plate imaging with ctp

06•2002 Heidelberger Druckmaschinen AG

Expert Guide

Plate Imaging with Computer-to-Plate

Contents

Contents 1

1 Printing’s More Popular

than Ever 2

2 Computer-to-Plate offers

Key Competitive Advantages 3

2.1 Competitive Advantage 1:

Top Quality 3


Short Production Times 3


Competitive Production 4

2.4 The Competitive Advantages

at a Glance 4

3 Essential for the Use of CtP:

The Digital Workflow 5

3.1 PostScript and PDF 5

3.2 Job Tickets 6

3.3 Preflight 6

3.4 Redigitization 6

3.5 Trapping 7

3.6 Color Management 7

3.7 Digital Proofing 7

3.8 Digital Impositioning 8

3.9 Archiving 9

3.10 Output Workflow 9

4 Computer-to-Plate

Technology 10

4.1 UV Imaging of Conventional

Offset Printing Plates 10

4.2 Laser Imaging with Visible Light 10

4.3 Thermal Imaging 11

5 Computer-to-Plate

Printing Plates 12

5.1 CtP Printing Plates for

Violet Laser Diodes (405 nm) 12

5.2 Thermal Printing Plates for

Infra-Red Laser Diodes (830 nm) 12

5.3 Printing Plate Development 13

6 Heidelberg’s CtP Solutions 14

6.1 Heidelberg’s Workflow Solutions 14

6.1.1 MetaDimension 14

6.1.2 Delta Technology 16

6.1.3 Prinergy 16

6.1.4 MetaShooter 17

6.1.5 Heidelberg

Screen Technologies 17

6.1.6 Redigitization with

NewCopix 7000 17

6.1.7 SignaStation –

Impositioning and More 17

6.1.8 Color Management 18

6.1.9 Digital Proof 18

6.1.10 PrepressInterface:

The CIP4 Interface 19

6.1.11 Job Definition Format:

The Next Step 19

6.2 Heidelberg’s

Printing Plate Recorders 19

6.2.1 Complete Solution

Packages for Every

Market Segment 19

6.2.2 CtP with Polyester

Printing Plates 20

6.2.3 CtP with Metal

Printing Plates 20

6.2.4 The Prosetter Family 20

6.2.5 The Topsetter Family 22

7 How Can I Find the Right

CtP Solution? 25

8 Time Is Money:

So Why Wait any Longer? 27

9 Checklist 28

2 Plate Imaging with Computer-to-Plate Printing’s More Popular than Ever

Who can forget the vision of the ‘paper-

less office’ that captivated the trade

press and unsettled many printers in

the 1980s? A similar effect is currently

being created by the alternative ‘elec-

tronic media’. But this doesn’t mean

that the graphic arts industry should

regard the future with uncertainty

or with a doleful eye. Printing’s more

popular than ever.

Job structures have changed consider-

ably, that’s for sure. The trend is towards

more and more color and shorter and

shorter job runs. As a result of this, and

because of the increased deadline and

cost pressures, modern presses need to be

equipped with ever more printing units.

This is the only way of cost-effectively

producing print jobs in the short amount

of time available and using preferably

a single pass. Or to put it another way,

a significantly higher number of printing

plates need to be produced in the same

amount of time.

The high demands on the print pro-

cess are associated with tremendous

demands at the prepress stage. Auto-

mation is the key. Increasingly similar

production stages, which in the past

had to be worked through one after the

other in a very time-consuming process,

can now be automated with workflow

systems. These save time and eliminate

sources of error. The digitization of all

data and the integration of all processes

into a single workflow makes this pos-

sible. But of course, the quality of the

printed result should not suffer. Top-

quality offset printing is currently the

most significant distinguishing asset

for printshops.

Despite increased competition, top

quality should be readily available to

everyone and must certainly not be the

exclusive reserve of the industry giants.

In this brochure, Heidelberger Druck-

maschinen AG (Heidelberg®) illustrates

its solutions for various sizes of print-

shop and offers guidance for selecting

and configuring a suitable Computer-

to-Plate (CtP) system. And because a func-

tional workflow that is perfectly coor-

dinated with the production stage is so

important in CtP, this topic will be dis-

cussed at length.

Printing’s More Popular than Ever1

Computer-to-Plate Offers Key Competitive Advantages Plate Imaging with Computer-to-Plate 3

Computer-to-Plate Offers Key Competitive Advantages

Computer-to-Plate offers businesses in

the graphic arts industry many advan-

tages that are inherent in the process

itself. It doesn’t actually matter which

imaging technology or design of CtP

recorder is used.

The CtP workflow does away with

a whole range of operations – for exam-

ple, the need to image pages or page

sections onto film (partly in-house, partly

outsourced), manual assembly of these

elements into print sheets, analog plate

copying and separate register punching

for plate loading in the press.

This opens up a whole range of direct

competitive advantages, which the user

can turn into tangible results and use

to give his company’s market profile

a significant boost.


Top Quality

The screen dot on the CtP printing

plate is composed of imaged pixels and

is razor-sharp. This degree of quality

cannot be achieved through copying.

In extreme cases, dots may be copied

several times and, even if the utmost

care is applied, this can lead to unavoid-

able losses in detail. Instead, this is an

original ‘first-generation dot’. No specks

of dust or cut edges can impair the

result. Bad copies are ruled out. Added

to this is excellent register accuracy.

The typical properties of digital ther-

mal plates make imaging even more

precise. Dot or no dot, black or white –

there’s no difference. The results from

silver halide plates with their high

resolution and photopolymer plates

with their extremely steep gradation

curve are also impressive. And even

frequency-modulated screens that pre-

viously only delivered good results

under extremely stringent conditions

can now be used with ease.

What’s more, because of the greater

range of tonal values with enhanced

detail in the light and shadow, this pre-

cision results in an immediate improve-

ment in print quality. The dot gain on

the press is significantly less – not least

because of the ability to precisely cali-

brate each individual printing unit.

Higher color densities are possible, with

more brilliance.

Summary: Because of the signifi-

cantly improved accuracy made possible

with digital printing plates, a higher,

more consistent and more predictable

standard of quality can be achieved.


Short ProductionTimes

Through a rigorously-implemented,

end-to-end digital workflow, production

times can be significantly reduced in the

prepress stage. And following on from

the digital plate imaging stage, a whole

raft of time and cost advantages can be

gained in the production process.

Because each printing plate is of a

very high standard of quality, manual

plate correction that was previously

routine is now no more. The transfer

of digital press presets also makes the

setup process significantly faster. So the

job gets to color faster. And if a printing

plate should be damaged during clamp-

ing, then another one can be output

quickly in exactly the same high quality.

Because the job can remain stored in

the CtP recorder’s processing queue, this

is also possible during the night shift

if the prepress department isn’t fully

manned.

In many cases, the marketing advan-

tage gained through the faster avail-

ability of the print result is a key to fur-

ther orders and therefore to financial

success. When print products such

as reports, newsletters or newspapers

depend on speed-to-market, this allows

editorial deadlines to be pushed back

as far as possible.

2


Competitive Production

To work out the savings that can made

with CtP, the workflow and the prepress

equipment need to be taken into account.

When the manual sheet assembly pro-

cess is substituted with a powerful work-

flow system with digital impositioning

program, considerable savings can be

made in terms of personnel costs and the

costs involved with labor and materials.

Outputting print-ready full sheets on a

large-format filmsetter can make further

savings. But end-to-end process auto-

mation will ultimately only be possible

with the integration of digital plate

imaging – in other words, when the

prepress, press and postpress stages

are combined into a fully integrated

production line.

