Spectroscopic examination of layered coating failures in flexographic printing

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Pollard Banknote, headquartered in Winnipeg, Manitoba, currently has three facilities in Canada and two in the United States for the manufacture flexographic printed products. Flexographic printing is widely used to create images on flexible substrates, including cardboard, plastic, metallic films, cellophane, and paper. The structural integrity (chemistry of layers, bonding between interfaces) is critical to product quality. Pollard Banknote products must meet high standards for both security and durability. In this project, we will use Fourier Transform Infrared (FTIR) with Attenuated Total Reflection (ATR) microscopy to obtain two dimensional images of exposed transparent layers, from products manufactured at different sites. This information will be collected in controlled experiments designed to explore the chemistry of the layers and interfaces. Research quality spectroscopic analysis of these products will lead to a better understanding of the manufacturing process. The information will increase their capacity to understand the outcomes of seemingly identical inputs and processes, and lead to refinement of manufacturing and quality assurance processes that can reduce waste and improve efficiency. The company will thereby achieve greater production capacity, enhancing their ability to compete in a broader marketplace. In conclusion, determination of the critical factors in layer makeup and application will facilitate improvement of manufacturing parameters, enable the development of effective and efficient testing methods for quality control in layered applications, improve product quality and increase sales. The immediate benefits to Canada include increased marketability, productivity and profitability for this Canadian manufacturer; and greater knowledge and understanding between the academic and industrial personnel involved. In the longer term, a successful outcome to this Engage project will give the PI and co-applicant a better understanding of Pollard Banknote's needs, strengthen our relationship and open opportunities to develop an I2I project.