Integrating plate imaging and front and back exposure in one solution simplifies the entire process
As flexo print runs get shorter and tight deadlines become the norm, the issues of managing plate processing are becoming ever more challenging. The volume of work may not be changing but flexo printers and converters have to consider a large variety of diffident jobs. Michal Lodej reports.
Different run lengths and different job requirements are making effective plate processing more complicated. With order admin, file handling and all the necessary fundamentals of pre-press, printers and converters are finding that set up and make-ready time can sometimes take longer than running the actual job.
Converters that have chosen to invest in their own plate making and pre-press departments in-house gain the flexibility to produce flexo plates more efficiently in a faster timeframe. For instance planning becomes easier and more flexible with higher press uptime as a result. Also dealing with rush jobs becomes easier and broken plates can be replaced at short notice. Combined with further optimisation by ganging jobs, the impact of in-house platemaking on the press floor is considerable.
All in one
Esko has developed a solution designed to help the converter take full control. By bringing the physical platemaking set up in-house for imaging, exposing and developing the plate and owning the own entire workflow, a converter can simplify plate production and importantly align it to the press room. Integrating plate imaging and front and back exposure in one solution simplifies the entire process. What is typically a manual seven-step procedure is now reduced to as few as two steps. Using Esko CDI imaging devices, XPS exposure devices and dedicated pre-press tools, converters can now monitor job status, prioritise queues, insert rush jobs and balance workloads.
Also for all the stages between the one-up file and the ready-to-image plate file, Esko has tools to help out which can be highly and easily automated. These tools are intuitive to use and master all the know-how needed to apply the right screening on the right plate for the right substrate according to predefined press profiles.
Flexo converters still hesitating to take steps in this direction may be looking at the return on their investment. There is proof that after bringing platemaking in-house, the investment can be paid off in a very short timeframe through cost efficiencies. The benefits of having complete control over platemaking, press handling and final production are persuading converters to look at this option as a plus for their business growth.
Geert de Proost, Esko director of solutions marketing, stated, ‘In the past few years, a rapidly increasing number of converters have made the investment to bring their platemaking in-house. The feedback from converters is that there is more and more evidence of a fast return on their investment as well as a simple and effective implementation process. Combine this with the belief that the market dynamics will make ‘near press’ platemaking a must have in the future and it all becomes clear why we see so many converters insourcing their platemaking operations.’
Full automation
Unprocessed plates are difficult to handle, being sensitive and easily scratched. When imaged in high volumes they need to be moved quickly through the production process, there is no danger of them getting damaged and disrupting production.
In the past the solution was to count on the operator’s ability and carefulness to hold each plate and move them to the exposing unit and processing line as it was imaged, but now this can become an automated process.
Vianord has developed a technology that receives imaged plates and moves them to the EVO plate processing line with the aid of number of servo-controlled mechanisms combined with an intelligent sensing system that warrant precision motion, control performance and enhanced operating efficiency.
Loading, imaging, back exposing, exposing, washing-out, drying, finishing, de-taking and stacking of the plates, all can now be performed without the need of any human intervention.
The company joined forces with other manufacturers to pool their knowledge with the common objective of designing a unique end-to-end solution and turning the nine platemaking steps in a single streamlined process.
The result of this is the Easy to Plate Fusion, a multidisciplinary automated system that combines all the popular elements of straightforward automation into one compact, integrated, high performance system thus further innovating and boosting the flexo platemaking process.
The Smart-Bridge is where the magic happens, a compact robotic system that links the Fusion system to any OEM imaging equipment or system. Specifically designed and tailored to fit and communicate with any stand-alone digital imager or combination of multiple digital imagers, it can also house proprietary LED exposure. The first Easy to Plate Fusion E, developed in partnership with Esko, was installed in 2017, at Inci-Flex.
Hot stuff
MacDermid’s offering to the market is its LAVA thermal plate processing unit, which it markets as ‘Plates Without the Wait’. The unit is built for processing 25×30 inch. plates, but can process in sizes up to 42×60 inches for maximum productivity. The LAVA integrates easily with the most popular front-end pre-press systems and software, making it a plug-and-play solution for almost any workflow.
The main features of the processor are that the plates are press ready in an hour and the unit eliminates solvents and VOCs in platemaking. The advanced design uses an internal filter system for reduced footprint and improved ergonomics along with an automated lid lift for work efficiency.
There are three iterations available of the unit, the LAVA NW, the LAVA 4260 and the LAVA 5080. The LAVA NW is specifically designed for narrow web applications and incorporates an internal filter system, vapour management system, durable sub-frame, an automated lift lid, ultra-modern motors and LED illumination.
The LAVA 4260 and the LAVA 5080 are for larger plates, however, the plate processing system’s small footprint reduces platemaking space and can still create press-ready plates in less than an hour, improving productivity and workflow.
The ThermoflexX 20 has increased production capacity
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Allen-Bailey Tag & Label recently acquired a Xeikon ThermoflexX 20 from Anderson & Vreeland year. The investment was made to speed production, improve quality of printing plates, reduce costs, and eliminate time-consuming steps while increasing production capacity.
Adding this new technology is a significant step forward for the Caledonia, NY company. While operating independently for more than three decades, with a limited number of plates procured off-site, and but in a growing economy Richard Phelps, owner and director of marketing at Allen-Bailey, knew it was time for a new strategy. ‘We are very optimistic in this rising economy and see positive activity across a broad spectrum of markets. Our customers are busy, growing, and anxious to serve their customer base. Adopting state-of-the-art technology helps us meet their needs.’
The Anderson & Vreeland technologies team and Xeikon worked closely with Allen Bailey’s pre-press personnel to implement and install the equipment in late 2017. While the new system is already running and productive, the A&V technologies team continues providing additional training while refining the system to make every component as productive as possible.
‘It took us a while to fully appreciate all the advantages the new platemaking technologies provide,’ said Mr Phelps. ‘Working with Anderson & Vreeland’s business team made all the difference for us. It ensured the technology we purchased was tailored for our needs, was integrated into our operation without disruption, and that our staff was trained on how to get the most out of the new equipment.’
