rm-01 digital flexo solutions roadmap - monochrom digital flexo solutions roadmap.… · rm-01...

1

18.06.2012

Ian Hole

Rory Marsoun

18.06.2012

Ian Hole

Rory Marsoun

RM-01 Digital Flexo Solutions Roadmap EskoWorld

New Orleans

RM-01 Digital Flexo Solutions Roadmap EskoWorld

New Orleans

2

ESKO –

Leading the way

Packaging Design and Pre-production Software

Digital Flexo PlatemakingSoftware and Hardware

Short Run ConvertingSoftware and Hardware

3

CDI Spark 4260 AUTOPlates up to 42x60 inches

Flexo CtP product portfolio

CDI Advance Cantilever 1450Plates up to 42x60 inches

CDI Spark 4260Plates up to 42x60 inches


CDI Advance Cantilever 1750Plates up to 50x80 inches



CDI Spark 4835Plates up to 47.2x35.4 inches

CDI Spark 1712/A3Plates up to 17x12 inches


4

273

56

548

291

163608

113

The success of Digital & HD Flexo

1998 –

CDI TwinBeam

1998 –

CDI Compact

2000 –

CDI Spark

2000 –

CDI SecuFlex

2001 –

CDI PowerBeam

2002 –

CDI Spark XT

2003 –

CDI Advance

2005 -

CDI Spark 4260

2005 –

CDI Spark 2120

2007 –

CDI Spark 5080

2008 –

CDI Spark 4260 AUTO

2008 –

CDI Advance Cantilever

2009 –

CDI Spark 1712

0

500

1000

1500

2000

2500

'97 '98 '99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '09 '10 '11 '12fc

Year Installed

Tota

l Num

ber

Installed CDI's

HD Flexo

CDI installs 04/2012

2012 –

CDI 2420

5

ESKO - Innovations for Flexo Printing

1995 –

Introduction

of CDI1995 –

Introduction

of CDI

2000 –

Introduction

of Fiberlaser2000 –

Introduction

of Fiberlaser

2008 -

Inline UV12008 -

Inline UV1

2009/11 -2009/11 -

1975 –

Introduction

of Direct

Engraver1975 –

Introduction

of Direct

Engraver

YearYearPri

nt

Qu

ality

an

d C

on

sist

an

cyP

rin

t Q

uality

an

d C

on

sist

an

cy

1980 –

Introduction

of Laser Engraver

for

Anilox rollers1980 –

Introduction

of Laser Engraver

for

Anilox rollers

Flexo Business Mission StatementEnhance Flexo print quality

and improve acceptance of Flexo printing

in the whole Packaging Industry

2012 Pixel+ Full HD Flexo

2012 Pixel+ Full HD Flexo

6

–

Fiber Laser technology used in all CDI models●

Low electrical energy consumption

●

High reliability

●

Long MTBF

–

No Banding / Moiré due to mathematical clashes●

Identical Ablation behaviour of all beams

copies of master beam

●

Sufficient power per beam (min 1.2W/beam

0.9W/diode)

●

Resolution and screening depending beam combination

●

Automatic Beam Selection is standard for all imagers

–

Perfect ablation behaviour independent of the plate relief●

High Focal Depth of almost 0,5mm (500µm)

●

No halo spots

–

Super-skip is standard●

No wasted time between graphic objects

●

Average imaging time savings = 70%

The basics are still valid (and standard)

Plate tolerance

±25µm

±500µm

7

Productivity enhancement

●

Maximize

the

productivity:–

Spaces between graphic elements use

Superskip

–

30% time savings average is normal

Superskip zones

8

The key benefits are still there

●

Modular machine concept

1.

Size and productivity of imager -

according to customer needs

2.

Same technology throughout the whole product range

3.

Consistent quality output due to hardware and software concept

4.

Reliability and service organization to back it up

5.

HD Flexo giving Offset and Gravure quality and consistency

6.

High Res Optics for smaller details also assists other technologies

7.

Integrated into Esko workflow solutions (DFS, JDF)

8.

Proven concept with 75% of market share

9.

