Simultaneous Ablation & UV Exposure for

Digital Plates and Sleeves

Simultaneous Ablation & UV Exposure for

Digital Plates and Sleeves

Ian HoleIan HoleDirector for Market DevelopmentDirector for Market DevelopmentESKOESKO

Established Digital PlatemakingEstablished Digital PlatemakingEstablished Digital PlatemakingEstablished Digital Platemaking

3

Established Digital Flexo Platemaking Process

• Ablative Laser imaging to post processing

UV Main Exposure

Digital Flexo Platewith LAMS coating

Laser

AblationBack Exposure

Conventional Solvent Processing

Thermal Dry Processing

4

Digital Flexo - Status

digitaldigitaldigitaldigital

-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

14 micron dot

5

‘97 - 13.2 sq. ft

‘95 - 8.3 sq. ft

’99 - 17.4 sq. ft

’00 - 27.7 sq. ft

’02 - 43.1 sq. ft (full image 40” x 30” - 12 minutes)

(sq.ft/hr)at 2000 dpi- any lpi

PLA

TES

AN

D S

LEEV

ES

Digital Ablation through 2005

Advancements in ablation speed and productivity

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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 TodayDigital Platemaking Today

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Digital Flexo Platemaking Workflow - Today

• Simultaneous Laser Ablation and UV Main exposure

Conventional Solvent Processing

Thermal Dry Processing

UV Main Exposure

Laser

Ablation

9

Digital Flexo dot shape comparison

Simultaneous Digital Simultaneous Digital Simultaneous Digital Simultaneous Digital Digital 2004 Digital 2004 Digital 2004 Digital 2004

+ smaller highlights better formed+ dots have good shoulder support+ long press life due to dot formation+ better ink transfer

- smaller highlight dot possible- improved drain of residues- clean negative print- stable throughout press run- no vacuum / OXYGEN inhibition

14 micron dot 14 micron dot

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Speed development of Flexo Imager family

13.2 sq. ft 1997

8.3 sq. ft 1995

17.4 sq. ft 1998

27.7 sq. ft 2000 TWINBEAM/Optics 25

43.1 sq. ft 2002 POWERBEAM/Optics40

(sq.ft/hr)at 2540 ppi- any lpi

PLA

TES

AN

D S

LEEV

ES

86.1 sq. ft 2005 / Optics 8086.1 sq. ft 2005 / Optics 80 – 50x80=19 minutes

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Why Simultaneous Ablation and UV Main Exposure?

- 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

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The Technology (patented)

- Liquid cooled mercury capillary source- Pre focused UV reflector

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The Technology for Plates

- Fixed distance from plate surface

OPTICS

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The Technology for Sleeves

- Automatic lamp distance adjustment for sleeve repeat sizes- NO Productivity loss for ALL sized sleeves (same as plates)

OPTICS OPTICS

Benefits from the technologyBenefits from the technology

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time

Time Reduction of Platemaking process - before

Imaging, UVexposing, processing, drying, finishingSolvent CTP

1.Color

2.Color

3.Color

4.Color

Thermal CTPImaging, UVexposing, processing, (no drying), finishing

1.Color

2.Color

3.Color

4.Color

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time

Time Reduction of Platemaking process - after

Imaging/UVexposing, processing, drying, finishingSolvent CTP

1.Color

2.Color

3.Color

4.Color

Thermal CTPImaging/UVexposing, processing, (no drying), finishing

1.Color

2.Color

3.Color

4.Color

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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

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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

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time

Productivity - Digital Flexo vs Direct Engraving

Imaging/UVexposing, processing, drying, finishingSolvent CTP

Direct Engraving

1.Color

2.Color

3.Color

4.Color

1.Color2.Color

3.Color4.Color

Thermal CTPImaging/UVexposing, processing, (no drying), finishing

1.Color

2.Color

3.Color

4.Color

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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

The Results on PressThe Results on Press

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Press Dot Gain comparison

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 10 20 30 40 50 60 70 80 90 100

FILM DOT %

PRINTED DOT

Analog

Bank Light Digital

Dot Gain from Digital is 50% less than analog plates and more predictable

Even less Dot Gain from Simultaneous plates

Simultaneous Digital DGC curve

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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?

One application for this technology

Improved workflows - Corrugated and Label Market

One application for this technology

Improved workflows - Corrugated and Label Market

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• Workflow (Savings in RED)

• 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

PlatePatcher – workflow example - tradeshop

XL-Table

CDI

PlatePatcher

*.map

10-15% polymer

70% cutting time saving10% plate savingPlot slug positionsMounting 90% time saving

PRESS

Including plate processing

100% mounting time& perfect register on press

UV lamp reduces Main exposure time

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• Workflow (Savings in RED)

• 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

• 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

PlatePatcher workflow example – label printer

XL-Table Post-Mounter

CDI

PlatePatcher

10-15% Polymer saving

70% cutting timeID plotting on back of plate

PRESS

UV lamp eliminates time - 15 minutes

Position file cuts mounting time – 10 minutes per color

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www.esko.com

Ian.Hole@ESKO.com