In the first instance, the costs of film

and film developing will disappear.

Added to this are the savings generated

by no longer having to repeat poorly-

copied printing plates. The higher qual-

ity of the printing plates and the digital

press presettings also means that far less

print waste is generated. As a result, the

consumption of ink, dampening solution

and paper falls noticeably. In the past,

the production run was frequently

delayed by last minute manual correc-

tions to printing plates or printing

plates that had to be remade. All this

now belongs firmly in the past.

The key factor for cost savings lies

in the boost to overall productivity

achieved by greater process automation.

If it is possible to increase utilization

levels of a state-of-the-art offset press

equipped with a large number of print-

ing units by just two or three percent,

then this will have an enormous effect

on the workplace costs, on profit con-

tributions and on the company’s overall

annual profits.

Advantage 1:

Top quality

Advantage 2:

Short production

times

Advantage 3:

Competitive

production

The Competitive Advantages at a Glance

• Ultra-sharp dot through digital plate imaging instead

of analog copy.

• High register accuracy.

• No specks of dust, cut edges or bad copies.

• Easy-to-use, frequency-modulated screens.

• Greater range of tonal values with enhanced light and

shadow detail.

• Minimal dot gain enables greater color density during

printing.

• Shorter preparation times thanks to 100% digital

workflow.

• No manual plate correction required.

• Faster press setup thanks to digital presettings.

• Faster to color = shorter coordination phase at print

startup.

• Problem-free post-imaging of printing plates.

• Faster availability of the printed product means

more up-to-date products.

• Maximum cost savings in terms of staff, labor time and

materials through the use of a digital workflow system.

• Savings in terms of film and film developing.

• Less waste reduces the consumption of ink,

dampening solution and paper.

• Elimination of idle press times caused by manual

correction or remake of printing plates.

• End-to-end process automation in prepress, press

and postpress.

• Increased utilization of presses and postpress

facilities. CtP as a marketing argument.

Sample analysis CtP CtF

Utilization

of the printing press 83 % 80 %

Setup times

of the printing press 25 min 30 min

Cost per plate set € 207 € 215

Print jobs per year 2,300 2,100

10 percent additional press capacity =

additional profit.

4 Plate Imaging with Computer-to-Plate Computer-to-Plate Offers Key Competitive Advantages

Creating an end-to-end digital workflow

is an essential requirement for using

Computer-to-Plate. To do this, in addition

to a raft of internal requirements – which

will be briefly discussed below – a good

working relationship and excellent

communication with data suppliers is

essential. Heidelberg’s solutions for the

integrated digital workflow, including

CtP, are described in detail in the section

entitled ‘Heidelberg’s CtP Solutions’.

3.1 PostScript and PDF

Until recently, most postpress service

providers or printshops received files

that had been generated from applica-

tion programs. This was however

always associated with a number of

risks, since missing high-resolution

data for images, differences in the

fonts used or incompatibilities between

the program versions often made fur-

ther processing impossible. PostScript®data, with its device-specific commands,

was very often responsible for a job

going wrong. What’s more, PostScript

files are extremely large, leading

to long transfer times for digital data

transfer.

A new industry standard, established

and approved by standards commit-

tees as an international norm for the

exchange of advertisements and print

pages, provided the much sought-after

solution – namely, the Portable Docu-

ment Format (PDF) from Adobe®Systems. Version1.3 of PDF and later

contains all the key information

required for prepress production and

has developed over recent years to

become the universal standard for

exchanging pages for print production.

This standardization offers greater

security for everyone involved. PDF is

therefore the ideal basis for state-of-the-

art workflow systems aimed at auto-

mating the output process.

It is important to note that anyone

can generate PDF files with ease. Data

created in any layout or graphics pro-

gram can be output as PostScript files

and converted into a PDF file using

Acrobat®Distiller. A few application

programs allow data to be exported

directly as PDF files.

Essential for the Use of CtP: The Digital Workflow3

Text

Layout

PostScript

PDF

PostScript

TXT

Graphics

Layout

PDF

Computer-to-Plate

Images

Layout

PostScript

PDF

EPS

QuarkXPress

Essential for the Use of CtP: The Digital Workflow Plate Imaging with Computer-to-Plate 5

3.2 JobTickets

A PDF, unlike a PostScript file, cannot

contain device control commands. For

this reason, Adobe had to develop a new

method for PDF which allowed control

information to be stored in such a way

that it had nothing to do with the actual

page content. And so the Portable Job

Ticket Format (PJTF) was born.

Separating page content and process-

ing instructions leads to greater flexi-

bility in production. In the event of any

subsequent changes, the individual data

elements no longer have to be opened

in the original application in order to

adapt them to the new conditions (e.g.

different values for dot gain, screen

ruling, traps). Instead, only the infor-

mation in the job ticket is changed.

The following information can be

stored in a portable job ticket:

• Instructions for page processing

(e.g. imposition layout, trapping

rules).

• Output parameters (e.g. screen

ruling, screen angle, resolution).

• Material (e.g. designation, size,

weight, color).

• CIP4 information (presettings and

instructions for presses and finishing

equipment).

• Supply data (addresses, number of

items).

• Planning (e.g. deadlines).

• Administration (e.g. customer, cus-

tomer or order number, operator).

3.3 Preflight

To verify supplied files, ‘preflight’ pro-

grams must be used which check the

transferred PDF files against an agreed

checklist. This enables data to be

‘repaired’, according to rules set down

in advance by the user (e.g. embed

fonts, increase hairlines). The following

criteria are crucial when PDF files are

being preflighted:

• PDF version.

• Data format (binary or ASCII).

• Reliability (printing/editing).

• Font embedding (all/subgroups/

none).

• Font types (Type1, Type3, Truetype,

multiple master).

• Color models (CMYK, RGB, Lab).

• Special colors.

• Image resolution (color, grayscale,

linework images).

• Image rotation/scaling.

3.4 Redigitization

The best of both worlds – the advantage

of a PDF-based workflow system also

lies in the fact that it is possible to move

gradually to a PDF-based workflow. This

isn’t the case with CtP output, however.

Digital plate imaging requires100%

digital data right from the start. But

what happens with the archived films?

And what if an original is supplied as

a finished separation on film, perhaps

not even in the right resolution?

A job ticket can be embedded in a PDF file or saved as a separate file.

One-stop scanning and redigitization saves expensive investments in special equipment.

6 Plate Imaging with Computer-to-Plate Essential for the Use of CtP: The Digital Workflow

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Of course, it is possible to run a twin-

track system for a certain period of

time, i.e. outputting one order as a full

sheet on film while outputting another

directly on the CtP recorder. A good

number of printshops are already using

this approach to respond to market

needs. The advantages of an integrated

process chain can however only be

harnessed with complete digitization.

As a result, the scanners in many print-

shops are equipped with an add-on

function for redigitizing existing or

supplied films. From a technical perspec-

tive, redigitization is possible in excel-

lent quality. Because of the additional

workflow stages, however, this is not

really a long-term solution. Ideally,

orders should be received as PDF files.

3.5 Trapping

Trapping is a process in which color

elements are slightly enlarged and

positioned over other elements. This

is aimed at preventing white spots

or flashes from occurring in the event

of a registration difference within

the press.

Trapping should be delayed until

just before the imaging stage. This way,

the printer knows for definite which

print process and which trapping rules

are required. As a result, the right trap-

pings can be generated for each print

process using the same master data.

