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New Innovations in Plates and Sleeves Rich Emmerling Technical Manager 770-366-5689 Rich Emmerling Technical Manager

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Presentation on theme: "New Innovations in Plates and Sleeves Rich Emmerling Technical Manager 770-366-5689 Rich Emmerling Technical Manager"— Presentation transcript:

1 New Innovations in Plates and Sleeves Rich Emmerling Technical Manager Rich Emmerling Technical Manager

2 Flint Group Flexographic Products Comprehensive Expertise in Flexographic Printing

3 3 Flint Group: Powerful Roots

4 4 Flint Group History November 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 Flint Group Printing Plates and rotec became Flint Group Flexographic Products.

5 5 Flint Group Overview 2011 Sales: €2.2 billion (US$ 3 billion) Number of employees: >170 company sites in over 40 countries Global network of partners and distributors

6 6 Flint Group Locations Worldwide

7 7 Flint Group – Business Segments Flint Group’s products are everywhere in our daily life and can be split into two segments: Packaging Products Print Media Products

8 8 Flint Group – Products PackagingPrint Media EuropeAmericasAsia-PacificPackaging and Narrow Web Flexographic Products Packaging inks Inks for labels and other narrow web printing applications Sleeves and adapters for flexo and offset printing Photopolymer printing plates for flexo and letterpress applications Processing equipment Printing inks for heatset, coldset, sheetfed, gravure and specialty printing Lithographic printing blankets and sleeves Pressroom chemicals Pigments

9 9 Flexographic Products - Extensive Product Range Sleeves and adapters Printing plates for Flexible packaging Label printing Corrugated (Pre- and postprint) Ready-to-image ITR Sleeves Processing equipment Washout solvents Printing plates for Label printing Tubes, cups and tins printing Security printing Pad printing Embossing & hot moulding Processing equipment rotec ® nyloflex ® nylosolv ® nyloprint ®

10 10 Worldwide Presence Main Offices Germany, Stuttgart* Subsidiaries Australia Brazil China* Denmark France Netherland Spain UK USA* Production sites Plates, equipment and washout solvents Germany, Willstätt** Sleeves and adapters Germany, Ahaus** Czech Republic, Chrastava USA, Asheville Distributors in more than 100 countries * holding Technical Center ** holding R&D Center

11 11 Market Shares World 2011: Photopolymer Printing Plates Data Source:internal estimations

12 12 Market Shares World 2011: Sleeves Data Source:internal estimations

13 13 Topics The NEW nyloflex® ACE: The Benchmark for High Quality Flexo nyloflex® NExT Exposure Technology: High Definition, Flat Top Dots & Surface Screening Improvements With Solid Ink Density High Opacity Values Using Less Ink Fit For Flat Top Dot Technology

14 Introducing nyloflex ® New ACE

15 15 nyloflex ® ACE - Why Change a Proven Winner?.. Introduced in 2001 quickly becoming market standard for high quality print Confirmed by numerous print awards throughout the years

16 16 nyloflex ® ACE – What Could Be Improved? Performance and Cost Better solvent resistance Improved ink transfer, fewer press stops Compatibility with new plate technologies Press RoomPlate Room Reliability and Productivity Higher quality ingredients Stable color, less tack improves handling and is more user friendly No change in pre-press necessary

17 17 62 Shore A (DIN 53505), same as previous nyloflex ® ACE Designed for solvent, water and UV curable flexographic inks Improved overall image quality and color stability, with a brighter green color The NEW nyloflex ® ACE – Physical Properties

18 18 Comparison of ACE and NEW ACE Dot Percent on Print Dot Percent on Plate Dot Percent in File Nearly identical dot area Can use same files Verified in 100+ trials

19 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.” “A difficult hygiene packaging job 650,000 ft could be printed without stop for cleaning - constant print quality over the whole production run.” “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.” “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!” “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.”

20 20 Outstanding performance with HD Flexo screening Designed to work well with both digital Round Top Dots as well as Flat Top Dots The NEW nyloflex ® ACE – nyloflex® NExT Exposure Technology

21 Improving Solid Ink Density Combining Plate and Surface Screening Technologies

22 22 Topics Surface Screening - Solid Ink Density Surface Screening – Opacity Flat Top Dot Approaches Fit For Flat Top Dot Plates

23 23 Basic advice: Optimize parameters Harder plate cushion, more ink, substrate treatment, etc. Problem is that an improvement HERE may take away from THERE Improve SID and smoothness

24 24 Better method: Surface Screening In use for a long time Many versions throughout the years, but idea remains the same – textured plate surface reduces mottle through better ink distribution and coverage Screenings historically 300 – 600 LPI Use 90-97% Tint in Solids Plate Cell Patterning DigicapGroovy Screening Minimize or control mottle

25 25 Reasons for Dot Shapes The oxygen effect during exposure of digital flexo plates Conventional exposure with film negative and UV-A tubes UV O2O2 O2O2 O2O2 O2O2 O2O2 O2O2 O2O2 O2O2 Dot reduction Digital exposure with LAMS-layer and UV-A tubes Dot reduction due to the oxygen effect Dot gain UV

26 26 Reasons for Dot Shapes The oxygen effect during exposure of digital flexo plates Conventional exposure with film negative and UV-A tubes UV O2O2 O2O2 O2O2 O2O2 O2O2 O2O2 O2O2 O2O2 Tonwertreduktion Digital exposure with LAMS-layer and UV-A tubes Dot reduction due to the oxygen effect UV

27 27 2X2 Pixel Checkerboard Digital w/ O 2 Flat Top MicroCell MC Ablated Mask Plate with different surface screens

28 28 Plate=Solid Low Screens (<800 LPI) Mid Screens ( LPI) High Screens (>1000 LPI) Digital with O / / / / Flat Top / / / / Print results Based on 22 Print Trials

29 29 Crosslinking w/o oxygen effect Solid screening with oxygen effectSolid screening without oxygen effect The Potential

30 30 What About White Opacity? Can Surface Screens Using Flat Top Dot Technology Improve Opacity With Solid Whites?

