Packaging

Printers Discover How to Improve Their Flexo Packaging at Kodak Event

Friday 19. November 2010 - Event staged at Reproservice Eurodigital (Munich) focuses on the power of the Kodak Flexcel NX Digital Flexographic System

More than 40 representatives from the packaging printing industry discovered how to improve their flexo packaging output at a special event hosted by Kodak. Under the theme ‘More quality in flexo packaging printing’, Kodak experts explained to attendees how they can raise the quality of their flexo packaging products using the Kodak Flexcel NX Digital Flexographic System. The event was staged at Reproservice Eurodigital GmbH in Munich on 27 October 2010.

Reproservice Eurodigital – a Matthews International company – has been using the Flexcel NX System for approximately 18 months. The trade shop specializes in producing digital flexo plates, mostly for high-quality UV flexo printing on plastic film, aluminum and other substrates.

Why Reproservice Eurodigital turned to the Flexcel NX System

Reproservice Eurodigital invested in the Flexcel NX System after taking on a project for Gallus, the press manufacturer, which launched its ICS 670 model for folding cartons as an alternative to offset that can also be equipped with flexo modules. The KODAK FLEXCEL NX Digital Flexographic Plates marked an important quality breakthrough.

Flexcel NX Plates offer a wider tonal range than their conventional digital counterparts, as well as brighter highlights without the ‘flexo break’ effect. They can also be used to print higher densities with finer and more stable gradients. These important characteristics ensure the KODAK System meets the stringent quality demands of Reproservice Eurodigital’s customers. Following the implementation, the company has migrated 30% of its flexo plate production to the FLEXCEL NX System – and with the solution’s high process stability, this figure is set to rise.

Flexcel NX System and folding carton packaging – an exciting combination

Stefan Hagn of packaging printing press manufacturer Gallus Stanz- und Druckmaschinen GmbH in Weiden (Bavaria) confirmed the print quality delivered by Flexcel NX Plates. He noted that it is possible to reproduce a tonal range from 2% to 98% when printing folding cartons in 175lpi, along with very high solid ink densities because of the excellent delivery of ink to paper. The plates have proved extremely resistant and screen plugging is no longer a problem, regardless of the run length, which means cleaning is required far less often. These advantages have convinced even the most experienced offset and gravure users at a series of printing demonstrations staged at Gallus’ premises.

The quality enhancements afforded by the Flexcel NX Plates have prompted Reproservice Eurodigital to consider reducing the number of colors it uses. For example, if only six colors are needed instead of the current eight, the company can reduce its platesetting and printing costs.

Reproservice Eurodigital has also received suggestions from end users for optimizing the Flexcel NX System. At the event Dieter Weinle, Segment Manager Packaging Industries, Kodak, confirmed that Kodak will respond to end-user feedback accordingly. For example, in January 2011, Kodak will answer the call for a larger format with a Flexcel NX System that caters for this need.

The details that make all the difference

Weinle offered a fascinating insight to the key elements of the platesetting process that have spurred the Flexcel NX System’s huge leap in quality. The process kicks off with high-resolution imaging of the KODAK FLEXCEL NX Thermal Imaging Layer. This results in a negative mask, which is laminated onto the Flexcel NX Plate in the Kodak Flexcel NX Laminator, so that the sharp-edged mask image is in direct contact with the photopolymer coating. In addition to improving process reproducibility, the laminated Thermal Imaging Layer prevents contact between the plate surface and the ambient air, ensuring oxygen inhibition and its undesirable side-effects are ruled out. All subsequent steps with UV exposure etc are the same as when photopolymer flexo plates are processed in the conventional way.

The advantages of making Flexcel NX Plates using this technique were illustrated by Weinle via photomicrographs and graphical visualizations. He showed how even 0.4% highlights with flat, sharp top dots appear on the plate without a round shoulder profile, while the dots have sturdy bases. In contrast to LAMS plates, which have a distinct shoulder and less sturdy dots, FLEXCEL NX plates retain their stability at higher printing pressures and do not suffer from excessive dot gain.

Weinle explained that another key component that has improved the print quality of the Flexcel NX System is that it exploits the ultra-high resolution of Kodak SQUAREspot Imaging Technology for micro-fine KODAK DigiCap NX Screening. DigiCap NX Screening lends all image areas a uniform microstructure, which effectively enlarges the surface of the flexographic printing plates. The result is improved ink transfer, enabling flat fields and line art such as barcodes to be printed with higher densities. The superior solid ink density means a second black or white can often be dispensed. DigiCap NX Screening also offers benefits in screen areas, as good densities can be realized without excessive dot gain.

Packaging examples prove the point

The impact of these refinements on the final print result was demonstrated to attendees via numerous samples of flexible packaging materials, labels, cup lids and folding cartons.

Kodak rounded off the event by outlining the benefits of its workflow, proofing and color management solutions for packaging production. Andreas Gruber, Sales Manager DACH, Kodak Inkjet & Color Solutions, aroused keen interest with his description of the new Kodak Proofing Software Version 5.0, which is now offered in three editions. The software’s Packaging Edition can be used with two fundamentally different proofing technologies: the Kodak Matchprint Inkjet Proofing System, which supports the complete EPSON Stylus Pro printer range (including the WT7900); and the Kodak Approval NX Digital Color Imaging System, which works with true screening.

Reproservice Eurodigital has been using the Approval System for some time to make contract proofs with excellent color and screening predictability on original substrates.