3.6 Color Management

The production processes in the prepress

and press stages must be closely coor-

dinated with each other. Heidelberg’s

open workflow systems and the use

of ICC profiles fully meet the challenge

of ensuring high levels of color fidelity.

ICC stands for ‘International Color Con-

sortium’, a group of numerous leading

hardware and software manufacturers,

which includes Heidelberg, who are

striving towards the development of a

non-proprietary standard for exchanging

color information. In the open workflow,

ICC profiles are responsible for mutual

color coordination using conversions

that take place automatically in the back-

ground – a process known as the Color

Matching Method (CMM).

3.7 Digital Proofing

Proofing is without doubt one of the

most important stages in a digital work-

flow. Because CtP does not use films

from which analog proofs could be

created, digital proofs are used instead.

In order to find a process that satisfied

both the customer and the printshop,

countless samples and much discussion

were required. This isn’t exactly easy,

but even the introduction of the Chro-

malin or MatchPrint systems, which have

been accepted as standard for decades,

had its problems.

The development of inexpensive

units for printing out continuous-tone

proofs and devices for generating true

halftone proofs has since come a long

way. Provided that the Color Management

principle is applied correctly, excellent

agreement can be achieved with the

print result. The proofer’s output per-

formance and that of the downstream

press are simulated exactly using the

properties of the paper used in the

production run.

Units can display all colors that are within their color space.

Interactive and object oriented trapping with Supertrap.


• Halftone proof for checking the color

‘feel’, including screen structures

and effects using systems with color

films and thermal transfer.

• Impositioning or sheet proof as a

simple plotter printout or as a true-

color contract proof on large-format

inkjet printers.

A number of printshops are currently

offering their key customers digital

proofing equipment, so as to achieve

fast color coordination at an early stage.

Nobody should be without the ‘blue-

print’, even in the digital workflow.

Provided a large-format plotter is avail-

able for the sheet proof, complete print

sheets with all printing, folding and

cutting marks can be output once more

as a final check – possibly even including

perfecting – before the digital printing

plates are imaged.

The following variations of the digital

proof are available within the digital

workflow:

• On-screen soft proof (use as a single-

page proof or for the entire print

sheet; also as a ‘remote proof ’ at the

customer’s).

• Color proof as a true-color page

proof up to A3+ format on inkjet

or thermal sublimation printers.

3.8 Digital Impositioning

The PDF data format is ideal for impos-

ing anything from single pages to

entire print sheets. Object-oriented

data storage enables PDF documents

to be separated into single pages and

individual PDF pages to be put back

together in any order to form a single

file. All the associated resources (e.g.

fonts, illustrations) are delivered with

each page.

During PDF impositioning, entire

pages are assembled into PDF sheets

directly via an intermediate format.

These sheets can then be checked on

the screen and sent for outputting.

The digital proof is the key to quality assurance in the CtP workflow.

Impositioning is one of the first stages in the production of printed goods.

8 Plate Imaging with Computer-to-Plate Essential for the Use of CtP: The Digital Workflow

3.9 Archiving

The most commonly used archiving

medium in the printing industry until

now has been imaged film. But when

data is processed digitally, this film

has to be replaced with other tools and

media. A distinction needs to be made

between short-term storage/backup

during the production process and long-

term archiving. In the first case, the

data is mostly stored on large hard disks.

Long-term storage involves media such

as CD-ROMs or magnetic tapes.

When a decision is being taken for

a specific archiving system and the calcu-

lations for the storage space required

for the entry-level stage are being made,

a decision also needs to be taken regard-

ing whether the data involved in the

individual print jobs is to be returned

to the customer after production or

whether it is to be archived as an addi-

tional service provided by the services

department or in the printshop.

but not least, it can be extended to com-

plete order management with costing,

invoicing and distribution logistics for

the finished print product. The goal

is to regard printing as an industrial

process instead of seeing each stage

as a manual operation that is a goal

in itself.

3.10 Output Workflow

The implementation of an integrated

complete process chain naturally doesn’t

end – as shown in the example – with

digital imaging of the printing plates.

It starts with new, improved organi-

zational structures in the customer’s

workflow and within the company’s

workflows, and continues with order

planning, the output workflow in the

prepress stage and data archiving.

Then comes the data transfer for the

press presettings and finishing. Last


OPI ColorConvertor Trapping Rendering Page Proof

Imposition Form Proof Rendering Imagesetter

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Computer-to-PlateTechnology4

The first CtP solutions were already

being unveiled at the end of the 80s,

and by drupa1990, they were the focus

of tremendous interest. Even in the

early 90s, investments in a CtP system

provided scope for better market posi-

tioning and enabled a company to set

itself apart from the majority of com-

petitors. It should however not be for-

gotten that the first users still had to

struggle with a number of uncertainties.

It wasn’t just the equipment and imag-

ing techniques that were new – the CtP

printing plates, their chemicals and

the right developing equipment were

also totally new.

But these teething problems have

long since been overcome. CtP has since

become firmly established in all indus-

trialized countries, and is used in many

thousands of installations. ‘Early adap-

ters’, the first users, have now already

switched to the workflow and output

systems of the latest generation.

The installed CtP recorders can be

categorized, depending on their design,

into internal drum, external drum or

flatbed devices. Today, the difference

is better determined by the imaging

technology, which we also use as a means

of categorization.

4.1 UV Imaging of Conventional

Offset Printing Plates

At the moment, there is only one system

on the market for digitally imaging con-

ventional printing plates. This system

uses the light from a UV lamp which

travels via a lens and micro-mirror chip,

as used in video projectors, for example,

and is then directed onto the printing

plate. With each imaging pass, partial

images are projected onto a flat, fixed

plate, as with a copying frame. As the

imaging head travels back and forth,

the partial images are built up to form

an overall image. The process requires

a lot of technological input. For the user,

however, the advantage lies in the ability

to image conventional offset printing

plates cheaply.

4.2 Laser Imaging with Visible Light

In the early years of CtP, expensive lasers

had to be used for imaging the plates

that were around at the time. These lasers

emitted light in the blue and green

ranges of the spectrum. Gradually, the

use of significantly cheaper laser diodes

took hold. In addition to the red light

diodes which operate in the 633 – 670 nm

range and are used primarily for small-

format, flatbed CtP recorders, very

inexpensive violet light diodes have

been causing great excitement since

drupa 2000. These diodes operate in

the 400 – 410 nm range and deliver an

initial output of 5 mW. Highly-sensitive

silver halide plates are available for

these, and they can be imaged with

an imaging energy of just 26 mJ/m2.

Digital photopolymer printing plates

have been announced that require a

laser diode with six times more output

power (30 mW) for imaging.

For most of these CtP recorders, the

plate is secured in an internal drum via

a vacuum during the imaging process.

Digital imaging generally takes place

using a single beam shone over a mirror

or polygon that rotates at very high

speed. This reliable, proven imaging

technology has been tried and tested

in film imagesetters. Plate handling

Functional principle of an internal drum imagesetter.

UV imaging Laser imaging with visible light Thermal imaging (infra-red)

10 Plate Imaging with Computer-to-Plate Computer-to-PlateTechnology

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is relatively easy, and the manufacturing

costs for CtP recorders are favorable,

thanks to the use of inexpensive violet

light diodes.

A few CtP recorders with violet light

laser diodes also use a rotating mirror

or polygon, but instead of an internal

drum, they use a flatbed construction.

The disadvantage of this type of con-

struction is the long distance from the

center to the plate edge, which can

only be optically compensated within

a limited plate format. This leads to

less quality.

