurate.
" Battery-operated, portable pH meters are
reliable and easy to use.
42

Determining pH.
" Ink-makers recommend a fountain pH
of 4.5 – 5.0 for optimal performance.
" Certain duplicators, using paper plates,
may require a slightly lower pH.
" Higher pH readings may cause scumming
and toning, whereas pH readings of less
than 4.0 may retard or inactivate ink
drying by locking up the catalytic dryers
in the ink.
43
Determining pH. (Buffering)

" Without getting over-technical, buffers
are chemicals that are used in fountain
concentrates to help stabilize the pH
level of the mixed solution.
" Buffers reduce the tendency of pH to
drift (becoming more acidic or alkaline)
due to the introduction of contaminants
such as paper coatings, inks, wash-up
solutions, and any other contaminant
you can think of.
44

Determining pH.
! When purchasing fountain solution:
"Is it a buffered or non-buffered solution?
"Is it compatible with your water source?
"Does the fountain solution provide the correct
pH level and compatibility specified by the
ink and plate manufacturers?
"Do Not use a variety of different solutions!
Find one that works for your type of printing.
45
What is conductivity?
46

! Conductivity is the ability to transmit or
conduct an electrical charge.
! The degree of conductivity is determined
by the number of ions present as a result of
minerals or other compounds in the water.
! The higher the concentration of ions, the
higher the degree of conductivity (and
usually the harder the water).
47
! Water normally has a very low ion level
and registers very low in conductivity.
! Alcohol does not conduct an electric
charge and has a conductivity reading of 0,
as does glycerin.
! Therefore alcohol and glycerin act to dilute,
reducing the solution’s conductivity
reading.
48

Why the need for conductivity?
! With the new technology that has evolved
in the printing industry, including buffered
and neutral fountain solutions, pH is not
enough in determining the best level of
performance of a fountain solution.
! Conductivity gives a more accurate way
to monitor the conductivity level
throughout a press run.
49
! Whether the press operator adds 3 or 8

ounces of solution to a gallon of water,
the pH will remain the same, but the
over-all chemistry is not correct for the
type of press that you are trying to run!
50

! Conductivity readings let us know where

our starting solution should be, and if it
becomes contaminated and problems arise
we have a base number to refer back to
regardless of the pH level.
51
Why the
need for
conductivity?
This chart shows a
Fountain Solution
buffered at a pH of
4.5

How do we measure
conductivity?
How do we measure
conductivity?
! The unit of measure for expressing

electrical resistance is the “ohm”,
and the unit of measure for expressing
conductivity, the opposite of resistance,
is the”mho”.
54

How do we measure
conductivity?
! Because of the difficulty of measuring
conductivity in terms of “mho” units,
a fraction of a mho or a “micromho”
is normally used.
!A micromho is equal to one millionth

of a mho.
55
How do we measure
conductivity?
! Conductivity meters are accurate, easy
to calibrate, and simple to use.
! To take a reading just place the electrode
in the solution and stir a few seconds.
! Most conductivity meters are digital and
a reading will appear in the viewer.
56

How do we measure
conductivity?
! The level of a solution is measured with a
conductivity meter, which gives readings
in micromhos per centimeter.
! Conductivity should be checked before and

after adding alcohol due to the fact that
alcohol dilutes the solution and will render
a false reading.
57
How do we measure
conductivity?
! The rule of thumb for good
conductivity readings is about 900
to 1000 mmhos over the conductivity
of the water.
! The conductivity range encountered
by most printers will be under 3000
micromhos (mmhos).
58

How do we measure
conductivity?
! The important fact to remember is
that there is no conductivity standard.
You must determine the individual
standard for your press by conducting
tests.
59
Fountain solution problems.
What happens
when too much
concentrate is used
in the fountain
solution?

Too Much Concentrate
! If the recommended dilution ratio of the
fountain concentrate is 2 ounces per gallon,
this does not mean that 4 ounces per gallon
is twice as good.
! Excessive use of fountain concentrate will

cause problems and increase chemistry,
material, and labor costs.
61

! When an overdose of a buffered fountain
concentrate occurs, the pH reading will not
indicate this excess because the buffering
salts limit the pH reading of the solution.
! A conductivity reading, on the other hand,

will prove useful in determining excess
concentrate.
62

! Possible problems from too much concentrate.
"Ink emulsification (especially reds and blues).
"Background tinting.
"Poor ink-acceptance in image area, resulting in
mottling or blinding of the plate.
"Premature plate wear from lack of ink lubrication.
"Slow drying of inks and possibly, of chalking.
"Stripping of the ink rollers.
63
Fountain solution problems.

