Transcript Esko-Graphics 2004 template Name of speaker Title of speaker
Simultaneous Ablation & UV Exposure for Digital Plates and Sleeves
Ian Hole Director for Market Development ESKO
Established Digital Platemaking
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Established Digital Flexo Platemaking Process
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Ablative Laser imaging to post processing Laser Digital Flexo Plate with LAMS coating Back Exposure Ablation UV Main Exposure Conventional Solvent Processing Thermal Dry Processing
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Digital Flexo - Status
-Smaller highlight dots and digital consistency -Improved drain in shadow areas giving clean negative print -Stable image throughout print run -Processing not changed for digital plates or sleeves -Dot support issues possible if UV exposure is not well controlled -“Bump Curve” critical to compensate for highlight dot shrinkage on plate - Accepted by many as the way forward in Pack and Labels
digital 14 micron dot
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Digital Ablation through 2005 Advancements in ablation speed and productivity ‘95 - 8.3 sq. ft ‘97 - 13.2 sq. ft ’99 - 17.4 sq. ft (sq.ft/hr) at 2000 dpi- any lpi ’00 - 27.7 sq. ft ’02 - 43.1 sq. ft (full image 40” x 30” - 12 minutes)
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Digital Platemaking through 2005
• •
Advancements in plate processing technologies
– Thermal dry processing, saves time and less distortion to the polymer – Thermal dry processing has less emission issues – Extended range of available durometer, thickness and types of polymer
Minimal changes to plate main exposure
– Point light sources not proven over complete large plate area for dot shape and structure – Bank lights still need compensation from “Bump Curves” to achieve well formed highlight dots – Inconsistency easily possible, wastage expected
Digital Platemaking Today
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Digital Flexo Platemaking Workflow - Today
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Simultaneous Laser Ablation and UV Main exposure Laser Conventional Solvent Processing Ablation UV Main Exposure Thermal Dry Processing
Digital Flexo dot shape comparison
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Digital 2004 14 micron dot Simultaneous Digital 14 micron dot
- smaller highlight dot possible - improved drain of residues - clean negative print - stable throughout press run - no vacuum / OXYGEN inhibition + + + + smaller highlights better formed dots have good shoulder support long press life due to dot formation better ink transfer
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Speed development of Flexo Imager family 8.3 sq. ft 1995 13.2 sq. ft 1997 (sq.ft/hr) at 2540 ppi- any lpi 17.4 sq. ft 1998 27.7 sq. ft 2000 T WIN B EAM/Optics 25 43.1 sq. ft 2002 P OWER B EAM/Optics40 86.1 sq. ft 2005 / Optics 80 50x80=19 minutes
Why Simultaneous Ablation and UV Main Exposure?
11 - Possibility for targeted UV light simultaneous with ablation giving higher productivity, less total process time - Rotating plate/sleeve addresses the light exactly perpendicular and very close to polymer surface brings perfect exposure of fine highlight dots - UV light emission is exactly consistent across ENTIRE plate/sleeve surface for highlights and shadows - Easily adapted for plates or sleeves of any size - Reduced handling brings labor down and polymer savings up
The Technology (patented)
Liquid cooled mercury capillary source - Pre focused UV reflector 12
The Technology for Plates OPTICS
- Fixed distance from plate surface 13
The Technology for Sleeves OPTICS OPTICS
14 - Automatic lamp distance adjustment for sleeve repeat sizes - NO Productivity loss for ALL sized sleeves (same as plates)
Benefits from the technology
Time Reduction of Platemaking process - before
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Solvent CTP Imaging, UVexposing, processing, drying, finishing 1.Color
2.Color
3.Color
4.Color
Thermal CTP Imaging, UVexposing, 1.Color
processing, (no drying), finishing 2.Color
3.Color
4.Color
time
Time Reduction of Platemaking process - after
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Solvent CTP Imaging/UVexposing, processing, drying, finishing 1.Color
2.Color
3.Color
4.Color
Thermal CTP Imaging/UVexposing, 1.Color
processing, (no drying), finishing 2.Color
3.Color
4.Color
time
Elimination of polymer waste – in detail
• • • Elimination of waste through Plate to Plate consistency from more digital control of process – UV light exposure was always analog Elimination of polymer waste through reduced polymer handling within process – No carrying of large (thick) plates to and from a UV frame – Once Ablated/UV is exposed, plate image is fixed, damage to mask layer is irrelevant, does not affect the final plate/sleeve image Strong dot shoulder structure from perpendicular light gives support to small isolated highlights 18
Perpendicular UV light forms better dots than Bank Light
• • • • • • As UV bank-light is being delivered to the plate, oxygen is being depleted thereby shrinking the dots – Digital Technology What would happen if you could deliver greater amounts of UV to the photopolymer in shorter periods of time? Is oxygen depletion still sharpening the dots?
