Summer 2004                    return to newsletter contents page

FPPA Member News

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Agfa Leaves PrintCity Consortium

Agfa announced that it is leaving the PrintCity consortium. While the company recognizes the accomplishments of PrintCity to date, it has chosen a new approach for demonstrating the benefits of connectivity to its customers.

Asahi Kosoku Printing Co. Prints Rotary Materials

Agfa Systems Provide Capabilities That Won the Bid Says Asahi Kosoku.

Agfa's :ApogeeX workflow and :Galileo CtP systems were recently used to print 50 different materials in 10 languages for the 95th Rotary International Convention. The convention, which was held May 23-26 in Osaka, Japan, was attended by 45,000 people from thirteen countries.

For more information, please visit the AgfaPress Centre at www.agfapress.com.

Esko-Graphics Rolls Out Updated Cyrel^TM Digital Imager (CDI) Features

Increased speed, semi-automated plate mounting and enhanced software highlight advances to the world’s leading CtP flexo imager

Esko-Graphics, the market leader in packaging pre-production solutions and world leader in digital imaging of flexo plates, announces a number of enhancements to its world-leading Cyrel™ Digital Imager (CDI) platesetters. Added features include improved optics that make the CDI the fastest flexo plate imager in the industry, semi-automatic plate loading, and updated Grapholas^Ò flexo software to increase the CDI’s productivity and ease of use.

Esko-Graphics has clearly sustained the 75% market share the CDI has enjoyed since its introduction in 1995. The CDI family of platesetters, the world’s first digital imagers for flexo plates, is now installed and operating in more than 400 plants worldwide. About 90% of all digital flexo plates globally are imaged on an Esko-Graphics CDI flexo platesetter. In 2003, Esko-Graphics shipped 40% more CDI units than in 2002. The demand for flexo-related packaging is growing due to a significant increase in quality, reliability and consistency – thanks to CDI technology.

World-record speed

Esko-Graphics has doubled the productivity of its CDI Advance with the introduction of Optics 80, an enhanced version of the CDI’s award-winning optical technology, now capable of imaging eight square meters of plate per hour. Optics 80 also offers seamless and variable resolution imaging. By imaging a full format 50”x80” plate in 19 minutes, the CDI now matches the fastest plate processing equipment available in the industry.

“We learned that some of our customers needed to double CDI productivity, especially at sites where there was more than one solvent plate processor,” notes Jan Buchweitz, CDI product manager. “By using the new 42”x60” DuPont Cyrel FAST processor, a printer can prepare a plate for press every 15 minutes. We considered it important to match this processing speed, and did so by enhancing the imaging performance of the CDI, thus eliminating any bottlenecks. And, we are looking further into the future. Plate access time will be critical as we develop more automated digital plate loading systems.”

In addition, Esko-Graphics’ Superskip, a function within the CDI’s Grapholas^Ò control software, increases imaging productivity by ‘skipping’ areas on the plate that do not contain any information to be imaged. Superskip is particularly helpful in the production of sleeves. Along with Optics 80, there is no longer any waiting for the imager in the platemaking department, and a continuous flexo CtP workflow is guaranteed.

New concept for flexo imagers: semi-automatic plate loading

Announced at Graph Expo 2003 and demonstrated at DRUPA 2004, the new CDI Advance semi-automatic is delivered with a semi automatic-plate-loader (Semi-APL): a ‘trolley’ that contains 16 cassettes, each capable of holding similar or different-sized plates up to 50” x 80”. Once plates are loaded into the cassettes, the trolley is rolled into place and docked onto a lift located behind the platesetter. Information provided by the CDI job queue selects the desired cassette holding the next plate to be imaged, and the lift automatically moves the cassette and plate to the EasyClamp drum. From there, the operator can easily slide the plate into place onto the drum. Imaged plates can either be released for immediate processing, or the trolley can be filled with imaged plates and removed for subsequent UV exposure.

The Semi-APL provides greater productivity, because each plate is quickly and easily positioned directly onto the EasyClamp drum. With less strain on the plates, there is less likelihood for damage.