What happens
when too little
concentrate is
used in the
fountain
solution?

Too little Concentrate
! Too little concentrate will cause many of
the active ingredients found in the fountain
solution to be inadequate in strength to do
the job they are designed to do.
! Lack of adequate concentrate can be
determined by both pH and conductivity.
! For best results, stay with a range of pH
and conductivity that is most successful
under your printing conditions.
65
Too little Concentrate

! Possible problems from too little
concentrate.
"Filling in of reverses and halftone screens.
"Scumming.
"Tinting.
"Inadequate gum will leave plate non-image
areas unprotected.
"Lack of anti-corrosive ingredients will lead
to premature plate wear.
66

Safety First
Safety First
! Use care while mixing to avoid dangerous
splashes.
! Measure out the required amount of water
first.
! Add concentrate to the water.
! If other components are required, add them
to the water/concentrate mixture.
! Stir or mix all components to achieve a
uniform blend.
68

Safety First
! Check pH and conductivity to be sure
they meet the manufacturer’s
recommendation (or the pre-established
standards for your press).
! If alcohol is required, add it after the

solution has been mixed to the desired
conductivity range.
69
Summary
! pH and Conductivity determinations are
the first logical troubleshooting steps
when press related problems arise.
! Most problems attributed to fountain
solution are due to too much or too little
fountain concentrate and the source water.
! Maintenance and cleaning of dampening
systems will also eliminate a lot of
dampening system problems.
70

Where to Get More Information
! The following companies have provided
the information used in this presentation:
" Varn Product Company (201) 337-3600
" Kohl Madden (800) 367-4657
" Kodak Polychrome Corp. (414) 784-3720
" Van Son Ink (800) 645-4182
" GATF http://www.gatf.org
71
Thank You
! If you ever need Help!
EuGene L. Van Roy
Western Wisconsin
Technical College
304 N. 6th St.
LaCrosse, WI 54602
(608) 789-6260 or (608)
526-6600
E-mail:
vanroy3@juno.com
72

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pH, Conductivity

EuGene Van Roy

pH, Conductivity and Offset Printing 1

pH, Conductivity and Offset Printing 2

What is the purpose of

pH, Conductivity and Offset Printing 3

pH, Conductivity and Offset Printing 4

Fountain Solution Components

pH, Conductivity and Offset Printing 5

"Usually a mild acid, which helps reduce

Fountain Solution Components

pH, Conductivity and Offset Printing 6

Fountain Solution Components

pH, Conductivity and Offset Printing 7

Fountain Solution Components

"Alcohol is added to the fountain solution as

pH, Conductivity and Offset Printing 8

"Isopropyl alcohol is a volatile organic

pH, Conductivity and Offset Printing 9

! Water can be either hard or soft, acid or

! Understand that tap water can be a variable

pH, Conductivity and Offset Printing 10

! There are three stable substitutes for tap

"A complex chemical process that uses two

pH, Conductivity and Offset Printing 11

pH, Conductivity and Offset Printing 12

pH, Conductivity and Offset Printing 13

! What is Hard Water?

pH, Conductivity and Offset Printing 14

pH, Conductivity and Offset Printing 15

We evaluate water hardness by:

pH, Conductivity and Offset Printing 16

pH, Conductivity and Offset Printing 17

pH, Conductivity and Offset Printing 18

What is the pH Scale?

pH, Conductivity and Offset Printing 19

What is the pH Scale?

pH, Conductivity and Offset Printing 20

pH, Conductivity and Offset Printing 21

Determining pH. (Buffering)

pH, Conductivity and Offset Printing 22

pH, Conductivity and Offset Printing 23

pH, Conductivity and Offset Printing 24

Why the need for conductivity?

! Whether the press operator adds 3 or 8

pH, Conductivity and Offset Printing 25

! Conductivity readings let us know where

pH, Conductivity and Offset Printing 26

! The unit of measure for expressing

pH, Conductivity and Offset Printing 27

!A micromho is equal to one millionth

pH, Conductivity and Offset Printing 28

! Conductivity should be checked before and

pH, Conductivity and Offset Printing 29

Fountain solution problems.

pH, Conductivity and Offset Printing 30

! Excessive use of fountain concentrate will

Too Much Concentrate

! A conductivity reading, on the other hand,