Plate and Sleeve compatible imagers

9

HD FlexoHD Flexo --

HighlightsHighlights

1a

10

CTP Flexo – High Resolution Imaging Technology

●

Imaging Resolutions for CTP Flexo:

Laser dot size = Tool size

18 µm2100 ppi

12 µm2540 ppi

1995: 1998: 2008:

6 µm

4000 ppi ppi = „Pixel per Inch“

11

High Resolution Imaging Technology

●

Better definition of

Small screening dots

Mid tones and dot closure area

Text, Linework and Barcodes

70 L/cm

12

High Res Optics

●

2400ppi vs 4000ppi

13

High Resolution Imaging Technology

●

Grey levels and image contrast–

Number of natural grey levels = (PPI/LPI)²

(PPI = CTP Imaging resolution, LPI = job linecount)

-

At the repro side, images are composed of 256 grey levels

-

Natural grey levels are further reduced by dot gain compensation

-

Only 4000ppi is reproducing the full image contrast

at 150lpi and above

-

4000 is a deliberate resolution based on LPI and available grey levels

2400 ppi 2540ppi 4000ppi

150lpi (60L/cm) 256 287 711

175lpi (70L/cm) 188 211 522

200lpi (80L/cm) 144 161 400

250lpi (100L/cm) 92 103 256

14

Typical Flexo Problems

●

Large Minimum Tonal Value (especially at higher LPIs)

low tonal image contrast, improper image appearance

●

Transition to Zero

Visible vignette edge due to too large minimum tonal values

● Flexo-Problem - Minimum dots bend on the press!

Minimum tonal value 1%Gravure/Offset:

Minimum value 12%Standard CTP Flexo:

15

Highlight stabilization by balanced dot sizes

Dots stay on regular grid

Smooth highlight appearance

16

HD Flexo

●

Solution of the Flexo-Problem

●

Combination of 4000ppi und HD-Screens

Supporting dots for mechanical stability

and as distance holder to Anilox roller

Stable printing

minimum dots

17

Print Quality Improvements with HD Flexo

●

Vignettes down to zero compared to Offset

Offset (PE Adhesive Label, 175lpi)

HD Flexo (PE Adhesive Label, 175lpi)

Offset Image Vignette down to zero %

18

HD FlexoHD Flexo --

SolidsSolids

1b

19

Ink Laydown in Solids and Overprints

●

Flexible Packaging printing often suffers from inhomogeneous ink

laydown:

Pinholes are reducing the solid appearance to the human eye

Overprints and pantone color emulations become uneven and checky

Also important for white underprints and overprints

●

For better ink laydown, printers often have to

-

Print colors twice (for white) or use two separate plates for solids/process work

-

Use higher-volume anilox rollers to print solids and process work in one plate

(reduces highlight quality)

higher cost (more plates and more ink usage)

Pinholes in solid area printed

with digital flexo plate

20

HD Flexo – Solids and Ink Laydown

●

Improved ink transfer due to MicroCell Screens

Self-organisation patterns of the printing ink are destroyed

Very smooth and regular ink laydown in solids and linework

●

HD Flexo delivers best compromise between good solids and cost

–

Perfect solid appearance with only moderate SID increased (+0.1 ... +0.2)

●

SID +0,1

25% more ink usage on press

●

SID +0,3

100% (!) more ink usage on press

–

Solids easily print inside ISO standards

–

Pantone inks can be emulated (< 3 ∆E) by using C,M,Y,K

Standard Flexo with

MicroCell Screens

21

Flexo-Problem - Poor Ink Laydown

100 micron

Solid printout

with standard

plate surface(Solvent Ink)

22

Fixing Flexo-Problem - Poor Ink Laydown

●

Solution to the ink laydown problem: MicroCell Screens

100 micron

Solid printout

with standard

plate surface(Solvent Ink)

Solid printout

with Micro Screening

on plate surface

MicroCells

SID = 1,25 SID = 1,45

23

HD Flexo - Microcells in Solids and Tones

Microcells between75% tint

24

Pri

nt

%

File %

HD Flexo – Solids and Shadows

●

MicroCell screens works in solids and screening dots ...

●

... and delivers also more contrast in the shadows!

