Simultaneous Ablation & UV Exposure for
Digital Plates and Sleeves
Ian Hole
Director for Market Development
ESKO
Established Digital Platemaking
Established Digital Flexo Platemaking Process
•
Ablative Laser imaging to post processing
Laser
Digital Flexo Plate
with LAMS coating
Back Exposure
Ablation
Conventional Solvent Processing
UV Main Exposure
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
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digital
14 micron dot
Digital Ablation through 2005
Advancements in ablation speed and productivity
PLATES AND SLEEVES
‘95 - 8.3 sq. ft
‘97 - 13.2 sq. ft
(sq.ft/hr)
at 2000 dpi- any lpi
’99 - 17.4 sq. ft
’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 wellformed highlight dots
– Inconsistency easily possible, wastage expected
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Digital Platemaking Today
Digital Flexo Platemaking Workflow - Today
•
Simultaneous Laser Ablation and UV Main exposure
Laser
Conventional Solvent Processing
Ablation
UV Main Exposure
Thermal Dry Processing
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Digital Flexo dot shape comparison
-
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Digital 2004
Simultaneous Digital
14 micron dot
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
Speed development of Flexo Imager family
PLATES AND SLEEVES
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 TWINBEAM/Optics 25
43.1 sq. ft
2002 POWERBEAM/Optics40
86.1 sq.
sq. ft
ft 2005
2005//Optics
Optics80
80 –
86.1
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
OPTICS
- Fixed distance from plate surface
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The Technology for Sleeves
OPTICS
OPTICS
- Automatic lamp distance adjustment for sleeve repeat sizes
- NO Productivity loss for ALL sized sleeves (same as plates)
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Benefits from the technology
Time Reduction of Platemaking process - before
Solvent CTP
Imaging, UVexposing, processing, drying, finishing
1.Color
2.Color
3.Color
4.Color
Thermal CTP
Imaging, UVexposing, processing, (no drying), finishing
1.Color
2.Color
3.Color
4.Color
time
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Time Reduction of Platemaking process - after
Solvent CTP
Imaging/UVexposing, processing, drying, finishing
1.Color
2.Color
3.Color
4.Color
Thermal CTP
Imaging/UVexposing, processing, (no drying), finishing
1.Color
2.Color
3.Color
4.Color
time
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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
•
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Strong dot shoulder structure from perpendicular light gives support to
small isolated highlights
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)
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•
Targeted amounts of light EVENLY delivered to ALL parts of the polymer
surface
•
Good quality dots across entire tonal range with good shoulder support
Productivity - Digital Flexo vs Direct Engraving
Solvent CTP
Imaging/UVexposing, processing, drying, finishing
1.Color
2.Color
3.Color
4.Color
Thermal CTP
Imaging/UVexposing, processing, (no drying), finishing
1.Color
2.Color
3.Color
4.Color
Direct Engraving
1.Color
2.Color
3.Color
time
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4.Color
Summary of Cost and Productivity Benefits
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•
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 Press
Press Dot Gain comparison
PRINTED DOT
100%
90%
Analog
80%
70%
60%
50%
40%
30%
Bank Light
Digital
20%
10%
0%
0
10
20
30
40
50
Simultaneous
Digital
DGC curve
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
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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?
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One application for this technology
Improved workflows - Corrugated and Label Market
PlatePatcher – workflow example - tradeshop
•
10-15%
polymer
PlatePatcher
UV lamp reduces
Main exposure time
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100% mounting time
& perfect register on press
XL-Table
CDI
•
•
•
•
•
•
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PRESS
Workflow (Savings in RED)
*.map
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
PlatePatcher workflow example – label printer
•
Workflow (Savings in RED)
UV lamp eliminates
time - 15 minutes
10-15%
Polymer saving
PRESS
70% cutting time
ID plotting on back of plate
XL-Table
PlatePatcher
Post-Mounter
CDI
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PlatePatcher for optimization of separations
Imaging on CDI – ablation and UV together
Position file cuts mounting
time – 10 minutes per color
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
www.esko.com
[email protected]
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