bringing the simplicity of digital printing to flexo! · · 2014-06-06polymer plates and...

BRINGING THE SIMPLICITY OF DIGITAL PRINTING TO FLEXO!

Index

• What is REVO Digital Flexo Revolution?

• Details of Technology

• What do I need for REVO Digital Flexo?

• What are the benefits?

• REVO minimum specifications

• REVO Frequently Asked Questions

• The future of REVO

What is REVO Digital Flexo Revolution?

REVO Digital Flexo Revolution is a Project Team of leading companies in the Flexoindustry, promoting a new manufacturing method to “digitize” the flexographic process, makingit uniquely consistent, cost effective and strengthen the leadership of Flexo in the Labels andPackaging industry.

Why?

• Because 7 colour separation is the FUTURE for the Labels and the Packaging industry• Because UV Flexo is the most consistent printing technology• Because Flexo presses are easy to operate and control


The RevoMembers

Product Revo Activity

Converter of Labels and Packaging Field Test and Validation of the REVO Digital Flexo process

Anilox rollers Anilox rollers suitable for REVO specifications

Helios 100% inspection Press Control & Quality Control

Polymer plates and pre-press HW Flexo plates suitable for REVO specifications

Pre-press software and hardware 7 colours separation SW and control HW suitable for REVO specifications

Printing Inks Flexo inks suitable for REVO specifications

Printing and converting machines Digital automation for REVO printing and converting specifications

Labels and Packaging substrates Substrates suitable for REVO specifications

• 7 Colour separation

• Digital Flexo Automation

• Next Generation UV Flexo inks

• Next Generation Digital Plates

• Next Generation Anilox rollers

• Next Generation Press control

REVO Members cooperate to provide a common, easy “off-the-shelf” “turn-key” solution toconverters, maximizing the advantages of the latest “digital” progress in the Flexo industry. Eachpartner contributes to develop existing flexo technologies and specific integrated solutions for theREVO project. Main focus of developments, and target objectives are:


Details of REVO Technology

REVO Digital Flexo is :

• UV Flexo for Labels and Packaging

• Extended colour gamut (7 colours to match PMS colours)

• Digital Automation in printing and converting.

REVO manufacturing method integrates the latest developments in UV Flexo, extended colourgamut and digital automation technologies. Traditional manual flexo operations like ink colourmatching, pressure and register settings, exchanging of print cylinders are fully automated anddigitally controlled. PMS colours are “digitally” prepared via Software, not in the ink kitchen.

Inks and anilox rollers are never changed in the press. With 7 colours most PMS colours arereproduced. Hundreds of PMS colours can be printed inside the same job. With an extremelyvibrant quality on process images.As a result, set up waste and time are comparable to typical Digital presses.

Easy:consistency across print operators as printing and converting operations are digitally automated.

Clean:never change inks and anilox. No washing, no cleaning, no ink handling.

Consistent:always 7 inks in the press, producing always the same quality and PMS colours.

Perfect for short runs 1:no colour matching on press, “digital” colour matching.

Perfect for short runs 2:digital set up, digital run.

Profitable:less ink consumption, less wastes, close to 100% press up-time .


Print quality:“real” and "vibrant" astonishing 7 colours pictures at 80 l/cm.

Unique images:Hundreds of PMS colours printed in one job, with no additional cost.

Fast 1:“digital” job change-overs, 4 job changes per hour or more.

Fast 2:printing at 10 m/min or 180 m/min without any change in ink density.

Flexible:no limits, print on every Packaging substrate.

Digital:One digital work flow for typical Digital and REVO Digital Flexo printing.


REVO Digital Flexo VS Typical Digital Printing

q Comparable waste and set up time

q Comparable print quality

q Improved flexibility

q Improved production speed

q Improved consistency

q Improved press up-time

q Independent from press supplier

q Printing on every substrate


What do I need for REVO Digital Flexo?

REVO- Digital Flexo Revolution is a new manufacturing method in flexography developed forthe full digitalisation of the flexo process. The REVO Project collects a Team of globalsuppliers of material and technologies, ADARE, APEX, AVT, DUPONT, ESKO, FLINT GROUP,GIDUE, UPM RAFLATAC, working together to introduce the REVO Digital Flexo Revolution inthe Labels and Packaging industry.

