4 Flint Group HistoryNovember 2004 CVC acquired ANI Inks and BASF Printing Systems.September 2005 XSYS acquired Flint Ink, a privately owned company with operations in USA, Europe, Latin America, Asia and India/Pacific.Integration of these businesses lead to creation of Flint Group, number two ink supplier worldwide.In 2007 Day International was integrated into Flint Group.2008 Flint Group Printing Plates and rotec became Flint Group Flexographic Products.
5 Flint Group Overview 2011 Sales: €2.2 billion (US$ 3 billion) Number of employees: 6 900>170 company sites in over 40 countriesGlobal network of partners and distributors
7 Flint Group – Business Segments Flint Group’s products are everywhere in our daily life and can be split into two segments:Packaging ProductsPrint Media Products
8 Flint Group – Products Packaging Print Media Packaging inks Packaging and Narrow WebFlexographic ProductsEuropeAmericasAsia-PacificPackaging inksInks for labels and other narrow web printing applicationsSleeves and adapters for flexo and offset printingPhotopolymer printing plates for flexo and letterpress applicationsProcessing equipmentPrinting inks for heatset, coldset, sheetfed, gravure and specialty printingLithographic printing blankets and sleevesPressroom chemicalsPigments
9 Flexographic Products - Extensive Product Range rotec®nylosolv®Sleeves and adaptersPrinting plates forFlexible packagingLabel printingCorrugated (Pre- and postprint)Ready-to-image ITR SleevesProcessing equipmentWashout solventsPrinting plates forLabel printingTubes, cups and tins printingSecurity printingPad printingEmbossing & hot mouldingProcessing equipmentnyloflex®nyloprint®
10 Worldwide Presence Distributors in more than 100 countries Main OfficesGermany, Stuttgart*SubsidiariesAustraliaBrazilChina*DenmarkFranceNetherlandSpainUKUSA*Production sitesPlates, equipment and washout solventsGermany, Willstätt**Sleeves and adaptersGermany, Ahaus**Czech Republic, ChrastavaUSA, AshevilleDistributors in more than 100 countries* holding Technical Center** holding R&D Center
11 Market Shares World 2011: Photopolymer Printing Plates Data Source: internal estimations
12 Market Shares World 2011: Sleeves Data Source: internal estimations
13 Topics The NEW nyloflex® ACE: The Benchmark for High Quality Flexo nyloflex® NExT Exposure Technology: High Definition, Flat Top Dots & Surface ScreeningImprovements With Solid Ink DensityHigh Opacity Values Using Less InkFit For Flat Top Dot Technology
15 nyloflex® ACE - Why Change a Proven Winner?.. Introduced in 2001 quickly becoming market standard for high quality printConfirmed by numerous print awards throughout the years
16 nyloflex® ACE – What Could Be Improved? Plate RoomPress RoomReliability and ProductivityHigher quality ingredientsStable color, less tack improves handling and is more user friendlyNo change in pre-press necessaryPerformance and CostBetter solvent resistanceImproved ink transfer, fewer press stopsCompatibility with new plate technologies
17 The NEW nyloflex® ACE – Physical Properties 62 Shore A (DIN 53505), same as previous nyloflex® ACEDesigned for solvent, water and UV curable flexographic inksImproved overall image quality and color stability, with a brighter green color
18 Comparison of ACE and NEW ACE Nearly identical dot areaCan use same filesVerified in trialsDot Percent on PrintDot Percent on PlateDot Percent in File
19 The NEW nyloflex® ACE – Customers’ Feedback “As a leading printer of confectionary bars we ran 1,500,000 ft and no cleaning of the plates was needed.”“…label printing job with the NEW nyloflex® ACE Digital ran 200,000 ft, no stops for cleaning were necessary.”“We printed 1,000,000 ft of pet food bags without cleaning (normally we stop to clean after 500,000 ft); We were able to run the job 175 fpm faster and saved 7.5 hours in press time!”“A difficult hygiene packaging job 650,000 ft could be printed without stop for cleaning - constant print quality over the whole production run.”“We ran 70,000 lbs of film substrate on the potato chips job with only one set of NEW nyloflex® ACE Digital where previously we needed to replace the plates after 30,000 lbs.”“High speed flexible packaging job, 1,650,000 ft printed without cleaning.”“110,000 ft diapers job with showed excellent ink transfer and the reduced ink consumption for achieving target density.”
