Latest Developments in Flexo Plate Solutions for Corrugated Printing
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Transcript of Latest Developments in Flexo Plate Solutions for Corrugated Printing
Latest Developments in Flexo Plate Solutions
for Corrugated Printing
Emma Schlotthauer
Dr. Andreas Albat
An FPPA-Sponsored Webinar
Agenda
• Kodak at a glance
• Kodak’s flexo development – an alternate approach
• Benefits in corrugated pre-print applications
• How can we use this technology to impact post-print?
– For ink transfer
– For highlights
– For line work jobs
– For process color jobs
• Summary
• Q&A
Kodak at a Glance
Latin America
Region
US & Canada Region
Europe, Africa & Middle East
Region
Asia Pacific
Region
2013 revenue: $2.35B
8,000 employees
FLEXCEL NX: Over 350 installs WW, growing 30% per year
Graphic Communications, Packaging, Functional Printing
Flexo Development History
• Kodak already had LAMS technology
• Kodak chose a different approach to achieve
– higher quality
– greater consistency
– greater stability
• Drew from Kodak expertise in imaging
science – especially for offset printing
Flat Top Dots
• Pioneered the flat top dot for digital flexo
• Industry acceptance for stability and plate life
• Kodak is firmly committed
to the flat top dot
approach
What is different?
Previous
imaging
technology:
used by
Thermoflex
with LAMS
plates
Technology
used in
FLEXCEL NX
System
What is different?
1 :1 Imaging
File Bitmap Imaged TIL Flexcel NX Plate
What is different?
• Micro surface texturization
• Islands – not cells
• Disperses layer of ink for
outstanding transfer
• Especially uncoated papers
DIGICAP NX Patterning
Introducing the FLEXCEL NXSystem for Corrugated Packaging
More print quality, less total delivered cost
Experience in pre-print
• Offset-like image reproduction
• Plate longevity
• Reports are 3 times as long as
competitive ‘flat top dot’
LAMS plates
Trends in digital plates for post-print
• Post-print gradually migrating to digital
• Flat top dots are accepted as required
• Can post-print compete with
pre-print on quality?
• Can we improve print quality on
lower grade / lower weight liners?
• Could better ink transfer improve
visual appearance and increase
press speeds?
Kodak technology in post-print
FLEXCEL NX Wide
5080 SystemFLEXCEL NXC
Plate
DIGICAP NX
Patterning
Post-print developments
and results
Dr. Andreas Albat, P.Eng.
Flexcel NXC – A Unique Plate
NX technology brings unprecedented dot formation control
• Superior dot formation
• Leading patterning technology
• Optimized shoulder angle
– Low highlight gain
– Robust on-press performance
• Durometer and pattern technology
chosen for minimal fluting
• Low anilox pressure and
low impression
• Expand your capabilities for
all corrugated applications
• Reduce board cost
• Importance of surface patterning
– Uniform lay down with the lowest amount of ink
– Standard DIGICAP NX
– Advanced DIGICAP NX for high-volume anilox
Cutting Cost
600 lpi
Density: 1.98
Coated board
300 lpi
Density: 1.26
Uncoated board
Coated Board Lower Grade
Low Gain – High Densities
Pushing the limits for density
00.10.20.30.40.50.60.70.80.9
11.11.21.31.41.51.61.71.81.9
22.1
0 10 20 30 40 50 60 70 80 90 100
Pri
nte
d D
en
sity
% Tint
Tonal Reproduction Curve - Density
Coated Substrate
00.10.20.30.40.50.60.70.80.9
11.11.21.31.41.51.61.71.81.9
22.1
0 10 20 30 40 50 60 70 80 90 100
Pri
nte
d D
en
sity
% Tint
Tonal Reproduction Curve - Density
Coated Substrate
NXC
Competitor I
Competitor II
Superior
densities
Low gain
1.98
1.45
Advanced DIGICAP NX
Advanced DIGICAP NX Process Patterns
Standard Advanced 01 Advanced 02
Advanced 03
“Low” BCM
Advanced 04
Medium BCM
Advanced 05
High BCM
More Anilox Volume
More Anilox Volume
Advanced DIGICAP NX White/High Anilox Volume Patterns
Matching Patterns to Anilox Volume
“Very low” Anilox Volume (1400 lpi) on Coated Board (E-Flute)
Increasing pattern size
Higher ink
volume
Fluting
“Medium Anilox Volume (600 lpi) on Coated Board (E-Flute)
“High” Anilox Volume (300 lpi) on Uncoated Board (B-Flute)
We help you Because
• Cut cost
- Reduced ink usage
- Lower cost face stock
• More “image pop”
• Reduced fluting
• Fuller tonal range
• Low gain
• Increase press speeds
• Longer plate life
• Improved ink transfer through
DIGICAP NX Patterning
• FLEXCEL NX flat top
Technology
• Optimized shoulder angles
Implications for 1 or 2 Color Jobs
Highlight Reproduction
Major differences among
flat top dot solutions
Large dot gain
Minimizing Dot Gain
Significantly
less dot gain
Choosing the Right Minimum Dot Size
Board quality
Anilox pressure Impression
Plate dot
holding ability
Shoulder angle
Surface
patterning
Hybrid
screen
Orientation
on press
Latest Generation Hybrid Screening
Fast
Transition
Smooth
Transition
Choose optimum
min dot
Fade to zero
• Point 1
Vignette Performance at its Best
600 lpi Coated E-flute
Good fade to zero
Controlling your highlight dot
Robustness
“Don’t try this at home!”
Looking for the Breaking Point - Gains at 175 lpi
Poor
highlights
Increased
dot gain
Significantly
less dot gain
In Prepress:
• Full tonal range with less prepress correction
• TIL Imaging with no heavy plate fly-off risk
• High speed imaging with DIGICAP NX
applied at imager
• 100% flat top dot
• Smaller files sizes for high definition
• Typically fastest processed plates in the market
• Longer UVC for better ink transfer
• DITR capability
Implications for 4/c Process
Implications for 4/c Process
In Printing:
• Better ink transfer mechanism
– Cleaner and brighter colors
– Reduced impression for good ink transfer
• Choice of density or ink savings
– Improved drying & higher speeds
• Improved tonal range and contrast
• Board stock savings with focus on
less coated face stock
• Support brand owners sustainability goals
Kodak technology in post-print
FLEXCEL NX Wide
5080 SystemFLEXCEL NXC
Plate
DIGICAP NX
Patterning
Delivered by developments in:
• Ink transfer
– Image ‘Pop’; Plate longevity; Substrate cost opportunity
• Highlight image reproduction
Kodak is committed to bringing innovative technology
solutions to the corrugated market
In Summary
Greater Visual
Impact
Reduced
Costs
A commitment to corrugated market
“Flexibility, time to market and improved total cost of ownership
are getting increasingly important to our customers. To extend
the capabilities of packaging production equipment, we decided
to join forces with Kodak in particular because of their strength
in the digital arena,”
JEAN-PASCAL BOBST, CEO OF BOBST GROUP
Questions?
