Consumables
VIM innovates with eco-friendly plates
Tuesday 13. May 2008 - Drupa sees launch of processless offset plate for inkjet and waterless plate for thermal platesetter imaging.
VIM Technologies is emerging as a powerhouse of innovation in eco-friendly offset plate manufacture. Following its best-selling 2005 release of a waterless polyester plate for on-press imaging, Drupa 2008 is the launchpad for a pair of equally ground-breaking new plate materials.
The VIM JT Direct Inkjet Plate is a polyester or metal plate that can be imaged in standard inkjet printers with standard aqueous pigment inks. It works with any standard wet offset press and is suited to mono or close-register colour halftone work.
“This is a technical breakthrough, as previous inkjet-imaged plates from other suppliers have required that a special imaging ink fluid is used,” says Avigdor Bieber, founder and CEO of VIM Technologies. “Because we use standard inks the printers warranty is preserved. It also means that the same printer can still be used for conventional full-colour printing, so it can act as a proofer for the plates, saving space and money.”
The other newcomer is DP-S, a processless metal plate for waterless litho printing that can be imaged on any standard thermal platesetter. After imaging a simple wash in a mild soap solution is all thats needed before mounting the plate on the press. Its suitable for up to 50,000 impressions.
Based in Western Galilee, Israel, VIM Technologies was founded in 2001 by Mr Bieber, who has had long experience in pioneering graphic arts products. In the 1980s he headed Scitex Corporations development of the printing industrys first imagesetter, the Raystar. He then went on to develop the Scitex Dolev family of pre-press imagesetters, which was the companys best-selling product ever.
In the mid 90s, Mr Bieber initiated and then headed Karat Digital Press company, a joint venture between Scitex and KBA. In 1997 he first introduced and a year after commercially launched the 74 Karat, an innovative direct imaging digital press that is still available from KBA.
VIMs strategic manufacturing partner is its neighbour Hanita Coatings, which specialises in the development and conversion of coated, laminated and metallised films, with applications in the label, electronics, and insulation industries, with a significant presence in the print media and window film markets.
JT Direct Inkjet Plate
The new JT Direct Inkjet Plate plate is particularly significant: a plate that can be imaged by standard low-cost inkjets that are already widely used as proofers in the printing industry. It uses no chemical processing: after the image is applied by the inkjet printer it is simply passed though a low cost heating unit, which hardens the imaged plate for the press. It is thus very economical and eco-friendly in use.
Initially the plates will be suitable for run lengths up to 10,000 impressions, and these will ship commercially in Q4 2008. VIM Technologies is working on future materials with a target of 30,000 impressions.
Using inkjets to make plates is not a new idea, but until now the technological limitations have largely outweighed the benefits, so very few products have reached the market, and even those have only seen limited take-up. The main limitation has been the need for a special ink fluid in the printer, so the standard inks have to be flushed out and replaced, which generally voids the manufacturers warranty and also means the printer cannot be used for normal print.
VIMs new JT plate overcomes these limitations in both its roll-fed polyester and sheet aluminum forms. Its coating accepts standard aqueous pigment ink from a completely unmodified inkjet printer – initially the Epson Stylus Pro range with its UltraChrome inks but similar printers from other manufacturers will be supported in future. VIM is now developing plates for Canons imagePROGRAF 5100 inkjets and plans to produce materials for HP Designjets in future.
“Imaging the VIM JT Direct Inkjet Plates is both easy and completely free of hazardous processing chemicals and solvent based inks,” Mr Bieber states. “After running through the inkjet they are simply heated in a low-cost heating unit to harden the image-forming area.” The plates can then go onto the press for use with standard inks, fountain solutions and cleaning chemicals.
The Epson Stylus Pro range is also very low cost compared with any conventional laser based platesetter. The entry-level Stylus Pro 3800 (for sheets only) costs under £900 and can take plates up to A2 format. The more heavy duty 4880, which can take 17 inch rolls or A1 sheets, costs about £1,500, while the 24 inch 7880 model, suitable for B2 and A1 formats, can accept both roll-fed polyester and metal JT plates and costs around £2,400. Initially the VIM JT Direct materials will be available in formats for presses up to B2 size.