25

HD Flexo – Quality Boost in Entire Tonal Range

●

Typische Tonwertkurve von HD Flexo:

HD Screens:

BrilliantHighlights

MicroCell:

Smooth and Dense Solids Pantone Emulations

High Contrast in Shadows

HighRes Optics (4000ppi):

Clean Mid-Tones Clean Dot Closure

Pri

nt

%

File %

26

HD Flexo implementation

●

Works with existing and new flexo plates

●

Improves quality based on existing press conditions

●

Industry standard: supported by leading plate manufacturers

●

Simple field upgrade to the CDI

●

Integrated with Esko workflow

27

HD Flexo

●

Summary

–

HD Flexo boosts the achievable Flexo printing quality

●

Higher detail sharpness and image contrast to entire tonal range

●

Transitions to zero –

real zero -

not a small dot across whites

●

Smooth solids, higher SID‘s (solid ink density)

●

Higher lineatures -

no rosettes or moire patterns

●

Faster to press from shorter prepress manipulation

–

Typical file changes for Flexo reduced by 75%

●

Works with ANY plate ANY process

●

Legacy imaging still available after HD upgrade

●

No change to normal anilox lpi

●

Consistent and Repeatable results

28

HD FlexoHD Flexo --

CertificationCertification

--

FIQFIQ --

ServicesServices

29

Inline UV

200Certified

customers

2150installations

500installations

90installations

ESKO FIQ Services – so far w/w

30

ESKO FIQ Services

●

Flexographic Implementation and Quality

●

Flexo

consulting services available to Esko

customers

●

Works directly with Esko

customers to successfully optimize their entire flexographic workflow

●

Fastest way to bring your new Esko

Flexo

products to full production at the highest level of quality

31

Implementation experts for Digital Plate-Making, Digital Flexo

Suite, HD Flexo, and Inline UV 2.

●CDI Training and Workflow Integration

●DFS Plate Cutting Training and Workflow Integration

●Flexo

Plate Optimization

●Flexo

Print Optimization

–

Press Variable Optimization

–

Screening Optimization

●Curves and Color Optimization

ESKO FIQ Services

32

●

Recently FFTA FIRST Certified!

●

FIRST Certified Implementation Specialists: Following FIRST principles to bring a scientific approach to controlling the flexo

process.

●

We can now assist Esko

customers towards FIRST Company Certification or just implementing key FIRST principles.–

Achieve optimal results for consistency & color/tone accuracy

–

Perform print evaluations & compose documentation procedures

–

Ensure each element within the workflow complies with

FIRST methodology

ESKO FIQ Services

33

HD Flexo becomes Industry Reference

●

HD Flexo Certification Benefits

–

Assure that our customers get full benefit from HD Flexo

–

Excellent marketing tool for certified customer & the client

–

35 customers certified over 1st 3 months

HD Flexo Post Sales Certification

34

●

HD Flexo Certifications for

–

Converters

–

Trade Shops

–

Flexo vendor products (Tape, Anilox, Press, ...)

Trade Shop support program –

Esko certifies their printing partners

e.g. „Served by ...“

HD Flexo Certification

35


●

Process description–

Step 1: Customers are contacted by SLC to become certified HD Flexo user

–

Step 2: Customer sends 5-10 prints of HD Flexo jobs to Technical Competence Center at Esko in Itzehoe, Germany●

Job needs to be 4 color production job (minimum), created by the

customer without Esko technical assistance

–

Step 3: Technical Competence Center Itzehoe evaluates the customer job

–

Step 4: Customer gets certified by Esko Marketing●

Customer receives a certification package, containing–

Congratulations and explanation letter

–

Certificate

–

HD Flexo Certified labels

–

HD Flexo logo for their own marketing materials and communication (on CD)

●

Customer is listed and linked on the website as HD Flexo certified user on www.esko.com/HDFlexo

–

Step 5: Customer must Certify every year to stay qualified

http://www.esko.com/HDFlexo

36


●

Certification criteria

–

Correct usage of HD Flexo repro guidelines

●

Scum dot removal

●

Correct usage of short/long transitions to zero (if applicable)

●

Correct usage of minimum dot guidelines (if applicable)

–

Correct HD screen usage

●

Stable minimum dots in highlights

●

Stable minimum dots at end of vignettes to zero (if applicable)

●

HD Flexo screening matches plate type

●

HD Flexo screening matches Ink/Anilox

system

–

There are also other criteria depending on the special application case, e.g.