New PlatePatcher option for Grapholas productivity and quality control software

All CDI platesetters are delivered with the outstanding Grapholas^Ò front-end software package. Its intuitive, easy-to-use fully graphical interface and screen viewer provide a number of productivity tools. Grapholas^Ò Merger is used to optimize plate usage, provides sleeve support, and assures seamless imaging. Grapholas^Ò Exposer is an operator tool to control the CDI; for example, it can change the order of jobs in the machine queue. Grapholas^Ò ScreenView is a QA-tool used to check dot shapes and overprints, measure screen angles and rulings, determine ink coverage of separations, and provide a monitor soft-proof.

New for Grapholas is the PlatePatcher option, a powerful tool to minimize overall plate consumption in corrugated printing. PlatePatcher automatically divides large format layouts into a number of smallest-size plate patches, adding crossmarks and reference codes for reassembly later. PlatePatcher takes these partial bitmap images and merges them, under full visual control, onto the smallest possible contiguous area on a plate. Some limited extra space is added around the patches, so the resulting digital plate (or film) can be cut into pieces more easily. During this process, PlatePatcher compiles positioning information, and generates positioning marks on the plate. It also creates CAD control files to drive camera-supported mounting systems, such as a DuPont Macroflex post-mounting device, a 1:1 plotter, or even a Kongsberg samplemaking table. PlatePatcher not only economizes plate use; in combination with a Kongsberg table it also prevents the loss of plate material due to cutting errors by the operator.

Grapholas^Ò is also available as a stand-alone package, PlatePrep, which supports job preparation and job viewing independently from a Cyrel^TM Digital Imager. The stand-alone version enables full access to the Grapholas^Ò features at any time, even while the Cyrel^TM Digital Imager is imaging a plate. Job preparation thus becomes a fully parallel process. A PlatePrep station can drive multiple CDI units.

Software innovations for the flexo printer

Some of the many software innovations Esko-Graphics will demonstrate at DRUPA 2004 have a direct influence on the performance of CDI output. Groovy Screens, a new hybrid screening technology, uses traditional AM screening throughout most of an image, but adds a line pattern (or ‘grooves’) into the dark, shadow areas. The transition between the normal screen pattern and the line pattern is gradual, leading to a smooth gradation in print between the lower density of the non-groovy print (highlights and midtones) and the higher density (shadows) of the groovy print. The major advantage of Groovy Screens is improved solid area rendering: solids have a smoother ink layer. Saturation of colors also improves.

Finally, FlexoPerfection provides a complete bitmap editor for final changes to TIFF-IT and LEN files before they are imaged on a CDI platesetter.  Operators can zoom in on a plate bitmap image before it is sent to the platesetter and, as a final quality check, assure that it traps well or that distortions are correct, or determine if there are areas of concern in the highlights or shadow. Bitmapped separations can even be assembled on screen – in color – to ensure they will print well together. If not, a full set of editing tools are provided to correct the bitmap before it is sent to the platesetter.

Unique and comprehensive technology for flexo

The CDI line of platesetters was built from the ground up for flexo, and the new features continue to build on that legacy. “ Esko-Graphics takes considerable pride in the productivity and quality achievements of the CDI. It requires a deep understanding of how our customers use their platesetter, and specific expertise in many technological areas. For example, we understand how difficult it is to transport and load plates onto a platesetter drum, which is why we introduced the semi-automatic CDI Advance,” says Jan Buchweitz, CDI product manager. “CDI platesetters have been built with unique optics to assure constant quality and repeatability. The Optics 80 system was developed to deliver the highest productivity. The CDI has established sleeve capabilities in a number of sites worldwide since 1996, as well as the ability to image other media such as ablative film, letterpress plates, and dry offset plates. And finally, our training and support offer our customers a fast way to produce top quality digital plates, leading to a rapid return on investment.”

NEWS FROM COMCO, A DIVISION OF MARK ANDY, INC.

High Quality Technology Improvements from Comco

Comco Hosts Successful EMA Summer Technical Program

High Quality Technology Improvements from Comco

Comco, a division of Mark Andy, Inc. announces continuing improvements for its range of package printing presses.  The Retrofit Group at Comco specializes in expanding existing equipment capabilities to provide long-term return on printing equipment investments.  The Comco engineers have decades of experience in designing and building a variety of modules, components and support products that add value to existing equipment.  The latest improvements are available to upgrade existing Comco presses.

