Digital Flexo Evolution- Reaching New Heights The Kodak Way
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- Gwendolyn Hopkins
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1 Digital Flexo Evolution- Reaching New Heights The Kodak Way Innovative technology for flexo printing Kodak Kodak is a trademark.
2 Challenging times The flexo industry today is challenged to: Print Better, Print Smarter Deliver greater shelf impact at same or lower price Maximize press efficiency and reduce internal costs Meet critical deadlines with compressed lead times Meet demands for the highest print quality regardless of job size Deliver differentiation Reduce inventory Make the right choices for environmental impact
3 The technical challenge Common dissatisfiers with flexo today that take time and effort to overcome: Inconsistency in the process Unacceptable color matching to proof Unpredictability of results job-to-job, and run-to-run Dirty print Hard breaks Insufficient density Narrow color gamut Complex prepress Flexo must move forward to another dimension to meet the increasing demands
4 Advances in Flexo Plate Technology Analogue Plates Current Digital Plates Next Generation Digital Plates Image Film Image (Ablation) Exposure! Light Scatter Image (Ablation)! Oxygen Inhibition Laminate and Expose Remove Carrier Sheet Processing Processing Processing 4
5 Offset-like Flexo Smaller printed dot Design Offset Flexo New 5
6 Typical Flexo Plate Results and the Flexcel NX System Flexo tries to match the original image 6
7 Typical Flexo Plate Results and the Flexcel NX System Flexo tries to match the original image Without adjustment it fails, and will typically leave hard edges 7
8 Typical Flexo Plate Results and the Flexcel NX System Flexo tries to match the original image Without adjustment it fails, and will typically leave hard edges A bump curve is used to set the minimum dot size 8
9 Typical Flexo Plate Results and the Flexcel NX System Flexo tries to match the original image Without adjustment it fails, and will typically leave hard edges The Flexcel NX System eliminates the need for a bump curve Through smaller minimum dots Elimination of oxygen inhibition variable Full tonal range Stable dot structure A bump curve is used to set the minimum dot size Results: offset like reproduction of the original 9
10 The Kodak Solution? A brand new approach to digital flexo designed to address the key demands of flexo printers today: Address key limitations of flexo Improve visual impact Stabilize printing Reduce costs Reduce waste Do More With Flexo
11 The Kodak Solution? Kodak Flexcel NX System Kodak Flexcel SRX System Do More With Flexo
12 What is the Flexcel NX System? A completely new approach to digital flexo plates: A unique Kodak combination of: Superior imaging technology World class Color and Material science Innovative software solutions Produces plates that deliver outstanding on-press performance This is digital flexo but not as you know it!
13 A complete solution With the following components: Kodak Trendsetter NX Imager Kodak Tiff Front End Kodak Flexcel NX Laminator Kodak Flexcel NX Thermal Imaging Layer Kodak Flexcel NXH Flexographic Plates X-rite 361T densitometer
14 Just 5 simple steps 1. Image the Flexcel NX Thermal Imaging Layer in the Trendsetter NX Thermal Imager 2. Laminate the imaged layer to the Flexcel NXH Plate 3. Expose the back and face side of the layer and plate 4. Simple removal of the Flexcel NX Plate from the layer 5. Standard solvent processing
15 Flexcel NX System + Flexcel Digital Plate Thermal Imaging Layer Trendsetter NX Imaged TIL Flexcel NX Laminator Exposure Unit Imaged Plate (drying before printing) Processor Flexcel NX Laminator (cover layer removal) 15
16 What makes the Flexcel NX System unique? Superior ink transfer Higher ink densities Clean print Wider color gamut Greater shelf impact Photorealistic images Differentiated = $ Print Hi-res imaging technology 1:1 Reproduction Full tonal reproduction Predictable plate making & printing Greater press latitude Faster set up Simplified prepress Fewer plates = Production Efficiencies $ Flat top dots Consistent stable, robust printing Ink savings Improved sustainability Increased press availability Reduced make ready waste = Waste Reduction $
17 Start with flat top dots Why do we want flat top dots? For print stability For wide impression latitude For even ink transfer For robustness and resistance to wear For predictability For consistency Flat top dots are the foundation for stable, consistent print Flat top dots Consistent stable, robust printing
18 What s wrong with traditional digital flexo? Traditional digital flexo dots are bullet shaped due to oxygen inhibition during formation Surface is prone to wear especially in highlights Scum dots form easily Inking and printing is unpredictable How do we calibrate? Kiss impression 3 µ interference 6 µ interference =? % dot = 4% dot = 9% dot
19 The effect of oxygen inhibition Traditional digital flexo plates: presence of oxygen inhibits dot formation Flexcel NX Plates: absence of oxygen leads to strong dot formation
20 Flexcel NX System solves the problem The Flexcel NX System lamination process ensures absence of oxygen The lamination process is quick and simple Flat top dots are formed across the entire tonal range 0.4% 10% 50% 90% Ramp shoulder close-up
21 Flexcel NX System users enjoy consistent, stable, robust printing We have found that with Flexcel NX Plates we can print at higher speeds. All of our process designs have been given a wider tonal range which gives us a higher stability when printing long runs and delicate designs. Torbjorn Garthammer Scandiflex Pac AB Flat top dots Consistent stable, robust printing Our operator has been able to mount the plates, set his impression and run. We ve improved our productivity by at least 10%, if not more. Mark Gaw, General Manager - Labeltronix, LLC.
