MIAMISBURG, OH—What if your flexo plates could anticipate issues before they happened? What if solids optimized ink laydown on their own? What if imaging quality was perfected through thousands of AI-calculated variations before a plate ever reached the press? 

That future is closer than many realize. Esko researchers have  leveraged AI to calculate imaging variations that contribute directly to  exceptional quality. 

And as AI becomes more deeply embedded across the Esko ecosystem, CDI Quartz is emerging not only as a breakthrough hardware platform, but as the foundation for the next intelligent era of flexographic print. 

Benchmark in Plate Making
Before exploring AI’s impact, it’s worth grounding ourselves in what CDI Quartz already delivers: 

• 4,000 ppi imaging resolution–nearly double the current industry standard 
• 2,000 lpi Q-Cells microstructures–improving ink transfer, density and solid-area smoothness 
• Sharper details and smoother gradients through advanced optics and surface structuring 
• Gravure-level print quality, achievable through flexo 
• Sustainability gains through compatibility with water-based inks, PU inks, lower-volume anilox rolls, and fully recyclable substrates (mono-foils and PCR–post-consumer-recycled materials
• Reduced setup time and waste, leading to more consistent production and lower costs 

As Pascal Thomas, director of flexo product management, notes: “Imaging at 4000 ppi is nearly double the current industry standard, and microcells engraved in the solid ink areas at a 2000 lpi resolution are proven to significantly boost ink transfer, delivering a way for print converters to match gravure print quality in flexography.” 

Quartz has already set a new standard. And now, AI is expanding what that standard can become. Here’s how. 

AI-Enhanced Research
One of the most significant–and least visible–advancements behind Quartz is the role of artificial intelligence in the development of  imaging performance. 

Esko’s research team has successfully used AI to: 

• Calculate and compare thousands of imaging variations 
• Identify the optimal combinations of exposure behavior, optical parameters and structural geometry 
• Refine microstructures (like Q-Cells) for better ink transfer, smoother solids and improved highlight detail 
• Accelerate development cycles with data-driven experimentation, rather than manual testing 

This means that Quartz’s high imaging quality is  the result of precision hardware–it’s the result of AI-guided optimization behind the scenes.

This delivers a powerful new message: AI-assisted scientific research is supporting performance improvements that traditionally require significantly longer development cycles. 

Where AI is Headed
While AI has already contributed to the quality Quartz now delivers, the next phase is about bringing AI closer to the operational workflow.

AI will increasingly support: 

1. Automated Plate-Quality Prediction–Models trained on Quartz imaging data could identify plate inconsistencies before they reach press
2. Adaptive Screening Recommendations–AI could dynamically select optimal Q-Cell patterns based on artwork, substrate or anilox combinations
3. Smarter Laydown–Data from previous jobs can guide operators toward the lowest-ink, highest-stability configuration 
4. Predictive Maintenance–AI will help detect optical drift, LED degradation or exposure inconsistencies early
5. Closed-loop Ecosystem–Press-side quality data feeds back into imaging recommendations, enabling self-optimizing print production 

Converters & Brands Benefit 
AI + Quartz strengthens the benefits converters experience : 

• More predictable plate-to-print performance
• Improved solids, smoother gradients and stronger density 
• Lower waste and reduced make-ready time 
• More confidence with water-based ink workflows
• Consistent brand color accuracy across runs
• Higher operator efficiency
• Fewer surprises on press

AI should likely amplify Quartz technology, moving flexo into an intelligent future. It already raises the bar for flexographic print quality and efficiency. And thanks to AI-supported research, its imaging quality is stronger, smarter and more optimized than ever. 

As Esko continues expanding AI across the S2 platform, the Quartz ecosystem is positioned to evolve into a next-generation, intelligent flexo technology stack. It’s seen as a system that learns, improves and ultimately helps converters print better–from the very first pull. 

About the Author: Alexandra Blanck is a member of the Esko corporate marketing team. She is known for her dedication to crafting engaging content that resonates with global audiences.

As a content manager, she brings strong editorial perspective and strategic insight to Esko communication. Her passion is turning complex topics into compelling narratives.

Blanck is known for her creativity and story-telling expertise. Hervdiverse writing portfolio spans lifestyle features, fiction and poetry.