The REVO Team developed the integrated REVO Set of Technologies, which includes:Flexocure® Ancora Low Migration UV inks, Cyrel® DFUV and DPR photopolymer plates, GTT™anilox rollers, Equinox separation pre-press, Fit™ range of substrates, Infinite Flower™ printunits, Helios II pressure control & 100% inspection.

REVO Method and REVO Set of Technologies are immediately available as an “off-the-shelf“turnkey” package. REVO DIGITAL FLEXO Revolution is accessible to every Labels andPackaging converter in the industry, from the REVO Team members worldwide.


DuPont™ Cyrel® Digital Photopolymer Plate Technology

Cyrel® DFUV is a thermal process plate that comes to color quickly and prints smooth and dense solids, without compromising dot gain, highlights or resolution. It performs very well with fine screens

Cyrel® DFUV is specifically designed for shorter print runs using UV inks on high priced stock where minimizing the startup waste is essential.

In combination with Cyrel® DigiFlow the new digital flat top dot technology, 80 lines percm screen count is the new achievable standard, changing again the rules of ourindustry. Extended color gamut technologies take great advantage of the improved inklaydown and the reduced graininess.

To achieve the best possible result, the 7 colors overprint needs to be printed with high linecount. Consequently the REVO technology is based on extremely fine screen rulings of the 7colors which are printed on top of each other. Full tones are printed as very fine “invisible”vignettes which simulate, for the human eye, the effect of a full solid. The new generationCyrel® DFUV digital plate provides the requested quality, thus a wide gamut of PMS colors canbe reproduced, without changing the inks in the press.

Extended colour gamut is the most logic solution for the flexo industry going “digital”. 4or 7 inks always in the press. No need to change anilox or ink. No special colours, nocolour matching, no waste of substrate, no press down-time. Most PMS colours can bereproduced by printing 4 or 7 colours on top of each other. With 7 colours separationpre-press can “digitally” reproduce up to 90% of PMS colours.

With Equinox™ colour separation software, Esko offer a total solution for theimplementation of extended gamut printing. Equinox standardizes your printingpresses on any set of 4 or 7 inks of your choice. With this, your press change-over workload between jobs is reduced to merely changing printing plates.

Esko™ 4 to 7 Colours Separation SW and HW Control


Next Generation FLINT GROUP UV Flexo Inks

REVO process needs top consistency printing quality and high colourdensity to achieve the best performances.

New generation Flexocure® ANCORA Low Migration UV Flexo inks support the REVODigital Flexo Revolution with migration levels compatible with the tightest foodpackaging health rules, high pigmentation, consistent ink transfer, consistent densityproperties, giving to REVO projects a wide range of graphic possibilities, and excellentconsistency performances.


Next Generation APEX Anilox Rollers

UV flexo ink and digital flexo plates deliver fantastic and consistent quality. Butinconsistent ink transfer, and inconsistency between anilox rollers might endanger the“digital” consistency of the REVO standards. In a 7 colour separation a key factor is toprovide accurate consistency of the lay down of the 7 colours.

New “slalom” engraving technologies developed recently on new generation GTT Anilox Rollersare able to overcome some inconsistency of standard anilox designs. REVO standards need apredictable ink density which can be achieved thanks to the new anilox rollers design whichdelivery ink transfer with less than 1% tolerance. New “slalom” anilox roller’s technologyprovide fundamental contribution to the REVO “digital” new standards. A further advantage ofREVO technology is that less ink transfer is needed, to achieve the same level of opacity. Byoverlapping 7 vignettes instead of using full solids, ink transfer is reduced, as well as inkconsumption. Ink costs, curing costs are reduced, and the whole PMS process is consistent andrepeatable.


UPM Raflatac FIT Range of Substrates

The REVO Digital Flexo Revolution is setting a global standard, and this calls for consistencyfrom all partners. Proprietary production technologies guarantee the same consistency ofsurface quality and ink reception in every corner of the world. Among the benefits of REVO arecost-efficiency and a reduction in waste, and next generation substrates developmentsupports this with materials like the Fit range, which are engineered for a more sustainableuse of resources, cost-efficiency and process-efficiency while retaining optimal performance.