The polyester plate can be used with the standard roll-feeder fitted to all of the Stylus Pro range apart from the sheet-only 3800. The standard sheet-cutter fitted to the Epsons is also used, as this is very accurate.
The JT metal plate can be used with the straight-pass slot feeder fitted to all Stylus Pros including the entry-level 3800. VIM provides a clip-on plastic guide to support the weight of the plate as it is fed in, and this also ensures accurate feeding for registration. The plate is only printed with a single colour, while all the colours are used for the proof.
Most Stylus Pros have a maximum resolution of 2,880 x 1,440 dpi. Inkjet resolutions are different to the laser platesetter resolutions, and dot generation works best with stochastic (FM) screening rather than conventional AM regular dots, so its hard to give direct comparisons. However Mr Bieber says that a JT plate imaged on a Stylus Pro can reproduce the equivalent of a 150 lpi AM halftone screen. The printer is accurate enough to be used for close-register full-colour work, he says – FM screens are more tolerant of slight mis-register on the press in any case.
Although VIM makes no recommendation about a front end, Mr Bieber says that any low-cost Rip/workflow capable of driving the Epson should be suitable.
DP-S plate for processless, waterless operations
VIM Technologies original DP-R roll-fed polyester plate for on-press imaging is now very well established worldwide. “Sales have increased dramatically in the past year, throughout Europe, the USA, Canada, Mexico and Australasia,” says Mr Bieber.
The DP-R material was introduced in 2005 for the Heidelberg Quickmaster DI press models plus the Ryobi 3404DI and its variants sold under different names (such as KBA 46 Karat). This material has proved a very successful seller worldwide through more than 30 dealerships. Its price is more competitive while offering longer press-runs and superior printed quality.
VIMs experience with the DP-R plate has now been incorporated into the highly versatile DP-S, a waterless metal offset plate that doesnt need chemical processing and can be imaged by any standard thermal platesetter. Its compatible with a huge installed base of platesetters and is currently in Beta testing at print sites prior to commercial shipments in Q3 2008.
DP-S is producing run lengths up to 50,000 impressions in testing, and Mr Bieber says that VIM aims to extend this to 100,000 up to 150,000 impressions within the next couple of years. “Our plan is to eventually extend the run lengths to be suitable for the KBA Cortina waterless web offset press,” he says.
Waterless printing is growing in popularity as regulations in some territories increasingly prohibit the use of alcohol dampening on litho presses. Waterless printing requires less skill and constant adjustment than switching back to a high-water fountain solution.
VIM DP-S is suited for use in any waterless offset press, including the KBA Genius 52, waterless configurations of the KBA Rapida, plus the Codimag Viva 340 Waterless label press. It can also be used with direct imaging presses that use metal waterless plates, including the KBA 74 Karat, the Heidelberg GTO-DI and the Kammann DISC 1140 waterless CD printer. In addition, standard presses with temperature-controlled inking rolls can be run waterless.
VIMs DP-S takes the ecological benefits a stage further by being one of the very few companies that brings waterless plate that doesnt need chemical processing. After the plate is imaged, is it simply cleaned off by a dilute soap solution – this could be done by hand but VIM can supply low-cost automatic washing units, from which the plate emerges dry and ready for the press.
“Unlike some ablative processless plates there is no dust produced by the imaging process on the DP-S coating, so there is no danger of contaminating the optics of the platesetter,” Mr Bieber explains. “The plate requires some 40% less imaging energy than some processless materials, so the laser diode power setting can be reduced to increase its lifetime.
VIM Technologies experience of direct imaging plates has allowed the company to take address worldwide concerns about pollution and energy consumption in platemaking. By removing the need for chemical processing but using existing hardware, VIMs plate offer a tempting value proposition to printers while allowing them to keep abreast of environmental legislation. Its a real win-win product line.