22 Now add 1:1 reproduction Why do we want 1:1 reproduction? For predictable plate making For predictable proofing For predictable printing For simplicity in prepress 1:1 image reproduction brings predictability to flexo 1:1 Reproduction Flat top dots Predictable plate making & printing Consistent stable, robust printing From the digital file to the plate
23 What s wrong with traditional digital flexo? Traditional digital flexo dots are difficult to predict due to oxygen inhibition during formation They rely on a process known as digital dot sharpening to achieve fine detail Process is uncontrolled Bump curves must be applied Proofing has to accommodate these effects Traditional Digital flexo
24 Flexcel NX System solves the problem Only the Flexcel NX System enables true 1:1 image reproduction from digital file to plate Unique Thermal Imaging Layer formulation minimizes light scatter Intimate contact ensured during exposure The Flexcel NX System lamination process ensures absence of oxygen 1% dot in TIL produces 1% dot on plate Flexcel NX System
25 Take a close look It really is true 1:1 reproduction File Bitmap Imaged TIL Flexcel NXH Plate
26 Pixel for pixel all the way
27 Flexcel NX System users enjoy predictability and consistency We experienced runs of more than 750,000m with no stops and with consistent results. Prepress is just easy: the system is so reliable that contract proofing with match the final printed results consistently. Rok Setina Compress d.o.o. 1:1 Reproduction Flat top dots Predictable plate making & printing Consistent stable, robust printing With Flexcel NX Plates, flexo printing is no longer an art, it s a predictable process. Andrew Sharp, CEO Packstar Flexible Packaging.
28 Hi-res imaging is the next step Why do we want it? For fine highlights and shadow detail For smooth transitions For FM screening For micro text Hi-res imaging combined with a stable printing process delivers outstanding print quality in every day production Hi-res imaging technology 1:1 Reproduction Flat top dots Full tonal reproduction Predictable plate making & printing Consistent stable, robust printing
29 What s wrong with traditional digital flexo? Traditional digital flexo ctp imagers create a round Gaussian laser profile With fiber lasers the energy tapers off towards the outer diameter High power in middle Low power at edges Results in a Gaussian (soft / fuzzy) profile Leads to variability in mask imaging Round beam trying to match a square pixel Beam has to be larger than the pixel to overlap for full coverage Increasing resolution does not overcome these fundamental limitations
30 Flexcel NX System solves the problem The Trendsetter NX uses Kodak SQUAREspot Imaging Technology The pixels start in the digital files as squares 1:1 reproduction with even energy distribution maximizes consistency, eliminating conversion errors 2,400 dpi resolution Effective 10,000 dpi resolution 10.4 micron dots and micro lines become a reality 2,400 dpi 10,000 dpi (4x4)
31 Comparing pixel accuracy
32 Flexcel NX System users enjoy great image quality, predictability and consistency There s nothing else out there that can come close. In a highly competitive market, the Flexcel NX System gives us a quality advantage that separates us from our competition. Tristan Zafra, Owner - Trisoft Graphics, Inc. Hi-res imaging technology 1:1 Reproduction Flat top dots Full tonal reproduction Predictable plate making & printing Consistent stable, robust printing The Flexcel NX Plate holds a better dot, especially on process plates. It gives you more vibrant colors, and a deeper image. Our existing customers see a world of difference already. Rhonda Baker-Capps, VP - Labels, Tags and Inserts, Inc
33 And finally, superior ink transfer Why do we want it? Visually appealing solids Higher densities Increased color gamut Effective ink transfer has a tremendous impact on both visual appearance and print production efficiency Superior ink transfer Hi-res imaging technology 1:1 Reproduction Flat top dots Higher ink densities Full tonal reproduction Predictable plate making & printing Consistent stable, robust printing
34 What s wrong with traditional digital flexo? Efficient ink transfer is always an issue, especially with solvent inks on flexible substrates Double hits are often required to get required opacity Poor ink transfer throughout tonal scale contributes to reduced color gamut Voids in printed solids reduce the visual impact Traditional Digital Flexo Black
35 Flexcel NX System solves the problem Flexcel NX System applies Kodak DigiCap NX Screening to dramatically improve the efficiency of ink transfer Gravure like print quality Extra solid density, with less ink Smoother ink laydown Increased color gamut, more 4-color process Kodak DigiCap NX is unique to the Flexcel NX System Waiting for image from John A