New substrates and printing technology are progressing in parallel with the same objectives.


AVT – Press Control and Inspection Technologies

AVT Helios II with “pResco NW” is the revolutionary solution for automatic press pressurecontrol and can also be specified with the optional 100% automatic inspection technologyand all currently available Helios features.

The Helios II fully automatic makeready pressure control solution is achieving excellentresults while meeting the vision of advancing a “digital revolution” throughout the greaterflexo industry. Helios II 100% inspection is the leading solution for total print quality controland through the development of the new image based make-ready pressure control, incooperation with GIDUE Digital Automation, is able to take a traditional, craft-based processand turn it into a consistent and repeatable digital function.

This new level of automation will remove another variable from the press set up procedure,fully supporting the goals of the REVO method and standards of Digital Flexo manufacturing.



Extensive Digital Automation in the printing press is needed to collect all theopportunities of the new REVO “digital” flexo process. On the printing and convertingsections, servo motors and digital HD Cameras substitute the eyes and the fingers of theoperator with digital eyes and digital fingers. The new generation presses exchange theprint and diecutting cylinders from “old” to “new” job fully automatically, withoutoperator.

Digital Automation in flexo presses completes the REVO “digital chain” from pre-press, toplates, to inks, to anilox and finally to printing and converting, to achieve a full REVOdigitalization of the flexo process.

GIDUE: A new Digital Automation press for REVO Standards

What are the benefits?

Cost reduction:

• less substrate, less inks, less time are wasted for colour matching in the press. Up to90% of PMS palette is reproduced with combination of the fixed colours in the press.

• less ink is needed to print PMS colours (up to 50%).

• less substrate is wasted during set-up in the press due to Digital Automation

• more up-time of the press is achieved due to down-time reduction for colourmatching, print and die-cutting cylinders change, press set-up, press inconsistencyduring production.

• no additional cost for substrates pre-treatment

Consistency:

• process parameters are digitised throughout the entire workflow “from pre-press toprint”. The full process is under REVO digital control.

• operators skills are not required for colour matching.

• anilox engraving and inks are optimized for consistent performances.

• digital automation on press greatly reduces the variables caused by operator’s skills.

• colour density is consistent from 10 m/min to 180 m/min


Quality:

• Extended colour gamut with 7 colours (CMYK + Orange, Green, Violet) provide vibranteffects on pictures with natural and realistic images.

• HD Flexo with 80 lines per cm (200 LPI) become standard, taking flexo to a higher printquality level.


Graphic flexibility:

• a single job can contain hundreds of PMS colours, without additional print stations.• REVO allows printers to combine multiple labels on the same plate.

Digital flexibility:

• the same file can be printed on a Digital or a REVO Digital Flexo press, withsimilar quality and costs. Production flow can be similar to a Digital press, with

I. frequent job changes,II. last minute job planningIII. fast speed to marketIV. reduced minimum order quantity


Adare is a UK leading converter who has experiencedREVO technology in “real” production.

“The advantage of REVO technology, which we are beta-testing as a Labels and Packaging converters sincelast year, is inherent to the “digital” control of all variables. We have encountered dramatic cost reductionsin substrate waste, press down-time, ink consumption. It is clear that colour matching for a converter is thegreatest problem, in real life production. With REVO “digitally” optimized technologies we can achieverepeatable and predictable PMS shades. A digitally automated press makes the rest in terms of fast turn-around. Thus we have changed our production structure, proposing much shorter lead times and greaterproduction flexibility to our customers. It is like having a digital press with flexo costs.”

Daragh Whelan - Technical Director of Adare UK

First REVO Testimonial

Conventional REVONo. of Set Ups 5 1No. of Colours 6 7No. of Ink Mixes: (Pantones) 10 0No. of Plates: 30 7Total Make Ready Material Mtrs: 600 501st Job Make Ready Time: 1 hr 30 mins 30 minsRun on Make Ready Time: 30 mins N/ATotal Make Ready time: 3 hrs 30 mins 30 mins

Conventional Flexo Vs REVO Digital Flexo

Conventional REVONo. of Set Ups 2 1No. of Colours: 7 7No. of Ink Mixes: (Pantones) 6 0No. of Plates: 14 7Total Make Ready Material Mtrs: 200 501st Job Make Ready Time: 1 hr 30 mins 30 minsRun on Make Ready Time: 30 mins N/A

Total Make Ready time: 2 hrs 30 mins

Conventional Flexo Vs REVO Digital Flexo

Lots of special colours in one print

The most vibrant images ever printed

REVO Minimum specifications

Total colour consistency is a must to achieve PMS matching in production.

