emerging trends in flexo technologies - flexo plate digital … · · 2012-04-21reduced set-up...
TRANSCRIPT
Agenda
DuPont Overview
Printing Technology overview
Flexo Overview
Flat Top Dot Technology
FAST Round Technology
Flexography and Sustainability
Conclusions
Our Mission - Sustainable Growth:The creation of shareholder and societal value while reducing the envir onmental footprint along the value chains in which we operate.
Core Values – The Foundation of DuPontSafety and Health. Environmental Stewardship. Highest Ethical Behavior. Respect for people.
Our VisionTo be the world most dynamic science company, creating sust ainable solutions essential to a better, safer, healthier life for people everywhere.
DuPont’s Mission, Vision and Core Values
4
Agriculture
Electronics &Communications
Performance Chemicals
Performance Coatings
Performance Materials
Safety &Protection
Industrial Biosciences
Nutrition & Health
* Total company sales exclude transfers.
$38B*
$9.2B
$2.5B
$4.3B
$6.8B
$3.9B
$3.2B
$7.8B
$0.7B
DuPont 2011 Sales by Segment
Agenda
DuPont Overview
Printing Technology overview
Flexo Overview
Flat Top Dot Technology
FAST Round Technology
Flexography and Sustainability
Conclusions
Flexography Gravure
Printing Technology for Flexible Packaging (Wide Web)
Picture on plate
Text image Flexo Plate surface (relief)
Picture on plate
Text imageGravure cylinder surface
54 Mins
123 Mins
60 Mins
120-150 Mins
60 Mins
54 Mins
13.8-16.33HRS Total Production
6-8 HoursBase Shell
Nickel Plating
Copper Plating
Polishing
Engraving
Chrome Plating
Polishing
Cylinder Engraving Process with Base Shell Fabrication
Delivery Lead time7- 14 days
Pre-Press CTP
Flexo Plate Making – Solvent Process Overview2000 ECLF
2000 P
• Digital Prepress• Color Separation
• Plate Arrangement• Plate Ablation
• Light Finishing
• Plate Processing
2000 D
• Plate Drying
• Main Exposure
• Light Finishing
Total Production Time 2.5 – 3 hours
Delivery Lead time 1-2 Days
Quality High
Process Time Fast 1-2 days Slow 7-14 days
Environmental Impact Low
GravureFlexography
High
Solvent Process Gravure
High
Printing Technology for Flexible Packaging (cont.)
Substrates Thin Extensible Film Reverse BOPP/PET
Speed FAST FAST (high End)
Start up Waste HighLow
Agenda
DuPont Overview
Printing Technology overview
Flexo Overview
Flat Top Dot Technology
FAST Round Technology
Flexography and Sustainability
Conclusions
What this means to converters?
� Frequent design changes
� New product design cycle times continue to shrink.
� Costs need to come down.
� Color match more critical globally.
� Environmentally friendlier solutions.
Why Flexo …
Challenges facing CPGs:
Run lengths are getting shorter
� Marketing demands for frequent graphics changes
� Cost, Environmental pressures on Packaging
� Upward trends in the costs of films and resins
� Substrates-Getting Thinner & Extensible
� JIT supplies to reduce inventories
� “SKU proliferation” requires increasingly different labels .
Image to Plate
Film/Analog
Laser/Digital
Solvent Process
In The Round Process
Total Production Time: 2.5 – 4.0 hours
Laser/Digital
Flexo – For Fastest Turnaround time
Flexo – For Versatility
The biggest benefit of Flexo is its great flexibility. It prints on virtually any substrate, being it smooth or rough, having absorbing or non-absorbing properties, using a variety of inks, water-based, solvent-based or UV.
It is best-suited for printing on a wide range of clear and opaque substrates such as Paper, Polyethylenes, Laminates, Labelstocks, Foils, TetraPaks, etc. It is the only process capable of consistently printing with perfect registration on thin, extensible films right down to 25 micron PE.
Flexo for Costs…
Overall economics better with Flexo due to -
� Marginal benefits in ink, plate, equipment costs
� Higher Press-speed – Entry-level presses at 400 m/m, 600 m/m presses already in!
� Reduced set-up and running waste – web length half that of Gravure.
� Drier-length typically half that of gravure. Typically gas-fired or electrically-heated for PE. Lower power-consumption.
� Lower VOCs due to completely enclosed doctor-blade, closed loop inking system. Minimal solvent loss due to evaporation.