●

Application of proper means for pinhole elimination in flexible packaging

●

Application of proper means for mottling prevention on paper substrates

●

Application of proper means for fluting prevention on corrugated

substrates

37

Inline UV1Inline UV1 --

Consistency & ProductivityConsistency & Productivity

38

Banklight vs Inline UV - Lifetime

•

30% UV light degradation over 1000h (individual to each lamp)

•

At least 2 corrective interventions to compensate degradation per year

Resulting in an

unstable plate quality production

13

14

15

16

17

18

19

20

0 250 500 750 1000h

mW/cm²

Lifetime extension by increasing exposure time

Typical lamp exchange

13

14

15

16

17

18

19

20

0 1250 2500 3750 5000h

mW/cm²

Plate adjustable Digital UV level

•

No UV degradation over time (year, month, week or day)

• Expected Lifetime = 5000h

Digital UV results in perfectly controlled plate production

39

Conventional Banklight UV – Plate surface

0

200

400

600

800

1000

1200

0 500 1000 1500 2000mm

mm

∆

=10%

Energy Emmission from lamp to lamp

mm0

200

400

600

800

1000

1200

0 500 1000 1500 2000

mm

•

Uneven light emission over the plate due to individual lamp aging

•

Quality of light emission is varying from lamp to lamp

•

Light emission is multi-directional not focused

Resulting in an unstable plate quality production

•

Uniform dot shaping throughout the whole plate

•

Light is perpendicular to plate surface enabling UV through very small apertures

•

Cool light –

no heat distribution to plate or sleeve

Resulting in a predictable and consistent plate quality production

Simultaneous movement of the UV source over the plate

Each cm²

receives exactly the same light quality and quantity

40

Letterpress for Can, Pod and Tube printing

41

●

Consistent and Repeatable plate imaging–

Plates to variety of presses in a controlled way

–

Standardisation in the supply chain

●

Crisp text and Barcodes–

Straighter shoulders and deeper reverses

–

Can produce even 3 pt text in reverse on plate

●

Higher Line Counts & Wider Tonal Range–

Jump from 85 lpi to 150 lpi

–

1% dot instead of 4% on your plate

●

Controlled Dot Gain, Material and Time Savings–

Elimination of Film, dust, scratches and errors

–

Faster press speeds more brilliant colors

●

Faster job turnaround and less mistakes–

Digital workflow and QC tools enable more production

–

Available for 2 or 3-Piece cans with add-on modules

CTP Letterpress – process & benefits

42

Reverse line Reverse line

Sharper

contours & finer

detail

digital

Plate comparison analog & digital

analog

43

analog digital

Plate comparison analog & digital

Sharper

contours & Finer

details

& better intermediate depth

Reverse line Reverse line

44

DigitalLetterpress Plate

CTP Letterpress – the process

Digital Imager& Inline UV

Washing& Finishing

45

CDI Spark Letterpress – Simple Layouts

46

Add separations to plates easily using templates

●

Predefine the template based on your punch–

Setup according to your production needs

●

Drag and Drop ripped data into empty boxes–

Will be positioned exactly

–

Imaging will follow template

●

Unique solution from Esko–

No need to type co-ordinates

–

Saves time and reduces errors

47

Inline UV unit

●

Predictable plate quality over years

●

Maintenance Free

●

Reduced plate wastage

●

No Press Down time

More than 90 Installs!Main Countries: Mexico, India, Brazil, Germany

48

Inline UV2Inline UV2 --

Full HD Full HD FlexoFlexo

--

Dot Shape ChoiceDot Shape Choice

49

HD Flexo – the new dimension in Flexo Quality

Offering up to now (Q2 2012)

Digital plates with Round Top dots

-UV Exposure with Oxygen present (bank light OR Inline UV1)

