Product Showcase: Plates and Platemaking - February 2014
Plates and platemaking are the final steps before the magic happens—the placing of text and images on substrates that are then printed on a container or converted into some type of package. It is that moment in time when all design and prepress operations converge to fit the needs of a specific printing press.
Over the past decade, new plate and platemaking technologies have resulted in significantly upgraded print quality and improved workflows. This month's Product Showcase features some of the current options from several leading companies for flexographic and offset printing. While the early versions of some of these plates and platemakers were greeted with skepticism when first introduced, every print operation we visit today has one or more of these systems in place, streamlining workflows and increasing overall throughput. And every year they seem to get a bit faster, offer a little bit better quality and have few more compelling new features. And because this is still an evolving technology, if the machines that churn out your plates are a few years old, it's probably worth taking a look at some of the latest offerings to see if they will provide a ROI that could give your bottom line a boost.
Agfa Avalon and Energy Elite Pro
Agfa's Avalon N8 is a range of thermal B1 size platesetters that combine an external-drum engine with a choice of imaging technologies and automation levels to offer customized CtP solutions that respond to a wide range of needs. Depending on plate size and the type of laser used in the imaging head, the Avalon N8 can produce between eight and 65 plates per hour.
The Avalon N8 offers a variety of automated features, such as internal plate punching, single and multi cassette loading and in-line processing to support steady production. A drum auto-balance system allows switching between different sized plates.
Agfa's N4 provides much the same capabilities as the N8 in a compact format for 34-up and 6-up printing on smaller plate sizes sucgh as Agfa's thermal or Azura chemical-free plates. The standard "E" model can be upgraded to the "S" model when more speed and higher performance is needed.
Also from Agfa are Energy Elite Pro plates, thermal no-bake plates developed to provide consistent quality printing with high productivity. Compared to Agfa's Energy Elite plates, Energy Elite Pro offer a speed increase of up to 20 percent (depending on plate setter), 20 percent less chemistry and improved run length for UV inks—up to 150,000 prints. Elimination of pre-heat and post-bake requirements, combined with reduced chemistry consumption, allows Energy Elite Pro to significantly reduce costs and energy usage.
Heidelberg Suprasetter A52
When floor space is at a premium the compact design of Heidelberg's Suprasetter A52/A75 lines can make it an attractive option. The basic manually operated unit has a small footprint—about 5x4x4.5'—and together with the loading system it is the smallest platesetter in its class. The Suprasetter A52/A75 uses the same Heidelberg-exclusive laser technology as the entire Suprasetter family. It has modest energy requirements and produces little waste heat, requiring no additional air-conditioning system. Plus, it features integration with the Prinect workflow and, according to Heidelberg, can be installed and up and running in about one day.
HD Flexographic Platemaking from ESKO
Esko's Full HD Flexo offers up a new, fully digital process for making flexographic plates. It combines high resolution imaging at 4000 ppi with digitally controlled main exposure inside an Esko CDI flexo plate imager. Exposure via an LED-array delivers enough power to provide full control over the polymerization process.
The resulting plates can print more consistently than standard digital flexo plates, featuring improved ink laydown for solid density, vibrant colors and excellent consistency. Images are smoother, sharper and have an expanded tonal range. Full HD Flexo is supported by all major plate vendors and is suitable for tags and labels, flexible packaging, corrugated and carton printing.
Kodak Flexcel Provides Turnkey Solutions
Kodak's Flexcel systems span mid-, narrow- and wide-format plate production. With linescreens of 175 lpi or more, Flexcel NX systems can match the strengths of gravure printing for flexible packaging on a variety of substrates with consistent quality, high print densities and decreased set-up times. According to Kodak, they are especially well-suited for the growing shrink-sleeve label market for both UV and solvent ink applications.
Then there's the Flexcel SRX, a new flexographic platemaking system that provides packaging convertors and trade shops with wider tonal range and has the productivity and print stability of Kodak-pioneered flat-top dot technology. The SRX system leverages the core imaging technology and material science of the Flexcel NX System.
Both systems can image onto Flexcel NX Plates, which offer superior ink transfer, smooth solids, uniform laydown, robust on-press performance and excellent ozone resistance.
MacDermid Printing Solutions
MacDermid's M System is a platform of products and services related to liquid photopolymer platemaking. This collection includes photopolymer, platemaking equipment, washout solutions and film alternatives, along with a dedicated service, production, and research team.
MacDermid has also developed M Jet, a silver film alternative, to eliminate the need for film processing chemicals while allowing for the continued use of film-based platemaking technologies.
Also from MacDermid, LUX enables flexo printers to increase print quality, improve print consistency, print more efficiently and reduce waste. The process uses the LUX Laminator and a specialized MacDermid membrane. It produces a digital plate with a unique dot profile that effectively eliminates the bump curve normally associated with digital plates. The process uses existing MacDermid digital plates, can be used with all flexo lasers and does not require modification to existing equipment.
ThermoflexX Span Full Range of Plate Sizes
ThermoflexX is a division of Xeikon, the digital press maker that's seeing success in the digital printing side of packaging, especially with labels and folding cartons produced on its Xeikon 3300 digital presses. Complimenting those machines is the ThermoflexX line of platesetters designed with the needs of package printers in mind. Offering six different-sized machines, all ThermoflexX 18, 20, 30, 48, 60 and 80 imagers feature resolution options from 2400 to 5080 dpi. Designed to offer smooth and productive operation, some models feature an advanced clamping system for easy plate mounting. A standard vacuum drum and an optional hybrid vacuum/magnetic drum ensure accurate plate positioning for exposure of flexo and letterpress plates. An integrated display enables fast, user friendly and reliable control of the imager.
Last month, Xeikon inked an agreement with Anderson & Vreeland of Bryan, OH, a leading manufacturer and distributor of flexographic plate processing equipment and materials, for distribuion of ThermoFlexX line imagers for flexographic platemaking.
All Printing Resources
APR—the home of TEAMflexo—is a dealer and distributor of plates and platemaking systems from Esko, Flink Ink, Dantex and Screen. Its headquarters includes a demo center where customers and prospects can test out the technlogy first hand to ensure it will meet their needs. APR offers equipment service and installation, plate and print diagnostic services, and ongoing support to ensure the customers' jobs run efficiently.
- Companies:
- Agfa Corp.
- Heidelberg
- Xeikon