20 nyloflex® NExT Exposure Technology The NEW nyloflex® ACE –nyloflex® NExT Exposure TechnologyOutstanding performance with HD Flexo screeningDesigned to work well with both digital Round Top Dots as well as Flat Top Dots
21 Improving Solid Ink Density Combining Plate and Surface Screening Technologies
22 Topics Surface Screening - Solid Ink Density Surface Screening – OpacityFlat Top Dot ApproachesFit For Flat Top Dot Plates
23 Improve SID and smoothness Basic advice: Optimize parametersHarder plate cushion, more ink, substrate treatment, etc.Problem is that an improvement HERE may take away from THERE...1.21.4
24 Minimize or control mottle Better method: Surface ScreeningIn use for a long timeMany versions throughout the years, but idea remains the same – textured plate surface reduces mottle through better ink distribution and coverageScreenings historically 300 – 600 LPIUse 90-97% Tint in SolidsPlate Cell PatterningDigicapGroovy Screening
25 Reasons for Dot ShapesThe oxygen effect during exposure of digital flexo platesConventional exposurewith film negative and UV-A tubesDigital exposurewith LAMS-layer and UV-A tubesUVUVUVUVUVO2O2O2O2O2O2O2O2Dot gainDot reductionDot reductiondue to theoxygen effect
26 Reasons for Dot ShapesThe oxygen effect during exposure of digital flexo platesConventional exposurewith film negative and UV-A tubesDigital exposurewith LAMS-layer and UV-A tubesUVUVUVUVUVO2O2O2O2O2O2O2O2TonwertreduktionDot reductiondue to theoxygen effect
27 Plate with different surface screens Ablated MaskDigital w/ O2Flat TopMicroCellMC8800 LPI @ 40002X2 PixelCheckerboard
28 Print results Plate= Solid Low Screens (<800 LPI) Mid Screens High Screens(>1000 LPI)Digital with O21.32+/- 0.091.43+/- 0.151.30+/- 0.13+/- 0.12Flat Top1.35+/- 0.111.541.64Based on 22 Print Trials
29 Crosslinking w/o oxygen effect The PotentialCrosslinking w/o oxygen effectSolid screening with oxygen effectSolid screening without oxygen effect
30 What About White Opacity? Can Surface Screens Using Flat Top Dot Technology Improve Opacity With Solid Whites?
31 PurposeGain an understanding of the optimum plate durometer, cushion tape and surface screening parameters to maximize white opacity readings at high press speeds.
32 Plates (High Speed Test) Plates – Digital (0.067”)FAM D and ACE D (Flat Top Dot)Cushion Tape – (0.020”)3M 1920, 3M 1020 and 3M 1820Surface ScreeningMicrocell DPI17 Patterns One Smooth Solid
35 High Values Of Plate And Tape Contrast Ratio Function
36 Values Ranked By Surface Screening Value These are the highest opacity readings found for each of the SS parameters. As you can see there is a high range of aprox 2%. The dark blue bar is the non SS patchContrast Ratio Function
37 Second TestEvaluate opacity using lower anilox volume and Flat Top Dot surface screening parameters.Will there be a greater differences in opacity using lower anilox volumes?Will this reduce ink consumption while delivering acceptable opacity?