4.3 Thermal Imaging

During thermal imaging, high amounts

of energy are used to effect a physical

change on the surface of digital thermal

plates. Depending on the plate type, this

can be a primary cross-linking or the

dissolution of existing polymer cross-

linking in the aluminum plate coating.

The soluble or dissolved components

are then washed off in the subsequent

development process.

Thermal CtP recorders are generally

external drum imagesetters, where

the digital printing plate is clamped

onto a rotating external drum – although

this can also be a press’s plate cylinder.

Depending on the system, the imaging

process uses a multi-beam technique

with a large number of laser diodes that

emit in the 830 nm range of the spec-

trum. A range of components such as

the imaging head, the plate clamps,

the punch and equipment for compen-

sating imbalance require greater atten-

tion on these recorders than on internal

drum imagesetters.

The main advantage of thermal

technology lies in the fact that thermal

printing plates make almost exclusive

use of binary principles. In contrast

to ‘lithographic’ plates, an image is only

generated once a specific heat threshold

is reached. This facilitates razor-sharp

dot formation.

Some of the thermal CtP recorders

available on the market also use the

internal drum principle. Similar to CtP

systems which use light-sensitive plates,

the imaging process uses a single beam

shone onto a fast-spinning mirror or

polygon. Because of the longer light path

from the mirror to the plate surface,

intricate high-power lasers with a wave-

length of 1064 nm must be used.

Further design principles for thermal

CtP recorders include an internal drum

with a diode imaging system in an inter-

nal ‘imaging drum’or a flatbed image-

setter principle.

CtP thermal recorders, especially

those with an external drum design,

have established themselves well on the

market and have won a market share

of more than 50%. And since drupa 2000,

there has been the new trend towards

CtP systems with violet laser diodes. This

trend is based on the systems’ low price,

coupled with high plate productivity

and excellent quality. Heidelberg offers

a complete range of CtP recorders that

use both imaging technologies. The

section entitled ‘Heidelberg’s Printing

Plate Recorders’describes their advan-

tages and differences.

Dot formation with thermal imaging – heat threshold value principle.

Functional principle of an external drum imagesetter.

No dot formation below heat threshold.

Dot formation by reaching the heat threshold.

No change of the dot above the heat threshold.

Computer-to-PlateTechnology Plate Imaging with Computer-to-Plate 11

heat threshold

Computer-to-Plate Printing Plates5

5.1 CtP Printing Plates for

Violet Laser Diodes (405 nm)

Violet recorders work using light-sensi-

tive plates based either on silver halides

or photopolymers. Both plate types

have been around for many years, and

their use has been proven in practice

with imaging systems that work in the

visible light range (between 488 nm

(blue light) and 670 nm (red light) ). The

latest development is further sensitiza-

tion to violet light with a wavelength

of 400 – 410 nm. The extreme sensitivity

and high resolution of silver halide

plates are retained, as are the durability

and job-run stability of photopolymer

plates.

There are currently two silver halide

digital printing plates available for

imaging with violet laser diodes (output

power 5 mW). These are the Agfa Litho-

star Ultra-V and the Mitsubishi Paper

Mills SDP-Alpha V. They provide advan-

tages of extremely high sensitivity and

a very low-cost laser light but use more

chemistry than conventional processes.

However, all manufacturers are devel-

oping products with the aim of signifi-

cantly reducing consumption levels.

Silver plates enable high job runs

of up to 350,000 prints. Further post-

baking to increase the size of the job run

is not possible. UV inks greatly reduce

the run length and are not recom-

mended

with the silver based plates.

The new violet-sensitive photopoly-

mer plates from Mitsubishi Chemical

(Western Lithotech) and Fujifilm, how-

ever, promise to remedy this. These plate

types require just one laser diode with

a higher output power of 30 mW. The job

run size for photopolymer plates is a

maximum of 200,000 prints. To increase

the job run size and to use UV inks,

a post-baking process can be used. The

maximum achievable resolution for

photopolymer plates is somewhat lower

than for silver halide plates.

Silver halide plates belong to the

class of positive plates, i.e. the imaging

takes place on the non-printing part

of the plate. Photopolymer plates, on

the other hand, are negative printing –

i.e. only the printing parts are imaged.

5.2 Thermal Printing Plates for

Infra-Red Laser Diodes (830 nm)

For thermal plates too, a distinction

is made between negative and positive

processes, the appropriate switchover

being effected simply by the digital print-

ing plate’s definition and by the RIP.

For negative processes, polymers are

cross-linked during the imaging of the

image parts to be printed. This takes place

when the laser beam energy exceeds

Speedmaster 74 DI

Agfa Lithostar Ultra-V. Structure of the silver halide plate’s coating for imaging with a 5 mW violet laser diode.

Aluminium

Barrierlayer

Receivingnuclei

Emulsionlayer

Anti-stress layer

12 Plate Imaging with Computer-to-Plate Computer-to-Plate Printing Plates

a certain threshold. This primary cross-

linking must then be reinforced via

additional preheating of the entire plate

before the non-cross-linked polymers

are dissolved in an alkaline development

process and the hydrophilic aluminum

is exposed (e.g. Kodak Polychrome

Graphics DITP 830, Fujifilm Brillia LH-NI).

In the case of thermal printing plates

using the positive process, the polymer

cross-linking of the non-printing parts

is destroyed by the laser’s high energy.

The polymers which have already been

dissolved are then removed in the alka-

line development process. The advantage

of this is that no further preheating

is required (e.g. Agfa Thermostar P970,

Kodak Polychrome Graphics Electra 830).

Most thermal plates can be post-

baked after development. Post-baking

provides longer run lengths, with some

plates producing jobs with more than

a million impressions. This post-bake

option also makes them ideal for use

with UV inks.

For many years, ‘processless’ thermal

printing plates have been on display

at trade shows. In the printing areas

of these plates, either covering layers

are dissolved or parts of the coating are

burned off. The dissolved parts of the

covering layers are then either washed

off or removed via the dampening rollers

in the press. Burned-off particles are

suctioned off in the imagesetter.

In the future, it may be possible to

switch the processes from non-printing

to printing by means of phase-changing

‘switchable’ polymers. With only a few

exceptions, most of these plates intended

for use with CtP recorders are still in the

development stage and are years away

from commercialization. Processless

plates for imaging directly in the press

(e.g. Heidelberg’s Speedmaster™ 74 DI)

in CtP applications are already available,

however, and are being used success-

fully.

Digital imaging of printing plates

for waterless offset printing is, however,

still only possible using thermal tech-

nology.

5.3 Printing Plate Development

The development of all of the printing

plates mentioned above also requires

a processor specifically configured for

the plate and the use of special chemi-

cals. For an automated processing line,

a conveyor is required between the CtP

recorder and the online processor, and

a plate delivery table or stacker must

be provided at the end of the processing

chain.

Developers for digital printing plates

are also available specifically for smaller

plate formats. This is definitely advan-

tageous for printing in small to medium

formats, or where space restrictions

mean that large equipment cannot be

installed.

With thermal plates and photopoly-

mer plates for imaging with violet laser

diodes, alkaline positive and negative

development is used. Silver halide plates,

on the other hand, require a special

development process which includes

development, a subsequent diffusion

process, washing off and finishing.

The final stage involves the plates being

gummed to prevent oxidation for a

few days.

Processors for positive thermal plates

often also facilitate the development of

conventional positive plates that use the

same chemicals. In any case, however,

the plate supplier’s technical services

department or expert advisors should

be consulted for a full explanation.

