The science behind the art of better flexographic results.

The big quality difference between R/bak Cushion mounting materials & other cushions can best be seen by taking a microscopic look inside the foam. Open-cell urethane bounces back over & over again so that the material provides the same level of cushioning no matter how many times it is compressed. Closed-cell polyethylene breaks down in use, not bouncing back & resulting in loss of ink density.


Open-cell urethane structure (magnified 100 times) naturally bounce back to deliver consistent results.

Closed-cell polyethylenes's structure (magnified 100 times) change with repeated use & requires repeated adjustments.


R/bak open-cell urethane foam

Open-cell structure "springe" recover after compression

Original performance

Closed-cell polyethylene foam

"Balloons" or closed-cell structure ruptures under over-impression

Loss of impression force & reduced resiliency

Features & Benefits

Higher Print Quality

R/bak materials provide a high degree of surface conformity with minima increase in plate pressure. the result in lower dot gain, cleaner revers print, improved registration, fewer dropouts & higher quality impression at increased press speeds.

Thick plate
Thin plate whit R/bak Cushion
Reduces Dot gain

Utilizing R/bak Cushions behind the printing plate allows the pressure applied to the plate to be absorbed by the cushion rather than the corrugated surface, thus reducing physical dot gain.

Thick plate Thin plate whit
R/bak CushionThick plate
Eliminates Board Crush

The R/bak Cushion mounting system provides wide process latitude without damage to the corrugated board, allowing for a finished product that truly stands out.

Thick plate Thin plate whit R/bak Cushion
Improved Handling

Lighter thin plates with shorter processing times.

Increased Press Speeds Without Bounce

Eliminating bounce allows increased throughput & ends double strikes.

Longer Plate Life

With less than 2% compression set, R/bak materials reduce plate wear by continually absorbing impact.

Reduced Costs/Improved Profits

Less waste and lower component wear mean more impressions & lower costs for you.

R/bak SF Plate Mounting Instructions

These instructions detail procedures for preparing and using R/bak SF materials in flexographic systems for corrugated products.

1.
View of R/bak SF cushion surface on a 0.010" (0.25mm) Polyester base. PU = R/bak material PET = Polyester base

2.
To cut the foam cushion from the Polyester base:

  1. Firmly hold a straight edge along area to be cut away.
  2. With a razor or utility knife, cut along the straight edge.
  3. Be certain not to cut through the polyester base.

3.
To peel Cushion from polyester base:

  1. With putty knife or chisel edged tool, start to lift foam from polyester base.
  2. Grip the cushion and pull away as knife is guided underneath the foam cushion.

4.
To attach a lead to polyester:

  1. Place duct or fabric tape onto lead. (optional)*
  2. On sewing machine, attach lead through polyester.
  3. Apply glue or sealer on sewn end. (optional)*

*Soft tape prevents damage to edge from stitching

5.
Trailers can be grommets, sewn Plastic tabs or heavy-duty tape as shown.

    6.
    To mount plate to R/bak material:

    1. Apply mounting tape to polyester base. Be certain air bubbles are not present. peel back release paper.

7.
With a curving motion, lay plate onto adhesive Surface. Be certain air bubbles are removed.

8.
To prevent solvents and washes from getting under the mount, it is recommended to apply die sealer or hot melt adhesive as shown.