FTA's Fall Conference 2022, by the Numbers - Flexographic Technical Association

FTA’s Fall Conference 2022, themed “The Future Is Here,” and chaired by PJ Fronczkiewicz of DuPont Cyrel Solutions, drew 330+ active, engaged flexographers determined to examine color workflows and evaluate print samples. At the same time, all stood ever ready to network in hopes of identifying new solutions offered by 61 exhibiting firms inside INFOFLEX at Fall Conference. The event lived up to its billing as potential breakthroughs in prepress technologies, likely to gain a foothold in flexography, were revealed.

Fall Conference 2022 Recap Fall Conference Photoes-5 — The print project at the center of Fall Conference 2022

Interaction was everywhere. Attendees did not refrain from expressing opinions, and polls conducted on site measured the industry’s current stance and potential future position.

Targeting Control

What Color Control Target Do You Utilize?

As alluded to in Steve Smiley’s recap of the major print process that served as the heart of the program, tone value printer control targets are being used by 76 percent of audience members surveyed. Near Neutral Calibration is deployed by 13 percent and a combination of Tone Value and Spot Color Tone Value is utilized by 3 percent. Twenty-one percent rely exclusively on visual perception/interpretation.

What Color Calibration Do You Utilize?

When it came to color calibration, 41 percent used TVI, 24 percent, NNC; 22 percent, ICC and 2 percent, SCTV. Eleven percent could not answer the question.

When pressed on future directions, only 4 percent voiced a preference for status quo operations. The vast majority, 96 percent, said, “flexographic printers should start using SCTV for process control.”

Optimizing Presses

What Proofing System Will You Use in Five Years?

Also looking to the future, Fall Conference attendees spelled out expectations for where proofs will come from—five years down the road. Nearly 4 percent opted for the PDF choice and a matching 4 percent said “accurate soft proof.” Inkjet was favored by 3 percent and non-color soft proof by 2.5 percent. Visual modeling—3D—was cited by just under 2 percent.

Who/What Is Most Responsible for File Problems?

In other revelations, problems with files were most often experienced with those furnished by the designer, according to 69 percent of those polled. Twenty percent cited the trade shop and 11 percent the brand owner.

Sixty percent of audience member respondents indicated they optimize their plate making system components when problems arise; 23 percent responded that it’s done whenever a new batch of plates is open. Similarly, 11 percent do it on a daily basis, 3 percent, weekly; and 3 percent monthly.

How Much Does Plate Mounting Affect Press Downtime?

By and large plate mounting activities were seen as having minimal to intermediate impact on press downtime. Forty-six percent of poll takers described it as minimal; a matching 46 percent determined it to be intermediate and just 8 percent decreed it to have heavy impact. Of the minimalists, 4 percent voted “almost none.”

Metering Mishaps

When it came to inspecting anilox rolls, the majority—60 percent—of poll takers cited six-to-12-month timelines as sufficient. Twenty-seven percent do it monthly, at minimum, while 7 percent prefer an every few years assessment. A similar 7 percent never think to perform an anilox review.

Anilox rolls led in the poll of metering system components most likely to cause press downtime, coming in at 4.4 percent of mentions. Following right behind at 3.9 percent was doctor blade materials, with ink dams at 3.3 percent and faulty ink pumps at approximately 2.5 percent. Backing blade materials came in at 2.2 percent.

Fall Conference 2022 Recap Fall Conference Photoes-49 — FTA President Robb Frimming (left) with Fall Conference 2022 Program Chair PJ Fronczkiewicz of DuPont Cyrel Solutions

When it came to controlling ink press side, the audience indicated that the biggest issue is pH viscosity becoming unstable, mentioned by 76 percent. Just behind at 71 percent was managing color consistently. Ink drying too fast or too slow drew the ire of 65 percent of respondents. Curing issues plagued 29 percent of those sampled. Foaming and spitting were mentioned by 18 percent respectively.

Automation Minded

Looking to the press itself, 100 percent of people polled indicated that automation was critical. On a scale of one to five, 71 percent assigned it the highest grade; 29 percent the second highest. Queried as to what recent innovations in the modern pressroom have been most beneficial, 47 percent selected print fault detection systems and an identical 47 percent opted for inline color measurement. The remaining 6 percent chose ink temperature controls.

Still, problems persist. Of those most often mentioned by Fall Conference goers, bounce and waste shared top billing at the press, coming in with 4.3 percent of mentions. Registration also remained paramount; it was followed by speed and tension control.

Initial Feedback

Attendees who took the time to complete reviews of each session liked what they saw and heard. Many expressed a desire to learn more and promised to follow up on what they learned.

Among the compliments: “Very informative.” “Presenters were great. Printer comments stood out. CMS was simplified. Chuck and Bill (the developers of The Optimal Method) taught me.”

In fact, FTA’s Director of Education Joe Tuccitto commented on Chuck and Bill’s presentation in signature fashion. “For a color-themed conference, that’s like having Mick Jagger and Keith Richards on stage.”

Fall Conference 2022 Recap Fall Conference Photoes — The Anderson & Vreeland team, with FTA Director of Education Joe Tuccitto (third from left), during INFOFLEX at Fall Conference

Also noted: “Very technical!” “Great need for more PDF workflow!” “Both morning sessions—Prepress Problems, Remedies and Results and Pressroom Problems, Remedies and Results—were highly complementary.”

And, on the opening session—Welcome to the Future—that laid down the central theme of the three days, the assessments were both complimentary and straightforward. “Great information. Love the data, would like more!” “Great presentation!” “Very engaging!”

INFOFLEX at Fall Conference attracted a sell-out contingent of 61 exhibitors representing most major segments of the package printing and converting community—everything from labels and flexible packaging to corrugated board, folding carton, envelope, and digital and specialty print. Converting and finishing equipment had a strong presence, and premedia service providers and plate processors, materials and cleaners were widely seen.

Nearly 25 percent of exhibitors fell into the plate, processor and cleaner category; a near-matching 25 percent made anilox rolls and doctor blades. Some 21 percent were press manufacturers. Just fewer than 10 percent specialized in automated workflow software and process control instruments/devices. Networking time stretched across some nine hours with the INFOFLEX floor open for almost eight hours.