Development processors for digital

printing plates, add-on equipment such

as stackers and tables for plate delivery

and post-baking ovens, along with the

relevant developing chemicals, are avail-

able from printing plate manufacturers

and suppliers, and are delivered via their

specialist dealers. There are also a number

of ‘independent’ suppliers (e.g. Glunz &

Jensen, Denmark) who also supply equip-

ment for plate development.

The processor Raptor from Glunz & Jensen.

Computer-to-Plate Printing Plates Plate Imaging with Computer-to-Plate 13

Heidelberg’s CtP Solutions6

Heidelberg has developed integrated

solution concepts for introducing Com-

puter-to-Plate in all sizes of company and

for all tasks in both violet and thermal

technology. Heidelberg’s solutions offer

much more than just the digital imaging

of printing plates. They involve the

entire workflow – including the transfer

of data, its processing and preparation

into print sheets, the output of digitally-

imaged printing plates and the transfer

of data for presetting press and finishing

equipment. This means that they already

form a key component of any end-to-end

print media workflow of tomorrow.

6.1 Heidelberg’s workflow solutions

Operating complex workflows quickly,

reliably and smoothly is essential for

ensuring the best possible flow for a CtP

production process. The three workflow

systems outlined below are all able to

meet this challenge head-on. They are

scaleable, thus representing solution

concepts for even the most diverse

demands in terms of productivity, levels

of automation and universal access

to production data.

A number of highly important

options and add-ons for CtP output are

discussed below and a brief description

provided of each.

6.1.1 MetaDimension

MetaDimension™ provides the ideal

gateway solution to a perfect PDF sce-

nario with all the benefits of job ticket

processing. The modularity of this PDF

RIP and PDF workflow means that it

suits any volume of jobs and any budget –

without any reduction in functionality.

This gateway can be opened by using

MetaDimension as a PDF RIP. This way,

the functions of PDF are incorporated

in the existing prepress workflows.

MetaDimension is completely modular.

It can be added to at any time with

InRIP Trapping, InRIP OPI, InRIP page

positioning or InRIP Color Manage-

ment. If the functions provided by all

these InRIP modules still aren’t enough,

specialist software from Heidelberg

or other software manufacturers can

be integrated as an Acrobat plug-in.

Of course, SignaStation®can also

be integrated into the workflow in order

to harness the benefits of the Print Pro-

duction Format (PPF) and to transfer

information, e.g. on the ink zone pre-

settings, to the press, or on folding and

cutting to the finishing stage.

In just the same way, MetaDimension

can be integrated into an existing Delta™

Technology workflow – a combination

that delivers the benefits of the screen-

based high-performance workflow with

the flexibility of the PDF-based work-

flow. Data from Prinergy can also be pro-

cessed. The ability to import 1-bit TIFF

files also means that MetaDimension

can be used in virtually any workflow.

What counts is access to data at every work phase and from all locations.

14 Plate Imaging with Computer-to-Plate Heidelberg’s CtP Solutions

Layoutstation Mac/PC

Prinergy

DeltaTechnology

TIFF Import

MetaDimension

SignaStation

Computer-to-Film

Computer-to-Plate

Color Proof

Form Proof

TIFF Export

Printing Press

Heidelberg’s CtP Solutions Plate Imaging with Computer-to-Plate 15

6.1.2 DeltaTechnology

Two key properties set Delta Technology

apart from all other PostScript systems:

Delta Lists and the R.O.O.M. concept

(RIP Once, Output Many). PostScript files

are first interpreted (ripped) and then

stored in an overlay-free, page-independ-

ent interim format known as a Delta List.

The R.O.O.M. concept – the chronolog-

ical and spatial separation of the inter-

pretation and screening processes –

enables data to be output on various

output devices without any need for

repeat ripping.

Delta Technology’s universal concept

is reflected in the diversity of the avail-

able Delta options for input, output and

processing. Delta Technology can pro-

cess PostScript, PDF and TIFF/IT-P1 files,

and with the Delta CEPS-Input option

can also process pages from the tradi-

tional repro sector. The Delta Image-

manager not only supports OPI services

in their native format, but also includes

images whose layout files have been

generated using Helios OPI and Color-

Central. Further options support pre-

flight checks, trapping, proofing, impo-

sitioning in conjunction with Signa-

Station and the generation and transfer

of data in the CIP4-PPF standard for

press and postpress presettings.

Delta Autoflow enables PDF docu-

ments to be processed automatically

using the job ticket instructions exe-

cuted in Prinergy. Delta Flow provides

the link to MetaDimension. The biggest

advantage of this combination is that

the strengths of both systems can be

harnessed. This is particularly interest-

ing given that there are more than

8,000 existing Delta Technology instal-

lations currently providing a basis

for CtP.

6.1.3 Prinergy

Prinergy is a complete PDF workflow

system for the high-performance sector

that automates every single step of the

prepress stage. Prinergy is open for all

popular standard formats and is based

on Adobe PostScript Extreme, with its

PDF 1.3 components and Adobe Portable

Job Tickets. Every stage of the workflow

is completed in the compact PDF data

format. Prinergy is open and accepts

standard data formats such as PostScript,

PDF, DCS or EPS. One unique feature

is the fact that workflow stages are com-

bined into process plans which are then

executed automatically in job ticket

processors.

Prinergy outputs proofs, films

or plates dynamically in the following

stages:

1. Refining

Data optimization (preflight check),

normalization to PDF, color manage-

ment, trapping, thumbnail generation.

2. Impositioning

Job tickets, generated by Heidelberg’s

SignaStation, assign the PDF pages auto-

matically to an impositioning layout.

This can be done either just-in-time

or immediately before output.

3. Proofing

Soft proof on the monitor, digital proof,

form proof.

4. Output

Either via the Prinergy primary server,

a special rendering workstation, Delta

Technology or MetaDimension. On the

fly, the renderer converts the PDF pages

and job tickets into a bitmap for the

recorder.

5. Forwarding

The CIP4 data created in the workflow

is sent in its entirety to the press and

finishing stage. All processing records

and the data are archived.

The Prinergy database provides

transparency for the progress of the indi-

vidual workflow stages and analyzes

all records using business management

criteria. What counts is access to data

in every work phase and from all loca-

tions. This ensures better communi-

cation and thus balanced and optimum

utilization of the prepress, press and

postpress stages.

Maximum productivity, more flexibility and reliability in the workflow.


One of SignaStation’s key functions

is its support for the Print Production

Format (PPF). SignaStation bundles all

the information required in the follow-

ing stages of the processing chain –

such as the job name, sheet number,

ink coverage information, location

of the positioned autoregister and color

control marks, plus cutting, folding

and collating information – into the

Print Production Format, thus enabling

it to be used on any system for printing

and finishing.

Impositioned print sheets with all marks and print control strips ready for output.

6.1.4 MetaShooter

Heidelberg’s CtP recorders are connected

to third-party manufacturers’ workflow

systems via MetaShooter™. MetaShooter

processes the imaging information

it receives in TIFF-B data format and

forwards it to the recorder.

Of course, MetaShooter can also

be integrated into Heidelberg workflow

systems. One advantage of this is that

the CtP recorder can be set up separately

from the prepress department. This

saves time, since the plates can be out-

put in the immediate proximity of the

press. MetaShooter also facilitates the

chronological separation of data screen-

ing/interpretation and plate imaging.

The screened data is saved in TIFF-B

format and can be called up at any later

point in time. This is also advantageous

if individual plates or an entire job needs

to be reproduced.

6.1.5 Heidelberg ScreenTechnologies

Choosing the right screen system is cru-

cial for the quality of a print product.

Heidelberg has developed the best,

world-renowned screen technologies

and makes them available in every sin-

gle Heidelberg workflow system:

• HQS Screening® (High Quality

Screening).

