DuPont Cyrel Solutions has a long history of developing products for the package printing and converting industry.
Many, in fact, have been recognized as innovative and are frequently credited with proving to be great contributors to the evolution of flexographic printing. Specifically:
- DuPont Cyrel Solutions was awarded an FTA Technical Innovation Award back in 1998 for the DuPont Cyrel Digital Imaging System (CDI)
- Later, in 2003, DuPont’s Cyrel FAST Thermal Plate Making system captured FTA’s prestigious award
- Proudly, this year, the company was again honored for the launch of Cyrel Lightning plates (See separate story, page 20)
Imaging System
CDI plate making systems—composed of the imager and the set of digital plates (Cyrel DPS, soft plates and Cyrel DPH, hard plates)—were officially launched during drupa 1995. Developed by a large team of scientists and external partners, like Baasel Scheel Lasergraphics for the imager, the goal was to build a new imaging system in flexography that would use the laser to image the plate.
Photo courtesy of DuPont Cyrel Solutions
Given the increased adoption of laser technology at that time, this proved an innovative addition to the plate making process when compared to film-based solutions. As such, it brought the flexographic industry to a different level. The evidence: When the team saw the 4-color printed sample developed for the marketing collateral of the product launch, they witnessed for the first time the highlights fade to zero and knew this technology would make a huge change in flexographic printing quality.
From its launch, the CDI was lauded. It received a 1998 FTA Technical Innovation Award and also the Graphics Arts Technical Foundation (GATF) Award in 1997. Since then, other digital plates have been developed by DuPont with different features, each specifically addressing the different needs of flexible packaging, labels, corrugated or paper packaging applications. Later the digital plates opened the opportunity to create new platforms, like the EASY platform, with the flat top dot built into the plate, and the Lightning platform—flexographic plates optimized for LED exposures.
CDI plate processing revolutionized flexographic printing at that time. Digital plates have become a mainstay in flexographic printing. Trade shops and printers, and converters alike, achieve higher resolution, image special highlights, deploy solid screening and operate more cost effectively.
Thermal & Fast
The next awarded innovation was Cyrel FAST. Launched in 2000, it was the world’s first solvent-free thermal plate processing system, proving truly groundbreaking. Cyrel FAST was a dry thermal system. It was a cleaner and safer way to make plates—once the use of solvents in the plate making process was eliminated, it made the environment safer for operators.
“Digital plates have become a mainstay in flexographic printing. Trade shops and printers, and converters alike, achieve higher resolution, image special highlights, deploy solid screening and operate more cost effectively.”
Throughput, as measured by plates per hour, is imperative in any plate making organization, but in 24/7 operations, high throughput turns critical. Without downtime to catch up, plate making can quickly become the bottleneck in production. DuPont’s Cyrel thermal processor was named FAST because of how quickly it can provide the first plate. Operators can save up to 120 minutes as plates don’t need the drying time, thereby bettering the number of plates processed per shift. One of the reasons these machines operate faster, and more reliably—especially under demanding environments—is their ability to manage heat.
In 2003, the first generation of Cyrel FAST, the FAST 1000 TD, received an FTA Technical Innovation Award, recognizing its impact on the flexographic industry. Since then, more investment and newer developments came, elevating the quality of the thermal plate making system:
- A few years later, the Cyrel FAST TD 4260s launched, allowing plate makers to process plates up to 42-in. x 60-in. format, which has become the main offering across Cyrel FAST processing
- In 2008, DuPont introduced Cyrel FAST Round, being the first solvent-free thermal sleeve processing system
- Later, in 2014, Cyrel FAST 3000 launched, giving the plate maker the ability to work with larger plate formats
- And in 2016, the latest version of the thermal processing system was launched: Cyrel FAST 2000 TD
Sustainability Minded
Plate makers are always seeking sustainable approaches to packaging printing and equipment. FAST thermal processors achieve it with a catalytic oxidizer (CatOx). Less than 0.3 percent volatile organic componds (VOCs) are released through the exhaust during plate production. And by eliminating the solvent and dryer, electrical demands fall and customers free up space in their plateroom.
When the first generation of Cyrel FAST processors was launched 20 years ago, they did not include a CatOx, as systems do now. Most of the heat generated from this catalytic reaction is recovered and used to preheat the incoming exhaust, significantly reducing the electrical heating demand. The latest-generation systems—the FAST 2000 TD—show a 99.7 percent elimination of VOCs in the exhaust—more than 75 percent cleaner than thermal processors without a CatOx system.
DuPont is the only company that has produced systems both with and without catalytic oxidizers, so it can scientifically measure the exhaust composition for both systems in its labs. Having cleaner exhaust matters, since the packaging is facing increased sustainability requirements from both government environmental regulations and consumer packaged goods (CPG) customers.
Results based on data collected by DuPont show during continual plate making, the cost of electricity using the CatOx is less than $1 per eight-hour shift. That is a small cost to reduce VOCs by an additional 75 percent over non-CatOx equipped thermal systems. And that ultra-clean operation is something sustainability-focused CPGs are looking for in a printer/converter partner and trade shop.
Value Proposition
The value of a thermal processor includes its output quality, throughput per shift/day, consistent performance, considerable contribution to uptime; and, of course, its sustainability score.
DuPont Cyrel FAST thermal processors exhibit superior reliability, seen through the large installed base globally—now, more than 1,500—and this number continues to grow each year. The systems are not only clean and reliable; they also produce award-winning plates. Packages printed with the DuPont systems have won many FTA Excellence in Flexography Awards for more than 20 years.