Targeted amounts of UV delivered to the photopolymer at exactly 90 degrees to the polymer Highlights and fine line detail gets almost ALL the light necessary to form a strong dot – Very reduced “Bump” exposure necessary (max 1-3% range) Targeted amounts of light EVENLY delivered to ALL parts of the polymer surface Good quality dots across entire tonal range with good shoulder support 19
Productivity - Digital Flexo vs Direct Engraving
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Solvent CTP Imaging/UVexposing, processing, drying, finishing 1.Color
2.Color
3.Color
4.Color
Thermal CTP Imaging/UVexposing, processing, 1.Color
2.Color
3.Color
(no drying), finishing 4.Color
Direct Engraving 1.Color
2.Color
time
3.Color
4.Color
Summary of Cost and Productivity Benefits
• • • • • • Reduction in platemaking process time with SIMULTANEOUS ablation and UV main exposure Elimination of waste through Plate to Plate consistency from more digital control across more of the process (no analog exposure frame) Elimination of polymer waste through reduced process steps and handling Reduced Bump Curve plus an extended tonal range – because plate is almost linear Use with Solvent or Thermal / Plates or Sleeves Productivity and quality increased even more versus Direct Engraving 21
The Results on Press
Press Dot Gain comparison
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PRINTED DOT 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0
Analog Bank Light Digital Simultaneous Digital DGC curve
10 20 30 40 50 60 FILM DOT % 70 80 90 100 Dot Gain from Digital is 50% less than analog plates and more predictable Even less Dot Gain from Simultaneous plates
Benefits on Press
• • • This Simultaneous UV dot holds up well on long runs - at least the same as Bank Light UV plates – strong dot formation means press impression has same impact Same shaped dot brings all printing advantages of Digital Flexo Indications of higher Ink Transfer from Simultaneous UV dot – Why?
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One application for this technology
Improved workflows - Corrugated and Label Market
PlatePatcher – workflow example - tradeshop
• Workflow (Savings in RED) 10-15% polymer PlatePatcher UV lamp reduces Main exposure time CDI *.map
PRESS
100% mounting time & perfect register on press XL-Table 70% cutting time saving 10% plate saving Plot slug positions Mounting 90% time saving • • • • • • • PlatePatcher for optimization of separations Mylar on table register pins, plot “slug” positions Cut and Mount “slugs” Using pins on CDI drum, load mylar carrier (with plate “slugs”) Image, UV expose on CDI Process plates on carrier sheet Attach press barstrips on XL table & onto press 26
PlatePatcher workflow example – label printer
• Workflow (Savings in RED) UV lamp eliminates time - 15 minutes 10-15% Polymer saving PlatePatcher CDI
PRESS
70% cutting time ID plotting on back of plate XL-Table Post-Mounter • • • • • • • • PlatePatcher for optimization of separations Imaging on CDI – ablation and UV together Thermal processing On XL table plates face down for pen ID plot on back of plate Position file cuts mounting time – 10 minutes per color Cutting of separations on XL table (still face down) Collating separations into work job tickets Send to Mounting dept. Automatic mounter will use camera position data from graphics file 27
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