Flexo for Environmental – Lower VOC and Safer Solvents
10%
25%
55%
10%
Pigment Resin Solvent Additives
What is in Packaging Ink? Inks and food can and will interact
Cooking in the pack Maintaining taste after storage
Avoid reaction with migrationMain problem
Odour and Taint
Migration
Retained solvents
Solvent Safety
Solvent extraction
Main Culprits Solvents
Flexo for Environmental – Lower VOC and Safer Solvents
� Flexo Uses Friendlier solvents
� Alc ohol Based Vs Toluene/MEK Methyl Ethyl Ketone (MEK) (Gra vure)
� Lower toxicity
Concern Toluene MEK Ethanol
Food package risk
Odour 30mg/sqmetre Extreme High Low
Migration into water 1000 ppm Extreme High Low
Taste 10ppm detection Extreme High Low
Retained solvent limit Food limits 2 2 30
Exposure Extreme High LowSkin absorption Extreme High Low
Emission From drying the print Extreme Medium LowGround water From Waste Extreme Medium Low
Risk
If found at this level
Serious Health Impact
Environmental Impact
Global standard Danger
Work Place risk
Environmental
To the body of the
printer
Flexo Applications
Tag and LabelTag and Label
Folding CartonFolding Carton
Paper BagPaper Bag
CorrugatedCorrugated
Print LinerPrint Liner
Carrier BagCarrier Bag MultiMulti --Wall BagWall BagBeverage CartonBeverage Carton
Flexible PackagingFlexible Packaging
EnvelopeEnvelopeOffOff --Set CoatingSet Coating
Paper CupPaper Cup
Agenda
DuPont Overview
Printing Technology overview
Flexo Overview
Flat Top Dot Technology
FAST Round Technology
Flexography and Sustainability
Conclusions
Conventional Analog vs Digital Dot vs Flat Top DotAnalog Dot Digital Dot Digital Flat Top Dot
Cover Sheet Film Nitrogen Membrane
LEDNX Film
Flexo require Pre-press work to optimise for print result
Summary of Flexo Screening O
rigin
al
Imag
eD
igita
l Fle
xoD
igita
l Fle
xoF
lat T
op D
ot
Tonal Break as Flexo cannot print details below 2%
Use Printable Minimum dot to fill in highlight area
Flat top dot able to hold fine dot with wide shoulder
Full tonal reprod uction from
0.4%-99.6%
Without pre-press correct ion, the print
result will show hard edge on tonal
With pre-press correct ion, no hard edge on tonal but
dirty highlight
Flat Top Dot can be stabl e on highlight
and robust for printing
(In some Job)
Digital Flat Top Dot – different approach by technologyNitrogen Gas
NitrogenMembrane
LED
Film
LED
LED
Lamination
Film Lamination
Nitrogen Workflow – Technical Details
Features formed in controlled DigiFlow
atmosphere
Features formed in air
Exposure in air vs. Nitrogen
Nitrogen Workflow – Technical Details
067 Plate – Visual Comparison
Solvent Process Digital Plate with Nitrogen
Unscreened Solid Screened solid – Plate exposed in Nitrogen
1.48 1.65
Solvent Process Plate
1.3
1.35
1.4
1.45
1.5
1.55
1.6
Digif low STD
Sol
id In
k D
ensi
ty
No pattern
Pattern
Solid screening programs resulted in much high solid ink density when exposed in Nitrogen workflow
Nitrogen Standard
Nitrogen Workflow – Technical Details
67Plate – 70L/cm(175Lpi) 1% dot
High Resolution & Low Dot Gain – Solvent Process Digital
PlateSurface
Text to one point is sharp and legible.
DuPont™ Cyrel® DigiFlow is a digital workflow enhancement designed to expand the capabilities of digital Cyrel® and digital Cyrel® FAST. The DigiFlow exposure system enables 1:1 image reproduction when a screened solid is beneficial, and with the flip of a switch returns to the standard digital exposure workflow whenever that is the preferred solution.
Features & Benefits- Optimizes performance of solid - No additional platemaking steps
screening programs such as Groovy or Microcell - Maximum workflow flexibility- Improved solid ink densities - Minimal consumable cost- Increased color gamut - No environmental impact- Easily integrated into existing workflows- Compatible with all CDI Versions & HD Flexo
DigiFlow Product Summary
Can Flat Top Dot deliver
In some cases yes with following conditions :
• Higher Strength Ink
• Finer Anilox roll
• High Quality Substrates
• Consistent Press performance
• Perfect registration
• Spot color replacement Software
• Skill Press Operator
High quality printing 200-300 lpi?
Impr ove Solid Ink Density?
Improve color gamut, more 4 color ?