36 Real prints show the power of Kodak DigiCap NX Screening Traditional Digital Flexo Flexcel NX with Kodak DigiCap NX Screening applied Traditional Digital Flexo with traditional plate cell patterning applied Flexcel NX with Kodak DigiCap NX Screening applied
37 Flexcel NX System users can have it all Due to the advantages of the Flexcel NX Technology, Corniche is now moving into new market segments, driving business into retail, marketing and brand awareness. Dave Ettie Corniche Fine Arts Ltd.. Superior ink transfer Hi-res imaging technology 1:1 Reproduction Flat top dots Higher ink densities Full tonal reproduction Predictable plate making & printing Consistent stable, robust printing We at Primopost feel that the Flexcel NX System offers us the opportunity to match gravure quality contributing to our ability to offer innovative and cost effective packaging solutions. Barry Bearman Primopost Ltd
38 The Flexcel NX System addresses ALL the key issues Superior ink transfer Higher ink densities Clean print Wider color gamut Greater shelf impact Photorealistic images Differentiated = $ Print Hi-res imaging technology 1:1 Reproduction Full tonal reproduction Predictable plate making & printing Greater press latitude Faster set up Simplified prepress Fewer plates = Production Efficiencies $ Flat top dots Consistent stable, robust printing Ink savings Improved sustainability Increased press availability Reduced make ready waste = Waste Reduction $
39 The Flexcel NX System Offers outstanding flexibility An enabler for Kodak Flexcel SRX System Introducing Kodak Flexcel SRX System System Overview
40 What is the Flexcel SRX System? A completely new approach to : Migrate Customers from Analog Flexo to Digital Flexo A real alternative to traditional Digital Flexo A unique Kodak combination of: Superior imaging technology World class Color and Material science Produces plates that deliver outstanding on-press performance This is a BIG Step towards digital flexo!
41 What is the Flexcel SRX System? The Flexcel SRX System is designed to provide: A real alternative to Traditional Digital Flexo (LAMS) Migration path from Analog to Digital Flexo World An entry point to Kodak Digital Flat Top Dot Technology incorporating SQUARESpot Imaging The Flexcel SRX System offers: Step up from digital flexo (LAMS) providing Excellent tonal reproduction print stability that is superior to LAMS. The Flexcel SRX System is an excellent companion to the Flexcel NX System, our flagship offering, that offers the highest levels of print performance and the very finest image reproduction
42 A complete solution With the following components: Kodak Trendsetter NX Imager Kodak Tiff Front End Universal Debris Removal Cabinet Kodak DITR 4401 Matte Film Kodak Flexcel SR Flexoraphic Plate
43 Just 5 simple steps 1. Image the DITR4401 Matte Film the Trendsetter NX Thermal Imager 2. Back expose Flexcel SR Plate 3. Face expose With Imaged DITR4401 positioned in vacuum frame 4. Process, Dry and Finish the Plate 5. Post - expose
44 Kodak SRX Image Quality DITR4401 Matte Film: Consistent and repeatable it s digital Similar to hard dot film in quality High-contrast, sharp image reproduction Excellent resolution 200 lpi maximum (AM) on Trendsetter NX and Trendsetter Spectrum Imagers 175 lpi maximum (AM) on ThermoFlex Platesetters Kodak DITR 4401 Film mask (175 lpi) 44
45 Flat Top Dots are a Reality Due to the absence of oxygen plate exposure to Kodak DITR 4401 Film (under vacuum), Kodak SR Plates feature Kodak s renown flat top dot technology Consistent, stable, robust printing Plates resist wear from substrate and cleaning Creates dots that are repeatable despite changes in impression Simple transition in on-press performance versus conventional plates Flat top dots Consistent stable, robust printing
46 One-to-One Imaging from File to Film Due to unique Kodak DITR 4401 Film and SQUAREspot Imaging Technology, and the exposure process of the film to the plate, the image on the file is directly transferred to film Kodak DITR 4401 Film is developed to reduce light scatter so only intended dots end up on the film and the plate Precise SQUAREspot Imaging Technology laser ensures faithful reproduction to the film This 1:1 reproduction enables a true reproduction of the intended image More predictable dots = more predictable plate making, proofing and printing 1:1 Reproduction Flat top dots Predictable plate making & printing Consistent stable, robust printing From the digital file to the film
47 Superior and Stable Dot vs LAMS
48 Superior and Open Shadow Dot vs LAMS
49 Superior Text vs LAMS
50 Both Digital Files Started With Square Pixels 2% Digital LAMS vs 1.2% Flexcel SRX
51 Both Digital Files Started With Square Pixels 40% Digital LAMS vs 20% Flexcel SRX