31 31 Purpose Gain an understanding of the optimum plate durometer, cushion tape and surface screening parameters to maximize white opacity readings at high press speeds.

32 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 1820 Surface Screening Microcell DPI 17 Patterns One Smooth Solid

33 33 Press Conditions Press – Wide Web Flexible Packaging Anilox – 220 lpi/9.0 bcm Ink – Flint High Speed Surface White Viscosity – 28 seconds Press Speed – 1200 ft/min. Substrate – Polyester

34 34 Test Target

35 35 High Values Of Plate And Tape Contrast Ratio Function

36 36 Values Ranked By Surface Screening Value Contrast Ratio Function

37 37 Second Test Evaluate 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?

38 38 Press Conditions Press – Wide Web Flexible Packaging Anilox – 440 lpi/5.5 bcm Ink – High Speed Surface White Viscosity – 28 seconds Press Speed – 1200 ft/min. Substrate – Polyester

39 39 Opacity – FAM D & 3M 1820 Cushion Tape MC 2X3N FAM D 3M 1820 Opacity 64.6% No Surface Screening FAM D 3M 1820 Opacity % 61.8 (440 lpi/5.5 bcm) Contrast Ratio Function

40 40 Opacity – ACE D & 3M 1820 Cushion Tape MC 3X3C ACE D 3M 1820 Opacity 64.1% No Surface Screening ACE D 3M 1820 Opacity 60.8% (440 lpi/5.5 bcm) Contrast Ratio Function

41 41 Coating Weight and Opacity Contrast Ratio Function

42 42 Conclusions Flat 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 43 Conclusions Higher opacity levels were achieved using surface screening allowing for the use of lower anilox volumes and potentially eliminating the need for a double bump.

44 44 FTD Approaches

45 45 “Flat Top Dot” Technology  Film lamination on special CTP device similar to offset Trendsetter laser  Requires special laser, special film consumable, requires use of special Kodak plate material  Format up to 42x60” size Kodax NX

46 46 “Flat Top Dot” Technology  Lamination of film material to plate with some heat and pressure  Requires laminator and special film MacDermid LUX

47 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 48 “Flat Top Dot” Technology Esko Inline UV  Retrofit or new machine with LED diode parts Used for both flexo and letterpress plates

49 49 nyloflex® NExT? Flint Group‘s Solution for Flat Top Dots and Surface Screening

50 50 NExT exposure process acceleration of polymerization speed reduction of oxygen inhibition effect New high intensity UV exposure oxygen exclusion inertisationoxygen barrier use of auxiliaries: inert gas (nitrogen) use of auxiliaries: film consumption additional processing step (risk, costs) inert gas consumption and risk high intensity UV irradiation for strong surface cure + conventional UV tubes exposure for through-cure

51 51 New approach of Flint Group Two step exposure Combination of UV-A LEDs with UV-A tubes Step 1 – High intensity UV LED surface crosslinking Step 2 – Through-cure with conventional UV tubes

52 52 nyloflex® NExT Operation

53 53 Digitally imaged LAMS layer and nyloflex ® NExT technology O2O2 O2O2 O2O2 O2O2 O2O2 O2O2 O2O2 O2O2 UV Almost 1:1 copy Precise reproduction nyloflex® NExT

54 54 3 pt font (2540 dpi) (transmitted light) 3 pt font (2540 dpi) (reflected light) NExT Plate Image Samples

55 55 5% (2540 dpi) (transmitted light) 5% (2540 dpi) (reflected light) NExT Plate Image Samples

56 56 2% (2540 dpi) (transmitted light) 2% (2540 dpi) (reflected light) NExT Plate Image Samples

57 57 3% (2540 dpi) (transmitted light) NExT Plate Image Samples

58 58 nyloflex ® NExT Exposure FIII Mid size exposure unit Format 920 x 1200 mm (47.2 x 36.2“) nyloflex ® NExT Exposure FV Large size exposure unit Format 1320 x 2032 mm (52 x 80“) nyloflex® NExT – Processing Equipment

59 59 UV LED module Electrical connectors water connection for cooling Housing with cooling profile LEDs with optics and quatrz glass water connection for cooling

60 60 NExT UV LED Bar Radiation length = 53.9“ Modular system → 12 x 4.5“ 49.4” radiation width even with one module out Ethernet port for each module for remote diagnosis / recovery at manufacturer

61 61 The Benefits of nyloflex® NExT High-intensity LEDs (> 800 mW/cm 2 ) for highest productivity Consistent UV emission guarantees long-term repeatability  Production consistency, especially for repeat orders Easy-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 flexibility Compatible with all standard prepress software & HD Flexo Easy implementation into existing digital workflow

62 62 nyloflex® NExT

63 63 nyloflex® NExT

64 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 65 Thanks for your attention! Questions? Flint Group Flexographic Products Extensive product range Customer oriented service Excellent technical knowledge Global presence Innovative solutions Rich Emmerling Technical Manager

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