-Supported by HD Flexo

-Increased tonal range into fine highlights

-Very good gradations & drop shadows

-Microcell screening for shadows and solids

Beautiful highlights

BUT color SID strength is not fully matching customer requirements

-Additional ink level for solids fills in shadows and loses detail

50


Offerings up to now (Q2 2012) from other suppliers

Digital plates with Flat Top plates

-UV exposure w/o Oxygen from

-DuPont = Digiflow (using Nitrogen gas environment)

-MacDermid = LUX (using clear film lamination layer)

-Flint = NExT (using high energy burst UV light & bank lights)

AND Using HD Flexo to support

-With optional Pixel+ imaging to enhance the results

Also Kodak NX

Vibrant colors with strong SID levels

BUT highlights are not matching customer requirements

-No highlights to substrate zero –

always a small dot size coverage

-Dot Gain on Flat Top highlights is much more than round dots

51

Full HD Flexo (2012)

1.70%

HD Flexo (2009)

0% 1.4

HD Flexo

HD Flexo

Microcells

Microcells

Digital Flexo (1995)

10% 1.25

Circular Screen Plain Solid

Bank light

Inline UV 1 or Good Quality Bank light

Inline UV 2

Technology Preview: next generation HD Flexo

52


HD Flexo on Round Top plate

HD Flexo on Flat Top plate

Customers have to choose:

-

either concentrate on the highlights

Round Top plates-

or concentrate on stronger color

Flat Top plates

53

Perfect ink laydown Very high SID possible

HD Flexo on Round Top and Flat Top Plates

54

Full HD Flexo offers the full range

No compromises

-Color and ink transfer capabilities of a Flat Top plate

-Highlight capabilities of a Round Top plate

How is this achieved?

-Controlled overrun of the Oxygen inhibition

Flat Top structures in shadows (high-frequency Microcells)

Unique highlight dot shape

(same stability as a flat top but print quality of round top dots)

+

55

What is behind Full HD Flexo?

Special HD Screening (part of HD Flexo)

+Inline UV2 (high UV power density)

+ Optical shaping of UV light (UV head design)

Unique Patent technology!

56

Full HD Flexo Demos at Drupa

Full HD Flexo samples on our booth:

Made by Glatz Klischee (Austria)

Demonstrates color and highlight capabilites

4 color + white (reverse print)175lpi

Printed by Amcor (Ledbury, UK)Pantone simulation with 7 colors225lpi

Made by B&K (Germany)Pantone simulation with 4 colors + white200lpi

Get PantoneLIVE / Equinox demo!

57

Full HD Flexo availability

Full HD Flexo is in Beta

-Controlled sales

-Orders accepted at DRUPA

-Full release for most plate types in Q3-4/2012

58

ISO Magenta

Example: What is the right SID for Magenta?

59* ∆E CMC 2:1

1,16 ∆E 3,09

1,22 ∆E 2,29

1,39 ∆E 0,21

1,74 ∆E 3,34

2,02 ∆E 6.56

1,82 ∆E 3,78

ISO Magenta

Spectral measurements on ink films with different SID values:

60* ∆E CMC 2:1

1,16 ∆E 3,09

1,22 ∆E 2,29

1,39 ∆E 0,21

1,74 ∆E 3,34

2,02 ∆E 6.56

1,82 ∆E 3,78

ISO Magenta

Spectral measurements on ink films with different SID values:

61

Optimum Ink Transfer and Solid Ink Density

HD Flexo MicroCells allow you to choose the Solid Ink Density while keeping print conditions constant

●1. Question: What is the optimal ink transfer?

No Pinholes

●2. Question: What is the optimum solid ink density (SID)?

CMYK: Color point matches ISO

Spot colors and White: According to the needs …

62

HD Flexo - Accurate Pantone Color Emulation

●

Smooth solids and

good highlights extend printable color space:

–

Over 80% of all pantones can be emulated on typical Flexible Packaging presses by using only C,M,Y,K inks (accuracy < 3 ∆E)

–

Smaller Highlights are more important than higher SID:

Red: SID = 1.3, minimum highlights 5%

Volume 799645

899 or 79.1% of Pantone colors in Gamut*

Blue: SID = 1.6, minimum highlights 10%

Volume 778203

881 or 77.5% of Pantone colors in Gamut*

L = 87

63

Pixel+Pixel+

64

Why Pixel+ ?