• I.S. (Irrational Screening).

• Diamond Screening® (Frequency-

modulated Screening).

• Megadot™ and Megadot Plus.

For a more detailed description with

print examples, refer to Heidelberg’s

special technical volume entitled ‘An

Introduction to Screening Technology’.

6.1.6 Redigitization with

NewCopix 7000

The new software NewCopix™ 7000 from

Heidelberg, when used in conjunction

with the Nexscan®and Primescan™

scanner families, offers a simple, high-

quality redigitization function. Color

separation films or printed originals can

be scanned using NewCopix 7000 and

converted into a digital data set. With

NewCopix 7000, Heidelberg scanners

become multi-talented machines. For

most printshops, this solution is more

cost-effective than investing in expen-

sive Copydot special scanners.

6.1.7 SignaStation –

Impositioning and More

The SignaStation is Heidelberg’s solution

for digital impositioning and is therefore

essential for end-to-end, digital produc-

tion. It prepares the entire print sheet

digitally for print-ready output on film-

setters or CtP recorders. Its strengths

include full visual controls, maximum

flexibility and maximum automation,

plus the option of being able to intervene

manually at any time.


6.1.9 Digital Proof

All Heidelberg workflow systems feature

the ability to link up to other manufac-

turers’ digital proofers via the Heidelberg

Color Management system. This uses

ICC profiles to adapt to the relevant print

process and the true-color output.

Prinergy makes proofing particularly

productive, since color management is

carried out during the refining process.

In addition to simulating the print result

for page and form proofers, it also con-

6.1.8 Color Management

Three coordinated software solutions

from Heidelberg provide end-to-end,

professional color coordination in an

open workflow for every stage of the

workflow right through to print:

PrintOpen for generating ICC output profiles.

verts to the output device’s color space.

Special colors can be either converted

into process colors or kept as special

colors. After the PDF pages have been

assigned to an impositioning layout,

a soft proof can be output on the moni-

tor, a printout made of single pages on

a color proofer or a printout made of the

entire print sheets on a form proofer –

all automatically and depending on the

process plan options.

The ICC profiles are generated just

once and can then be assigned freely.

If parameters change, they must be

updated in order to ensure the best pos-

sible adaptation to changed scan origi-

nals, monitors and print parameters.

With MetaDimension too, provided

it is equipped with the right options, the

proofing process is totally user-friendly.

In addition to the on-screen soft proof,

the job can be output at any time on

a connected color proofer or as a form

proof, on e.g. HP DesignJet plotters.

Proofing also has a major role in

the Delta Technology workflow, which

is based on Delta Lists. In addition to

WYSIWYG display on the monitor, the

print manager can be used at any time –

automatically too, if required – to out-

put a true-color, high-quality proof on

any proofer in the network. With the

Delta ProofOpen option, high-resolution

Delta Lists are converted to the appro-

priate proofing resolution.

Software Function

ScanOpen Software for generating ICC

input profiles. Characterization

for all types of input devices,

e.g. flatbed and drum scanners.

ViewOpen Software for generating ICC

monitor profiles. Characteriza-

tion of color monitors.

PrintOpen Software for generating ICC

output profiles. Characteriza-

tion of RGB and CMYK output

units e.g. color printers, color

copiers, proofers, presses.


6.1.10 PrepressInterface:

The CIP4 Interface

Frequent job changes are the order of

the day everywhere nowadays. Even state-

of-the-art printshops with big eight and

ten-color presses are processing smaller

and smaller jobs. The resulting demands

from printshops for shorter setup and

run times, higher quality and improved

workflows are met head-on by Heidel-

berg’s modular Prinect™ system.

PrepressInterface is the Prinect inter-

face that links the prepress, press and

postpress stages. To use this software,

a workflow component is required that

generates CIP4 data in the standardized

Print Production Format (PPF). Which

is exactly what the SignaStation does.

6.1.11 Job Definition Format:

The Next Step

Heidelberg bases much of its work on

the Job Definition Format ( JDF). JDF

integrates the functions of the Adobe

Portable Job Ticket and the Print Pro-

duction Format. What’s more, JDF con-

tains numerous functions for managing,

processing and checking print jobs.

Information on everything from the

job capture and print job execution

to delivery of the finished print can

be recorded in this format. The Job

Definition Format is becoming the

world standard for the entire print

process chain.

6.2 Heidelberg’s Printing Plate

Recorders

Heidelberg develops one-stop, future-

oriented solutions for the entire printing

and publishing industry that cover

every section of the prepress, press and

postpress chain and link these using

comprehensive solutions. In this sense,

all Heidelberg’s CtP solutions represent

end-to-end, fully-integrated solutions

that are aimed at ensuring top-quality

offset printing. From the digital work-

flow to printing and finishing, every

component works in harmony with the

others.

6.2.1 Complete Solution Packages

for Every Market Segment

Different market segments have very

different needs. But whatever these

needs are – be they fast, flexible and

cost-effective processing of polyester

printing plates in small offset, high

system throughput for medium-sized

job runs in the 70 �100 sector, or print-

ing plates that can be post-baked for

rough printing materials, UV inks and

long job runs – Heidelberg has special

solution packages for every require-

ment. All of these solution packages

feature the following:

• Digitization and automation of the

printing plate production process.

• Shorter setup times and a more

reliable, automated flow of data.

• Time savings through fewer work-

flow stages.

• Protects the environment thanks

to reduced material consumption.

• Harnesses costs benefits in the

prepress and press stages.

Quicksetter 46 and Printmaster QM 46 – the perfect team for polyester plate imaging.


6.2.2 CtP with Polyester Printing Plates

Computer-to-Polyester plate is an inex-

pensive alternative that is mainly of

interest to small printshops and quick

printers. Digital imaging of polyester

printing plates is possible on all Heidel-

berg imagesetters, e.g. on the Quick-

setter™ and Primesetter™ family. Because

of the lower dimensional stability of

polyester plates compared to metal ones,

four-color printing should be restricted

to the medium-format sector. It is also

possible to produce single-color prints

and prints with registration-tolerant

spot colors in the 70 �100 format range

when using 0.30 mm-thick polyester

plates. And for all format ranges, a maxi-

mum job run of 20,000 prints is recom-

mended.

6.2.3 CtP with Metal Printing Plates

Because of the differing needs in the

various market segments, Heidelberg

has developed two entire CtP recorder

families for digital imaging of metal

printing plates.

• The Prosetter™ recorder family for

violet plates.

• The Topsetter™ recorder family for

thermal plates.

The user therefore has every option

he needs to configure his workflow and

the digital plate imaging process with

its associated printing plates and level

of automation to suit.

6.2.4 The Prosetter Family

The Prosetter recorder family is Heidel-

berg’s answer to the trend towards inex-

pensive CtP recorders and the use of

violet laser diodes. Low investment costs

and inexpensive running and mainte-

nance costs make the crossover to CtP

technology possible for everyone – with-

out any compromises in terms of quality

or performance. The compact construc-

tion with its small footprint also helps

minimize the costs of providing suffi-

cient space.

The highly-flexible format range of

the individual Prosetter models covers

the plate formats for all Heidelberg

sheetfed offset presses and the majority

of other manufacturers’ sheetfed offset

presses:


Prosetter Printing press

Prosetter 52 Printmaster QM 46 to

Speedmaster SM 52

Prosetter 74/F 74 Printmaster QM 46 to

Speedmaster SM/CD 74

Prosetter Printmaster GTO 52 to

102/F 102 Speedmaster SM/CD 102

Integrated punching systems ensure maximum register accuracy.

