720382Development of a novel Hybrid Cylinder Technology prototype for use in the Gravure Printing IndustryClosedGRD Development of PrototypeInnovate UKThe printing industry forms part of the UK’s 5th largest manufacturing industries, employing ~140k people (BPIF). Packaging forms the largest part of the global printing market, set to reach $820bn by 2016 (Pira 2012), with consumers buying more packaged products worldwide than ever before. Currently, Gravure & Flexography (Flexo) are the preferred methods of printing, constituting 45% & 50% of the global market. However, Gravure printing is used by the majority of UK & EU flexible-packaging materials producers as it can produce millions of impressions without suffering image deterioration; it produces correct colour tone reproduction & uses less energy/m² than alternative methods. The Gravure industry is hampered by the expense & turn-around time of the engraved copper coated hollow steel printing cylinders used to transfer the image onto the substrate. Due to the on-going trend to smaller print runs, high emphasis is on reducing time required for job changes. In this regard, Gravure is currently outmatched by flexo printing. Whilst Gravure cylinders have an average delivery time of 5 days, flexo printing forms are available within 24hrs at much lower cost. Having completed basic prototyping to prove the technical feasibility, Karm Conductives Group seek to advance the novel Hybrid Cylinder Technology (HCT) that will help provide a future for the Gravure printing industry. HCT is based on the electroplating of conductive polymer (ICP) thermoplastic to create an innovative functional metal coated plastic material for use as Gravure printing cylinders. The project aims to overcome the significant challenges associated with design, scale-up & manufacturing of the electrically conductive thermoplastic polymer with surface electroplated copper. A series of prototype cylinders over a range of lengths/diameters will be developed & trialled on press to demonstrate mechanical & functional viability of HCT Gravure cylinders. Expected mkt introduction 2015