Extremely accurate register tolerances are needed to print with REVO also small negative types with 2-3 colours on top of each other.

• Accurate plate mounting is needed. • Presses with accurate register performances are needed.

• Infinite Flower print units guarantee 100% colour consistency from 10 to 180 m/min.• GTT anilox rollers guarantee worldwide that ink transfer tolerance between rollers is

limited to less than 1%.• Flexocure® ANCORA inks, Cyrel® DFUV/DPR photopolymer plates and FIT substrates guarantee

standardized and tested quality for all the supplies globally, to obtain global colour consistency.• AVT Helios makeready pressure control ensures accurate “operator independent” pressure

consistency.

REVO Frequently Asked Questions

Can I retrofit my existing flexo press?

No, the REVO Set of Technologies is the best “off-the-shelf” package to start printing with REVOmethod, and getting immediately all the REVO benefits.

What is the lifetime of REVO 80 lines plate comparing standard Digital Flexo?Same or better because the pressure control is automated

When I print a 5 colours job (a process job, with only one additional PMS colour), do I need always to use 7 inks and seven plates?NO, REVO will use minimum number of inks and plates. Only a selection (and not all) of the 7 inks available will be required to reproduce the desired PMS.

Can I print with just 4 process colours and print also PMS colours? YES, with REVO Technology you can print with 4 colours process inks and achieve up to 68% of PMS colours.


When I print a specific PMS colour, do I always need to print 7 colours on top of each other? NO, any PMS colour will be reproduced with max 3 colours selected between the 7 coloursavailable.

Can I use my existing anilox rollers?NO, you need to buy REVO compatible GTT anilox rollers which can guarantee the consistentand standardized ink transfer needed to achieve REVO quality.

Can I use my existing inks, substrates, press, inspection system?NO, you will not achieve the same accuracy in colour matching, the same quality in printing, thesame consistency in the printed results, and you would not get all the combined, standardizedadvantages of the integrated REVO Set of Technologies and of Digital Automation. In the futurethe REVO Set of Technologies will be further extended.


Who is going to make the plate for me?• ADARE REPRO HOUSE can support you on Repro graphic file preparation

for REVO standard.Contact Daragh Whelan ([email protected])

• The REVO Team will identify and propose you the closest REVO Service Point to your company. Please Contact DUPONT PACKAGING GRAPHICS: Mr. Carsten Bastian ([email protected])ESKO : Mr. Fredric Vanvinckenroye ([email protected])

Who is going to consult and qualify me or my service point on REVO?ADARE REPRO HOUSEContact Daragh Whelan ([email protected])


mailto:[email protected]




Can I make REVO plates in house?Yes, you need to buy Equinox program for 7 color separation and use HD flexo platemanufacturing process for Cyrel® DFUV photopolymer plates.


Stay updated and visit occasionally the official REVO web site. (www.revo-digitalflexo.com)

REVO will advertise and publish all the news and technical innovations achieved in the coming months.

The future of REVO

REVO Contact ListFor all kind of support you can contact the following REVO members:

ADARE : Mr. Daragh Whelan ([email protected])APEX GROUP of COMPANIES : Mrs. Jeanine Graat ([email protected])AVT : Mr. David Naisby ([email protected])DUPONT PACKAGING GRAPHICS: Mr. Carsten Bastian ([email protected])ESKO : Mr. Fredric Vanvinckenroye ([email protected])FLINT GROUP : Mr. Niklas Olsson ([email protected] )Nuova GIDUE Srl : Mrs. Cristina Toffolo ([email protected])UPM RAFLATAC : Mr. Marko Tiainen ([email protected])

www.revo-digitalflexo.com











Thank you!

The Revo Members

bringing the simplicity of digital printing to flexo! · · 2014-06-06polymer plates and...

Documents