The Prosetter series uses internal

drum technology with a high-quality

imaging system that has been tried

and tested in the field of imagesetter

construction and was developed for

imaging metal plates. A deflecting prism,

which is very small due to the violet

laser beam’s short wavelength, is rotated

at high speed by a spinning motor and

thus facilitates a high output power.

A 5 mW laser diode is used as a light

source, and this generates light in the

visible violet range of 405 nm. This

enables highly-sensitive silver halide

printing plates with a very high reso-

lution to be imaged in outstanding

quality.

For the far less sensitive violet photo-

polymer printing plates, a more power-

ful 30 mW diode is required to maintain

the same rate of plate throughput.

This diode can be retrofitted to all the

Prosetters currently in use by using

a conversion kit.

Because of their high sensitivity,

both types of plates are processed in

pleasantly bright, daylight conditions

with a yellow safe light. There is no

need for a darkroom.

The Prosetter’s plate loading guid-

ance system is extremely simple and

user friendly. The plate simply has

to be placed on the loading table and

is then automatically drawn in, cen-

tered, imaged, punched (if required)

and ejected. The Prosetter offers a high

productivity in the standard models.

The Fast versions of the Prosetter 74

and 102 provide an even greater level

of productivity.

The single cassette loader makes the

Prosetter fully automatic and it can also

work in daylight environments. The

single cassette loader can hold 100 print-

ing plates. After imaging, the plate is

transferred online via a conveyor to the

processor.

If required, all models in the Prosetter

series can be equipped with a punching

system with up to four punch modules

for Heidelberg presses and other manu-

facturers’ presses. The customer can

configure these himself. The Prosetter’s

integrated temperature compensation

provides added precision. This ensures

maximum register accuracy – especially

for plate repeats.

Why Temperature Compensation?

Printing plates made from aluminum are sensitive to the fluctuations in temperature

that occur during normal daily operation, or to temperature changes during the

imaging process. For a 0.30 mm-thick printing plate with an edge length of one meter,

the printing plate increases in size by 0.13 mm for each 5°C rise in temperature.

A temperature compensation system avoids registration errors caused by tem-

perature fluctuations. To do this, the temperatures inside the recorder are measured

precisely and the imaging part of the printing plate automatically adjusted if a change

in temperature occurs. Consistent, precise imaging with total register accuracy –

even for trapped image elements – can therefore be ensured. This function is espe-

cially important if e.g. a single plate has to be repeated from a four-color set due

to mechanical damage.


The Topsetter P and PF 102 models

are also suitable for large-format sheet-

fed offset presses up to a plate format

of 1160 � 940 mm.

The external drum construction,

combined with high-precision 32-chan-

nel laser head (Topsetter P 74, Topsetter

P 102), delivers excellent imaging quality.

The Topsetter PF 102 model features

a 64-channel laser head for maximum

performance. The optical system on

all models is also extremely easy and

inexpensive to maintain, since the laser

diodes can be exchanged individually.

The Topsetter range also has the

speed to match. With up to 20 printing

plates per hour in 1030 �790 mm format

at a resolution of 2540 dpi, the Topsetter

PF 102 meets even the toughest produc-

Topsetter delivers perfectly punched plates for every press.

6.2.5 TheTopsetter Family

Heidelberg’s flagship for maximum

CtP production is the Topsetter range.

It delivers top performance in terms of

quality and speed. The two models, the

Topsetter P74 for the 50 �70 format class

and Topsetter P102 and Topsetter PF102

for the 70 �100 format class, are perfectly

matched to the following Heidelberg

presses:

tion demands and is also perfectly coor-

dinated with the high-performance

Speedmaster SM102 press.

All popular 830 nm sensitive ther-

mal plates currently available from well-

known printing plate manufacturers

can be imaged. The thermal plates are

processed in daylight conditions.

All Topsetter models can optionally

be equipped with an automated punch-

ing system for Heidelberg presses and

other press manufacturers. Up to three

punching systems can be installed in

parallel. This ensures absolute register

accuracy. Setup times are also shortened

and waste cut.

All models in the Topsetter family

can be expanded modularly from the

basic model supporting semi-automatic

operation to a fully-automatic system

with multiple cassettes. They can be

customized perfectly to the user’s

requirements. And every Topsetter can

be upgraded at the customer’s premises

to meet changes in demands at a later

date.

Topsetter Printing press

Topsetter P74 Printmaster QM 46 to

Speedmaster SM/CD 74

Topsetter Printmaster GTO 52 to

P 102/PF 102 Speedmaster SM/CD 102


Semi-automatic mode

The plates are loaded and unloaded

manually using separate loading and

unloading tables. While one plate is

being imaged, the next plate can be

loaded – thus saving time. The plates

can also be punched automatically

(optional).

Semi-automatic mode

with online processor

The plate that has been loaded manually

is taken onto the drum automatically,

and after imaging is transferred to the

connected online processor. The plates

can also be punched automatically.

Automatic mode with one cassette

The printing plates are loaded auto-

matically from a cassette that can hold

100 same format plates. The interleaf

paper is removed as part of this process.

The punched and imaged plates are fed

automatically to the online processor.

If a job needs to be done quickly but has

a different plate format, manual bypass

mode is possible.

Automatic mode with multiple cassettes

The printing plates can be loaded auto-

matically from three, four or five cas-

settes, each of which can hold 100 same-

format plates. This means that a total

of 500 plates are available online in five

different formats.


First of all finding an optimum solution

for each user and his highly-specialized

needs must take precedence over any

technology discussions. Heidelberg’s

Prosetter and Topsetter families offer

both violet and thermal imaging. So the

first task is to weigh carefully where the

focus for the system’s use will lie, and

what decision criteria, if any, would jus-

tify the crossover into a more expensive

investment class.

A potential buyer can use the follow-

ing criteria to help him make the right

decision for his company’s needs:

How Can I Find the Right CtP Solution?7

• Job run length

The silver halide plates available

for violet technology cannot be post-

baked. Manufacturers specify that

the job run should be up to 350,000

prints. The limit for violet-sensitive

photopolymer plates and for thermal

plates depends on the manufacturer

and plate, but is typically between

150,000 and 250,000 prints. This can

however be extended through addi-

tional post-baking to up to a million

prints and more.

• Use of UV inks and rough printing

materials

The use of silver halide plates should

be avoided for UV inks. The solvents

are too aggressive. Even when print-

ing on rough paper, e.g. in packaging

printing, a printing plate that can

be post-baked is more effective.

• Space requirements

The construction of the Prosetter

family is designed to offer a particu-

larly small footprint. The Prosetter 52

can also be used with a special model

for small-format offset printing up to

a plate format of max. 670 � 525 mm.

• Level of automation

Every desired level of automation

can be catered to. The Prosetter family

and the Topsetter basic model are

suitable for use with flexible, semi-

automatic mode. Both families can

be delivered with various versions

up to a fully-automatic process, or can

be field upgraded at a later date.

• Investments

The inexpensive violet laser diode,

in conjunction with the simple

imaging principle, means that the

Prosetter models represent a low

cost investment with low mainte-

nance costs.

• Print behavior

In terms of print behavior (clean

running of the plate, ink/water

balance, ink feed, dot gain) and the

achievable print quality, there is

no real difference between violet

and thermal technology. The plate

throughput and the price of digital

printing plates for both processes

are also about the same.