1.33 SID

1.2 SIDSolid

Standard Microcells

65

Why Pixel+ ?

1.33 SIDStandard Microcells

1.72 SIDPixel+

66

Why Pixel+ ?

●

Engraving very high frequency MicroCell

patterns requires the CDI drum to rotate 300rpm or slower.

●

Without Pixel+, slowing down the drum directly impacts productivity.

●

Slowing the drum down to 250rpm from the standard 500rpm = 50% productivity.

●

Pixel+ enables the drum to spin slower while maintaining optics 40 productivity.

67

●

Special optics, software and screens used in CDI–

Available also for MacDermid LUX users on a CDI

–

Available also for DuPont DigiFlow users on a CDI

–

Available for Flint NExT users on a CDI

●

Ordered by vendors to ESKO for shipment and installation

●

Package includes–

High Frequency –

Pixel+ hardware

–

Plate specific screens and software for LUX or DigiFlow or NExT workflows

–

Installation and calibration for consistent imaging

●

Benefits–

Single pixel level results on the plate

–

Ability to enhance LUX, DigiFlow and NExT results

What is Pixel+?

68

●

No file size limitation (TIFF = 4GB max)–

Automatic definition of .LEN tags in PlatePatcher, Redo jobs, Plato, DFS etc…

–

.LEN secures moiré

free imaging by ABS activation (not with TIFF)

–

ABS use guarantees quality imaging

–

LPI and angle information within .LEN tag

●

Superskip included with .LEN format for productivity–

Higher speed combining, clipping, mirroring, rotating of .LEN files in Grapholas

–

No conversion needed with .LEN format means internal speed is faster

–

Simple step workflow with .LEN

●

Benefits of .LEN–

Guaranteed rendition of files through to imager

–

Predictable consistency and productivity

Pixel+ uses .LEN workflow to CDI

69

Hub & Spoke Scenario

●

HUB Without a CDI onsite

●

HD Screen Sets

●

Pixel + Screening (specific plate type)

●

Imaging Engine (Flex RIP Base) OR Nexus PDF RIP

●

LEN out

●

HUB WITH a CDI onsite

●

HD Screen Sets

●

Pixel + Screening (specific plate manufacture)

●


●

LEN out

●

HD Flexo

●

HD Flexo

Install, production & optimization

●

FIQ HD-Flexo

Implementation

●

High Res Optics

●

Pixel + Optics

●

Spoke Without a RIP onsite

●

HD Flexo

●

HD Flexo


●

High Res Optics

●

Pixel + Optics

●

Spoke Without a RIP onsite

●

HD Screen Sets

●

Pixel + Screening (specific plate manufacture)

●


●

LEN out

●

HD Flexo

●

HD Flexo


FIQ HD-Flexo

Implementation

●

High Res Optics

●

Pixel + Optics

70

SleevesSleeves

71

INCREASING customer’s

THROUGHPUT

●

Powerful and easy-to-handle automated sleeve making –

Fast sleeve exchange

by

automated

tailstock

and air

support

●

Upgrades for HD Flexo, IUV2, Pixel+ all available

●

Quick changeover from sleeve imaging to plate imaging–

Drum-Sleeve

with

pneumatic

EasyClamp (patent pending)

●

Highest consistency from job to job (CDI Optics, Inline UV)

More

sleeves

and plates

per hour

CDI Advance Cantilever

72

INCREASING customer’s

THROUGHPUT

●

Powerful and easy-to-handle automated sleeve making

●

Fast sleeve exchange by automated tailstock and air support

more sleeves per hour

Sleeve Imaging – CDI Advance Cantilever

73

INCREASING the customer’s

THROUGHPUT

●

Airbed plate loading table to assist for large thick plates

●

Vacuum drum is loaded like a sleeve onto the shaft

changeable within 5 minutes

Plate Imaging – on the CDI Advance Cantilever

rm-01 digital flexo solutions roadmap - monochrom digital flexo solutions roadmap.… · rm-01...

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