FLEXO: What pending developments in the plate/processing, mounting, cleaning and screening arenas should printers be watching for? Why? How will their introduction support printers’ priorities for action—maximizing efficiencies, adopting best practices, managing and by necessity minimizing manpower requirements, and reducing the plant’s carbon footprint? And at the same time, how does your firm, as well as its products and services, support this observation that summarizes the strongest poll findings?
- “We have to become more automated using available technologies. We need to invest in training/educating and higher pay/benefits for workers to ensure a consistency in production processes and outcomes. Growing relationships with suppliers is crucial to a solid pipeline of raw materials equipment necessary to meet customers’ work.”
MacDermid Graphics Solutions: Connectivity is a key element in this arena. Systems that talk to each other and are linked together digitally or physically allow for effective training, implementation and active use. Connectivity takes collaborative advancement, whether it be across companies or across technology platforms within the same company, to enable solutions rather than products.
Effective screening developments are dependent upon a plate technology that can support them, presses that can print them and press consumables that can optimize them. The true development is the ability to coalesce the various new technologies in each of the mentioned areas into a practical application that can be consistently applied to new prints, new plates or new processes.
Mike Agness, HYBRID Software: While there are a number of ways that workflow software can advance production, one of the most impactful ways to assure consistency is through a very basic concept: screening advancements.
Dot etching—photographically, chemically and, more often now, digitally—has always been used to print halftones better. Today, each trade shop and printer works within a different environment and with different print setups—from inks to substrates to resolutions to plates to anilox, etc. Why not employ advanced digital methods to assure better print results?
There are now ways to digitally dot etch screens to disrupt ink viscosity and utilize more fluid to reproduce graphics better, improving the quality of just about any plate. It can even be done to work on a non-proprietary fashion and fit into any environment, accepting and outputting any screened file. It can intelligently identify problem areas—looking for different zones in the artwork that warrant intervention—and then apply specific techniques to generate effects that will improve print quality. Significant is that users can even import their own special patterns and area parameters into the software, so that it is truly specific—and special—to each printer.
It can dramatically enhance the quality and stability of flexographic presswork, making it easier to assure consistent results.
PJ Fronczkiewicz, DuPont Cyrel Solutions: In recent years, we have observed the emphasis on plate photopolymer chemistry has been somewhat overshadowed by all the creative things that can now be imaged on the plate and innovation in the way the plates are exposed and processed.
As a plate manufacturer that offers a wide portfolio of products optimized for all sorts of flexographic applications, rest assured we are still continually thinking about what else we can do with our photopolymer chemistry knowhow to improve the performance of our plates, provide additional benefits on press, and to work optimally with other trends in flexography with our customers in mind.
A good example of this lies in our most recent plate innovation, Cyrel LSH. Designed for and dedicated to exclusive use with LED exposure, the unique chemistry of LSH allows for increased productivity with LED exposure by up to 42 percent when compared by DuPont to standard plates. This innovation removes a roadblock that many of our customers have struggled with when converting to LED exposure.
And after recognizing the needs of corrugated printer customers struggling with board crush, while trying to achieve suitable solid print on newer, thinner liners with higher recycled content, in 2019 DuPont launched Cyrel DLC, a low-durometer plate that provides excellent ink coverage with minimal print pressure.
Last but not least, the pride of Cyrel Solutions has been the emphasis we put on our relationships with customers, intimately learning their needs and providing tailored, world-class technical and customer service to help them achieve their goals. We encourage all our customers to participate in our DuPont Cyrel Quality Assured Plate Maker certification program for both new and longtime plate makers alike—another opportunity for some peace of mind during these times of change.
Rick Mix, Fujifilm Graphic Systems: Utilization of water-wash flexographic plates is only a starting point for adoption of best practices. The ability to rely on a partner like Fujifilm to move your organization forward with greater prepress and pressroom efficiencies, high-quality print and improved color management, while also reducing the organization’s carbon footprint, is possible for flexography.
Scott Thompson, SGS & Co: Again, the key enablers for improvement from the plate production side revolve around the new technologies for screening and plate exposure, which have greatly enhanced the print quality and reproduction, and increased efficiency through improved repeatability.
In addition, there is increasing visibility and action to advance the recyclability of polymer waste. While it has some room for improvement, new measures should help the overall carbon footprint and recyclability goals. Finally, the use of advanced plate cutting systems supports improved plate mounting and registration in press, once again reducing overall waste.
Flexo Wash: Our focus now is sustainability. We believe that evaluating your cleaning systems is the first step here. We are focused on the following in our efforts to lessen our footprint on the industry.
- Environmental solutions for each machine
- Sustainable cleaning solutions
- New generations of cleaning technology
XSYS Global: We’re constantly evaluating the market landscape with an eye toward ways to improve quality (both within the plate material and in printed products), increase productivity (through faster plate making processes, as well as automated plate making equipment), and reduce total costs for customers (through lower energy consumption, reduced waste and higher productivity); all while striving to make the plate making process as easy as possible by introducing plates with inherent flat top dot geometry, surface texturization and other features.
Tim Reece, All Printing Resources: As technologies evolve, automation expands and skillsets are adjusted, training and employee retention reach an all-time high level of importance. Years ago, I recall a session at FTA’s FORUM, and the question was asked, “What if I train my people and then they leave?” The response that followed was, “What if you don’t train your people and they stay?”
Hiring the right person is not an easy task, Once hired, the investment to bring that person up to speed is significant. How many times have you looked to hire someone new and were faced with the problem that the salary/wage demand was higher than existing talent?
Holding on to existing talent is critical. While appropriate compensation is critical, keep in mind that creating a company culture that does not lend itself to employees to be looking elsewhere is also important. When people leave a job, whether voluntary or involuntary, it typically is not because of what they don’t know, but rather interpersonal issues. Cultivate a company culture that you can be proud of.
- Increase productivity up to 15 percent
- Reduce machine idle time by 40 percent
- Avoid errors and plate wastage with sensors to ensure accurate plate loading
- Free up operator time to attend to other valuable tasks
Photo courtesy of Esko
Julian Fernandez, Esko: One statement speaks to the mission at hand and the vision required to implement it. Esko is simplifying the complete packaging production process, from idea to shelf—to help customers master today’s challenges and remain successful in the world of tomorrow.