How Can I Find the Right CtP Solution? Plate Imaging with Computer-to-Plate 25

26 Plate Imaging with Computer-to-Plate How Can I Find the Right CtP Solution?

Differentiation Criteria at a Glance

Prosetter family Topsetter family

Recorder features

Light source 1 violet laser diode 32/64-channel laser head

Imaging system single-beam technology, internal drum multi-beam technology, external drum

Space requirements minimal depends on configuration

Level of automation semi-automatic to fully automatic semi-automatic to fully automatic

Plate throughput no difference no difference

Investment costs low depends on configuration

Printing plates supported Silver halide plates Photopolymer plates Thermal plates

Sensitivity at 405 nm at 405 nm at 830 nm

Conditions daylight brightness, yellow safety light; daylight

daylight for fully-automatic mode

Job run length

without post-baking 350,000 200,000 150,000 – 250,000

after post-baking n/a ~ 1 million ~ 1 million

Use of UV inks no yes, after post-baking yes, after post-baking

Rough printing materials no yes, after post-baking yes, after post-baking

Behavior during print no difference no difference

Print quality no difference no difference

Price of printing plates no difference no difference

5. The goal will only be achieved

through clear specifications and

their on-schedule completion.

A precise plan of the necessary steps

(see also our ‘Checklists’) and the

creation of a timescale and finance

plan are key milestones.

Digital workflow systems and CtP

recorder technology are highly advanced.

An investment in a high-performance

workflow that ensures the complete

automation of the prepress stage and

leads on to the next stages (press and

postpress) is therefore an essential and

proper step towards competitive produc-

tion. Heidelberg offers comprehensive,

practicable solutions for every segment

and all sizes of companies.

Most of the advantages of a modern-

ized workflow and the level of automa-

tion that comes with it are linked to the

printing stage.

The press room and the quality

of the goods produced in it are the real

winners!

This statement of course has to be

qualified with a number of requirements,

and these will be discussed again briefly

below:

1. For entry into CtP, there must be

a sufficient number of jobs for pro-

ducing digital plates if the invest-

ment is to be justified. This number

averages around six to ten four-color

jobs per day/shift. However, this

figure is heavily dependent on the

current mix of customers and jobs,

and also on the current workflow

configuration.

2. From a business management per-

spective, a sufficiently large printing

capacity also plays a key role. When

a feasibility study is being drawn

up that is tailored to your company,

Heidelberg can provide you with

the expertise needed.

3. Trained staff with excellent experi-

ence in the PostScript sector – pos-

sibly also with PDF – should be avail-

able or training must be possible

within the planned time period. Cru-

cial factors in this context include

existing experience of digital proofs

and a positive response from the

customer’s staff. These requirements

will play a key role in defining a

schedule for the changeover to an

automated overall workflow.

4. A willingness to accept change

(both internal and external) must

be present. This requires good,

all-round communication between

all the departments within a com-

pany, including the field sales team,

and open communication with the

most important customers regarding

the planned changes (such as data

supply, correction cycles, proof ).

Time Is Money: So Why Wait any Longer?8

Time Is Money Plate Imaging with Computer-to-Plate 27

Checklist9

This checklist is intended as a planning

aid for investments in a digital workflow

with CtP output. It makes no claim to be

complete, nor does the implementation

of all steps have the same importance for

all sizes of company. The details of the

current snapshot and the target analysis

are intended exclusively for you at this

stage. They provide you with assistance

in creating the transparency needed

for your further plans. If you wish to dis-

close the data contained in this check-

list, they will definitely provide a valu-

able basis for further advice from your

Heidelberg sales partner.

Current Snapshot

• Existing prepress equipment.

• Analysis of the current workflow.

• Number of staff in the prepress

stage, incl. plate copy. What activity.

• Number of jobs per year, per month,

per day, per shift.

• At what times do peak loads occur?

• Number of pages, print sheets, sheet

format.

• Which data do you receive in digital

form?

• Which data is supplied as films?

Page parts, finished page films, print-

ready full-sheet films.

• Number of supplied films. Percentage

requiring redigitizations.

• Page films imaged in-house, full-

sheet films, number, square meters,

annual film costs.

• Is analog proofing (contract proofing)

used? Systems, units, annual costs.

• Is digital proofing (contract proofing)

already being used? Which devices,

annual costs.

• Acceptance among staff of digital

proof (as percentage).

• Number of printing plates to be

copied per year, per month, per day,

per shift.

• Number of remakes, percentage,

reason for remake (last-minute cor-

rections, faulty plates, other reason).

• Number of remakes when job already

on press.

• Press downtimes, reason.

• Level of utilization of press(es).

Target Analysis

• Detailed description of the planned

workflow.

• Network planning.

• Planning of data communication.

• Necessary server capacity.

Tools for backup and archiving.

• Redigitization of existing and sup-

plied films, volume, tools.

• Implementation of digital proofing.

• What existing equipment is to be/

can be used further in the digital

workflow.

• Number of staff available, new,

activity, costs.

• Total investment acc. to offer(s).

• Technical scope. Level of investment.

• Planned film costs. Planned plate

costs digital, analog.

• Planned savings or added capacity

in print.

• Feasibility study with TARGET/

ACTUAL comparison.

Space/Building Planning

• Drawing up of space plan and assign-

ment of implementation.

• Award of order for network and data

communication.

• Planning for air conditioning

of sections. Total air conditioning

including award of order.

Finance Planning

• Evaluation of investment aid,

regional economic subsidiaries.

• Evaluation of regional aid for intro-

ducing new, eco-friendly techno-

logies.

Time Planning, Security

• Total timeframe with checkpoints

for individual stages of CtP intro-

duction.

• Member of staff responsible (assistant

to technical manager) or team.

• Plans for the end of twin-track

operation (security).

• Disaster plan (worst case). Back-up

planning.

Training

• Training for a system administrator,

appoint representative.

• Training for further technical staff.

• Training for the field sales staff.

• Training/support for customers

(generation of PDF files, network,

communication, proof ).

Advertising

• More capacity, order planning.

• Enhanced quality to be communi-

cated.

• Image brochure.

• Internet.

28 Plate Imaging with Computer-to-Plate Checklist

Heidelberger Druckmaschinen AG

Kurfuersten-Anlage 52 – 60

69115 Heidelberg

Germany

Phone +49-62 21-92 00

Fax +49-62 21-92 69 99

www.heidelberg.com

Publishing InformationPrinted in: 06/02 Author: Günther Bregel Photographs: Heidelberger Druckmaschinen AG, Agfa-Gevaert AG, Glunz & Jensen Platemaking: CtP Printing: Speedmaster Finishing: Stahlfolder, Stitchmaster Fonts: Heidelberg Gothic, Heidelberg Antiqua Printed in Germany Copyright © Heidelberger Druckmaschinen AG, 2002

Trademarks Heidelberg, the Heidelberg logotype, Diamond Screening, HQS Screening, Nexscan, PrintOpen, ScanOpen, SignaStation and ViewOpen are registered trademarks of Heidelberger Druckmaschinen AG in the U.S. and other countries. Delta, GTO, Megadot, MetaDimension, MetaShooter, NewCopix, Primescan, Primesetter, Prinect, Printmaster, Prosetter, Quicksetter, Speedmaster, Supertrap and Topsetter are trademarks of Heidelberger Druckmaschinen AG in the U.S. and other countries. Adobe, the Clearly Adobe Imaging logotype, Acrobat and PostScript are registered trademarks of Adobe Systems Incorporated in the U.S. and other countries. Mac is a registered trademark of Apple Computer Incorporated in the U.S. and other countries.All other trademarks are property of their respective owners.

Subject to technical modifications and other changes.

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