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Corrugated Post-print:
Conventional or Digital?
Dan Rosen
Accounts Manager
BASF Printing Systems
BASF
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A Frequently Asked Question:
With CTP growing rapidly in other flexo markets, are there any benefits to using CTP in Corrugated Post-print?
• Does it improve workflow?
• Does it make better plates?
• Does it yield better print capability?
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Installation of Laser Systems - World wide
Indeed, CTP Is Growing Rapidly
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Do The Benefits Of CTPApply To Corrugated?
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Some Qualifying Comments
• This is a real world discussion:– B flute, not E flute or micro flute boards– Kraft and mottle white, not “high holdout” specialty
liners– Average presses with standard aniloxes– Thicker plates (.155”), not ultra-thin with foam– Line Screens in the range of 42, 65 and 85 LPI
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Just One Commercial…
BASF
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10° 20° 30° 40° 50° 60° 70° Shore A0°
32°
42°
58
62°
Hardness
°
Yes, We Have The Digital Plates!
ACE DII
FAH DII
ART DII
FAC DII
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End Of Commercial.
BASF
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CTP Handling
• Today's laser imagers are well suited for thicker photopolymers (.125” - .250”)
• RPMs are now lower, high throughput• Plate loading & gripper bars are
improved• Vacuum assist is very effective• Ergonomic designs allow for single
operator loading of very large plates
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Let’s Look At A Few Aspects:
• The standard points about film elimination
• Pre-flight workflow, Mounting
• Imaging / Printing – “where the rubber hits the road”
• Summary
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Let’s Look At A Few Aspects:
• The standard points about film elimination
• Pre-flight workflow, Mounting
• Imaging / Printing – “where the rubber hits the road”
• Summary
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Film Elimination With CTP
• No films to file or strip
• No dings, dust, or film quality issues
• Set-up of plate exposing is simple
A big plus, since most platemaking for corrugated involves large films that are difficult to handle.
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Image Layout
• Some strong advantages to using digital layout – compared to traditional film stripping
• Some aspects of digital layout can be done with film image setters today
• Other aspects, such as last minute image changes, plus pre-mounting techniques are better suited for CTP
The Following Three Slides Are Courtesy of Esko Graphics
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• Post-mounting support for corrugated workflow– Automatic reduction of full-format jobs with scattered
images - into patches, saving polymer– Automatic generation of cut marks – for higher/easier
accuracy– Parameter file sent to cutting & post-mounting video
devices– Decreases post-mounting time
PlatePatcher Software For Post-mounted Jobs
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• Time savings opportunity:– Allows for accurate post mounting using
coordinates from the graphics file… less guessing
• Workflow description:
– Job File PlatePatcher Datafile (plate cutting) CAD CAM table Datafile (positioning) Post Mounting Device
Video / Electronic Mounting Device
PlatePatcher Software For Post-mounted Jobs
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Productivity In Pre-Mounting Images Before Platemaking
• Unimaged polymer pieces pre-mounted on the carrier sheet using templates generated by the job file
– NO “image” mounting, ONLY blank pieces– Laser imaging time managed by “Superskip” software– Image placement on the mount is digital-perfect– Normal plate processing on the carrier, die sealer added
afterward– Best on large mounts
* Used at Rudolf, Schawrtz and Tiesen
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The Print Test…
BASF
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Team Involved
• BASF Printing Systems: Plates, Data, & Reporting
• Fox Valley Technical: Printing• Schawk Chicago: File Prep., Platemaking,
Mounting, & Data
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Materials & Conditions
• BASF’s nyloflex FAC Conventional & Digital• Imaged on Esko 5080 Power Beam• Mounted on 30 pt. Carrier with 2 mils tape and
underpacked with 90 mils foam• Printed on FVTC Workhorse Industries 3-color press
with a Harper 400 line, 3.8 bcm anilox roll• Menasha Corp. KLA white & Kraft b-flute substrate• INX Brite II Process Black ink @ 9.7 ph and 24s with
#4 DIN• Speed was 50 sheets / minute• Ran @ equal SIDs and Impression levels
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Image Target Designed
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Image Target Designed
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Keeping Things Fair…
BASF
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Scattering area Scattering area
Vacuum film
Film baseSilver emulsionRelease layer
Relief layer
Conventional plate
Light (UV) Light (UV)
Black mask
Relief layer
Digital plate
Light Scattering
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Dot Reduction From O2
ablation
Polymer
Black mask
UV Light
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Dot Reduction From O2
Ø conventional
Ø digital O2
O2
O2 O2
O2
O2
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Dot Reduction From O2
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We Worked To Make All Dots Physically Equal On The Plates
File Film
PlatePlate
=
=
==
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In Other Words, A 10% Dot Is The Size Of A 10% Dot
MaskFile Plate
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Measured Dot Physical Surface Diameters On Plates
65 LPI Physical Dots
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% Size
% S
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Conventional
Digital
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The Print Results…
BASF
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Solid Ink Density Comparison
Solid Ink Density
1.12
1.14
1.16
1.18
1.2
1.22
1.24
KraftConventional
Kraft Digital WhiteConventional
White Digital
Den
sity
Val
ue
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Side By Side Comparisons
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Side By Side Comparisons
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Side By Side Comparisons
Digital Conventional
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Side By Side Comparisons
DigitalConventional
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Dot Gain: 42 LPI White42 LPI Mottle White
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2 5 10 20 30 40 50 60 70 80 90 92 94 96 98
% On File
% P
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Digital
File
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Dot Gain: 65 LPI White65 LPI Mottle White
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2 5 10 20 30 40 50 60 70 80 90 92 94 96 98
% On File
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Dot Gain: 85 LPI White85 LPI Mottle White
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2 5 10 20 30 40 50 60 70 80 90 92 94 96 98
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Dot Gain: 42 LPI Kraft42 LPI Kraft
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2 5 10 20 30 40 50 60 70 80 90 92 94 96 98
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File
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Dot Gain: 65 LPI Kraft65 LPI Kraft
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2 5 10 20 30 40 50 60 70 80 90 92 94 96 98
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Digital
File
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Dot Gain: 85 LPI Kraft85 LPI Kraft
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2 5 10 20 30 40 50 60 70 80 90 92 94 96 98
% On File
% P
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Digital
File
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Side By Side Comparisons
Digital Conventional
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Summary of Advantages
• Filmless Output, Layout And Imaging• Possibilities For Imposition Digital Mounting• Ability To Hold Finer
– Highlights– Shadows– Fine Type & Reverses
• Less Dot Gain on 85, 65, even 42 LPI White• Marginal Print Improvement on Kraft
This was one test. Many more should be done!