52 Both Digital Files Started With Square Pixels 97% Digital LAMS vs 97% Flexcel SRX
53 Positive Text and Negative Text With Flexcel SRX
54 Achieve better printing today Differentiated Print Increase line screens (up to 300 lpi AM) Print fine detail Achieve clean tones and vibrant colors Implement stochastic (FM) screening in regular production Deliver print with greater visual impact Same print conditions: Higher densities Cleaner tones Finer detail Greater contrast
55 Explore new opportunities tomorrow Differentiated Print Match offset and gravure class quality Enjoy a consistent color match across substrates Explore microtext capabilities for brand security applications Consider lenticular effects for eyecatching packaging Discover new applications for flexo Do more with process color printing Make co-printed designs a reality Open the door for gravure class quality Optimize the press Print up to 175 lpi in regular production Give brand owners greater design freedom
56 Take a close look at costs Category Current costs as % of gross sales Annual cost based on $10M sales revenue Administration 9.0% $900,000 Sales 4.0% $400,000 CSR, ESTIM 4.0% $400,000 Prepress Labor 2.0% $200,000 Prepress Materials 1.5% $150,000 Outside Prep Costs 0.1% $10,000 Press Makeready 13.0% $1,300,000 Press Run Time 29.0% $2,900,000 Press Run Paper/Ink 29.0% $2,900,000 Other Outside 1.0% $100,000 Bindery 2.5% $250,000 Interest Expense 2.0% $200,000 Profit 2.9% $290,000 Prepress vs Press where does it make sense to focus? Production Efficiencies What would a 10% reduction in makeready time mean to your operation? If you could run your presses faster, would you bill more jobs? How could a 20% reduction in substrate waste impact your bottom line? Would a reduction in ink purchases make you more competitive?
57 Savings in your pocket today Production Efficiencies Save time and money with plates that last longer Customers are consistently reporting 2x to 5x longer Huge savings in plates and downtime for plate changeovers Re-use plates again and again Save time and money with plates that come to color faster 20% ink and substrate make ready savings on average Improve turnaround time and profitability for short runs
58 Greater efficiencies tomorrow Production Efficiencies Gain billable hours with plates that run faster Print stability can allow press to run 10-20% faster Do more with process color printing Fewer special inks, fewer plates, faster set up Unprecedented flexibility Simplify pre-press Predictable platemaking Offset based separations
59 A true cost saving environmental impact Waste Reduction While others debate solvent vs. thermal for plate processing Kodak asks the big picture question: How can your flexo plate choice have the maximum impact on your overall sustainability goals? The Flexcel NX System delivers maximum impact on sustainability by: Reducing the total number of plates made Reducing printing substrate waste on press Delivering a positive impact to your bottom line: Time and money savings And with no compromises: Unparalleled image quality Outstanding performance and durability I do find that the Kodak Flexcel NX Plates allow us to reduce our carbon footprint by the simple fact that we make less plates now. Mike Isaacs, Prepress Manager - Packstar Flexible Packaging
60 The industry has recognized the Flexcel NX System Awarded the Must See 'ems! Award at Graph Expo 2008 The sole recipient of the Flexographic Technical Association's 2009 Technical Innovation Award Awarded the 2008 Technical Innovator of the Year Award by the Flexographic Pre-Press Platemakers Association Awarded the prestigious PIA/GATF InterTech Technology Award in 2008 It s time to discover what it can do for YOU
61 A full portfolio of solutions Flexcel Direct System Flexcel NX System Flexcel SRX System Simple, affordable in-the-round platemaking for high quality flexo printing Simply the best solution in the industry for flexo printing with elastomers Exceptional process stability and outstanding print quality Simply the best solution in the industry for flexo printing with photopolymers High quality, versatile solution for a wide range of applications All the benefits of a digital workflow with well loved print performance With every flexographic solution you choose from Kodak: Complete Solutions with Imager, Media and Workflow designed to work together Superior Kodak imaging technology for excellent reproduction embedded in every solution All the print performance benefits of flat top dots no matter which solution you choose Excellent Ink transfer Print longevity Time and cost savings in set up Consistency and predictability in platemaking eliminating the traditional variables
62 Kodak Kodak is a trademark. Do More With Flexo
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