39 Opacity – FAM D & 3M 1820 Cushion Tape MC 2X3NFAM D 3M 1820Opacity 64.6%No Surface ScreeningFAM D 3M 1820Opacity % 61.8(440 lpi/5.5 bcm)Contrast Ratio Function
40 Opacity – ACE D & 3M 1820 Cushion Tape MC 3X3CACE D 3M 1820Opacity 64.1%No Surface ScreeningACE D 3M 1820Opacity 60.8%(440 lpi/5.5 bcm)Contrast Ratio Function
41 Coating Weight and Opacity Contrast Ratio Function
42 ConclusionsFlat Top Dot technology allows for a greater level of detail at the surface.Surface screening reduced pinholes and increased the opacity.Increasing the modulus of the cushion tape increased opacity.
43 ConclusionsHigher opacity levels were achieved using surface screening allowing for the use of lower anilox volumes and potentially eliminating the need for a double bump.
45 “Flat Top Dot” Technology Kodax NXFilm lamination on special CTP device similar to offset Trendsetter laserRequires special laser, special film consumable, requires use of special Kodak plate materialFormat up to 42x60” size
46 “Flat Top Dot” Technology MacDermid LUXLamination of film material to plate with some heat and pressureRequires laminator and special film
47 “Flat Top Dot” Technology DuPont Digiflow® (aka Digicorr)Retrofit to older top lift exposure units or equipped on new exposure units.Pumps nitrogen & oxygen gas mixture onto the plate
48 “Flat Top Dot” Technology Esko Inline UVRetrofit or new machine with LED diode partsUsed for both flexo and letterpress plates
49 Flint Group‘s Solution for Flat Top Dots and Surface Screening nyloflex® NExT?Flint Group‘s Solution for Flat Top Dots and Surface Screening
50 reduction of oxygen inhibition effect NExT exposure processreduction of oxygen inhibition effectoxygen exclusioninertisationoxygen barrieruse of auxiliaries: inert gas (nitrogen)use of auxiliaries: film consumptionadditional processing step (risk, costs)inert gas consumption and riskacceleration of polymerization speedNew high intensity UV exposurehigh intensity UV irradiation for strong surface cure + conventional UV tubes exposure for through-cure
51 New approach of Flint Group Two step exposureCombination of UV-A LEDs with UV-A tubesStep 1 – High intensity UV LED surface crosslinkingStep 2 – Through-cure with conventional UV tubes
57 3% data @146lpi (2540 dpi) (transmitted light) NExT Plate Image Samples3% (2540 dpi) (transmitted light)
58 nyloflex® NExT – Processing Equipment nyloflex® NExT Exposure FIIIMid size exposure unitFormat 920 x 1200 mm (47.2 x 36.2“)nyloflex® NExT Exposure FVLarge size exposure unitFormat 1320 x 2032 mm (52 x 80“)
59 UV LED module Electrical connectors water connection for cooling Housing with cooling profileLEDs with optics and quatrz glass59
60 NExT UV LED Bar 49.4” radiation width even with one module out Modular system → 12 x 4.5“Radiation length = 53.9“49.4” radiation width even with one module outEthernet port for each module for remote diagnosis / recovery at manufacturer
61 The Benefits of nyloflex® NExT High-intensity LEDs (> 800 mW/cm2) for highest productivityConsistent UV emission guarantees long-term repeatability Production consistency, especially for repeat ordersEasy-to-use – requires no additional processing steps or consumables (such as lamination, inert gas etc.)Suitable for all digital flexo plates – any plate type, thickness & format High flexibilityCompatible with all standard prepress software & HD FlexoEasy implementation into existing digital workflow
64 Do Not Forget The Tooling New plate and FTD exposure technologies assist in moving the quality target upward.However, are your sleeve and bridges up to this task?When was the last sleeve audit performed?An upgrade in this area may also be necessary.
65 Thanks for your attention! Questions? Flint Group Flexographic ProductsExtensive product rangeCustomer oriented serviceExcellent technical knowledgeGlobal presenceInnovative solutionsThanks for your attention! Questions?Rich EmmerlingTechnical Manager