Agenda
DuPont Overview
Printing Technology overview
Flexo Overview
Flat Top Dot Technology
FAST Round Technology
Flexography and Sustainability
Conclusions
Light Finisher
Thermal Processor
Thermal round: Therm al round: The Next Generation Processing TechnologyThe Next Generation Processing Technology
4 sleeves / hour First high quality sleeve after ~35 minutes
Finished Sleeves
4000 dpi Cantilevered CTP
Exposure Unit
Thermal round
sleeve
“loose fit” concept* – one size fits all
10-15 minutes cycle time
Thermal round Therm al round –– Thermal Processing*Thermal Processing*
heated roll
support roller
non-woven
impression
foam adapter
photopolymer sleeve
movable arc
*) patent protected
Print qualityPrint quality
•• Seamless Continuous designs Seamless Continuous designs (no plate gap)(no pla te gap)
•• Very good register Very good register (no manual mounting, no distortion)(no m anual mounting, no distortion)
•• Simpler Trapping Simpl er Trapping (better register, no distortion)(bett er register, no distortion)
•• Lower impression setting rel. to plates Lower impression setting rel. to plates (lower thickness tolerances)(lowe r thickness tolerances)
•• Lower dot gain Lower dot gain (rel. to rubber forms)(rel. t o rubber forms)
•• No edge lifting No edge lifting (continuous form)(cont inuous form)
•• no no ‘‘cuppingcupping ’’ (no distortion)(no dis tortion)
•• Long print form life Long print form life (reduced impression setting)(redu ced impression setting)
•• Very uniform ink transferVery uniform ink transfer (rel. to hand(rel. to hand --mounted plates)mounted plates)
Step Changes in Print PerformanceStep Changes in Print Performance
Register Contrast
Details CMYK / heptachrome
Productivity /Repeats
Agenda
DuPont Overview
Printing Technology overview
Flexo Overview
Flat Top Dot Technology
FAST Round Technology
Flexography and Sustainability
Conclusions
Hazards of Chrome
•Chromium compounds are considered highly toxic to humans.
•Chromium (VI), or hexachrome, can cause ulcers of the skin, irritation of the nasal mucosa, and irritation of the gastrointestinal tract, and adverse effects in the kidneys and liver.
•Based on animal and human studies, chromium (VI) and its compounds should be considered probable carcinogens in humans exposed by inhalation
THE CHROMIUM CONNECTION
Chromium (III) occurs naturally in the environment.
• Chromium (VI) is generally produced by industrial processes, and used in such industries as pigment manufacturing, leather tanning, wood treatmentand chrome plating.
• The primary use for chromium compounds containing chromium (VI) is in the metal finishing industry for both decorative and functional purposes.
• Chromium is often chosen as a surface finish because it possesses a low coefficient of friction, high hardness, good corrosion resistance, high heat resistance and anti-galling properties. Due to its toxicity and suspected carcinogenicity, however, chromium is heavily regulated for the protection of human health and of the environment.
• These regulatory requirements, as well as the growing awareness among metal platers regarding the health effects of chromium exposure, have led to a search for acceptable alternatives to using chromium in theelectroplating industry.
No
n-R
enew
able
En
erg
y U
se
(MJ
per
m2
of
pro
du
ct)
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
Average AlignedFlexo
Based on DuPont Life Cycle Assessment Study
Ink & Solvent Production
Electricity
Substrate Film
Combusted VOCs
Dryer & Oxidizer Fuel
Heat Credit & Recycling
Plate or Cylinder
Cardboard Cores
Flexography:� Higher viscosity inks reduce solvent use� Reduced energy & emissions for drying� Reduced substrate waste
Estimated SavingsChanging 1 Million m2 of Printed Substrate from Gravure to Flexographic Printing*
� Non-renewable energy savings equivalent to 102,400 liters of gasoline
� Greenhouse gas emissions savings equivalent to taking 69 average European passenger cars off the road for one year
Data Source: European Automobile Manufacturers Association Industry Report September, 2008
Life Cycle Analysis shows Flexography as a Sustainable Print ing technology
* Based on DuPont Life Cycle Assessment –Data obtained from trade shops and converters from Europe and USA
Gre
enh
ou
se G
as E
mis
sio
ns
(kg
CO
2 p
er m
2 o
f p
rod
uct
)
Average Aligned Flexo
Average Aligned Flexo
Average Aligned Gravure
Average Aligned Gravure
Average 50% Savings with Flexo graphic Printing
Agenda
DuPont Overview
Printing Technology overview
Flexo Overview
Flat Top Dot Technology
FAST Round Technology
Flexography and Sustainability
Conclusions
� Provides high flexibility for changes in design
� Assures speed to market launch
� Offers high printing quality
� Reduces environmental impact in green house gas emissions and renewable energy consumption� Average 50% savings with Cyrel® FAST Thermal System� Average 50% savings with Flexographic printing
Using Flexography for packaging
DuPont Packaging Graphics has a large experience in flexographic market, investing for more than 35 years in Flexography development, considered the technology of the
future, thanks to its versatility and low environmental footprint.
Info: [email protected]
Recorded in Asia All rights reserved worldwide. No part of th is publication may be reproduced or transmitted in any form, or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without the prior written permission of DuPont Packaging Graphic Asia Pacific
The DuPont Oval, DuPont TM, The miracles of science TM and Cyrel ® are registered tradem arks or trademarks of DuPont or its affiliates.
DuPont Packaging Graphics
Copyri ght© 2011, DuPont Packaging Graphics Asia Pacific
Published and Recorded in 2011by: Packaging GraphicsAsia Pacific Marketing