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?

Speaker Contact Info

Emma Schlotthauer

Emma.schlotthauer@kodak.com

Dr. Andreas Albat

Andreas.albat@kodak.com