Ballard Skin Rotogravure Process

The Ballard Skin Rotogravure Process of printing begins with a cylinder of known overall length (including spindle), known printable length and known diameter. These dimensions are determined by the type and size of press to be used, and also the pagination of the copy to be printed.

The cylinder face (this is the circumferential area of the cylinder that will be in contact with the paper) is coated with almost pure copper by electroplating. The amount of copper added to the cylinder is predetermined - always the amount needed to bring the cylinder up to within micrometres of printable diameter. It is then coated in artificial protein. This is the Ballard Skin, and will allow the cylinder to be reused after printing.

The cylinder is then coated (galvanically) by several micrometres of almost pure copper and then etched. The most advanced way to do this is using diamond styli.

It is then coated (galvanically) by a few micrometres of chromium VI which gives it a hardened circumference to endure many impressions of printing, while adhering to the etched pattern.

As with offset printing, a separate Form is created for cyan, magenta, yellow and mono (or black).

After printing the cylinder can be stripped back to the Ballard Skin, ready for new application for the next print job.