“We combined the latest technology and improvements to make the converter the most productive and highest quality producing machines in the industry,” states John Baer, Retrofit Applications Engineer for the Comco brand.

New Style Air Knives

Comco maximizes hot air drying with New Style High Efficiency Air Knives that are far superior to the previous models. With this newly designed air knife you can not only save energy cost from every day running but also increase your drying speeds. Unlike some competitive drying systems, Comco utilizes the existing blowers, heaters and plenum requiring no investment for additional hardware. Comco Drying Systems are not limited to electricity as the only heating source.

The new air knives require up to 50% less energy for operation with no whistling noise.  With increased drying speeds, the drying compares to or exceeds “high pressure dryers” for a fraction of the cost.  There is no hidden cost or additional parts needed, such as, air compressors, blowers or high pressure air lines.

Auto Register System

Comco introduces their new Auto Register System in a retrofit package that has been specially designed for the Commander Series printing press.  This system has 4-1/2 times faster correction rate, higher resolution and each register unit is self contained.  An optional Central Touch Screen unit allows you to monitor and control the entire system in manual or auto register from a central location.  The new Auto Register System is capable of running different size tooling within multiples of the repeat mark.  To optimize performance the parameters can be independently adjusted at each station.  Register adjustments can be made at multiple stations simultaneously.

Impression Cylinder Nip Roll Assembly

For use on the Comco Commander and ProGlide, Comco has designed a Pneumatically Controlled Nip Roll for the print station impression cylinders. The nip roll works by removing trapped air from between the impression cylinder and the substrate.

The new system allows the press to run lighter tensions through various film applications, improves lateral registration and helps maintain equal tension between print stations..  The nip rolls are pneumatically controlled through one central regulator to reduce conflicts between print stations.  The system is maintenance friendly and simple to operate.

For further information please contact: John Baer, Comco Retrofit Applications Engineer, 513 248-8000 phone, 513 248-8546 fax, jbaer@markandy.com

Comco Hosts Successful EMA Summer Technical Program

Comco, a division of Mark Andy, Inc. recently hosted the Envelope Manufacturers Association’s Summer Technical Program.  Over 75 guests enjoyed the incredible two-day event on High Definition Envelopes. The event was held at the Comco Advanced Training and Technical Center in Milford, Ohio on July 21 & 22, 2004.

The purpose of the symposium was for manufacturers to learn how to take printing to the next level using new technologies, tools and processes.  That was accomplished throughout the two days as the attendees heard expert speakers on a variety of topics.

• Translating Market Demands into Graphic Production Technology

• World Class Manufacturing

• The Elements of Your Printing System

• Optimization or Characterization

• Color Management and Proofing

• Prepress Tools

• Value Added Converting

The Comco facility showcasing its ProGlide MSP with its proven converting platform is a perfect fit to the EMA’s high definition agenda theme.  Guests were hosted to live demonstrations on the ProGlide MSP and FLX as well as a factory tour where busy teams were seen building a variety of custom design presses that ranged from solvent combination printing to film presses to a 17-color lottery ticket press.

“It’s great to host a group who is interested in new technologies to further advance their own industry.  We are happy support any organization that is interested in educating converters on the advances of the industry.  The EMA is invited to Comco anytime for this type of event,” stated Mary Sullivan, Manager, Global Marketing at Mark Andy, Inc.

Along with Comco, International Paper and Weyerhaeuser opened their doors to allow attendees to take a walk through and tour their facilities.  At International Paper, the group had the opportunity to see the Flexo/Gravure In-line Pilot Printing Press.  At Weyerhaeuser they saw a facility that runs high quality printing using the FIRST (Flexographic Imaging Reproduction Specifications and Tolerances) process.  All in all, the two-day event delivered much needed knowledge of flexo printing excellence to the Envelope Manufacturers Association.

Temple Inland Graphic Resource Center 100% Celebrates 100% Digital Workflow

This month marks a new achievement for Temple-Inland’s Graphics Resource Center.  Our facility has successfully become 100% digital in our facilities prepress workflow, which includes digital prepress, proofing, and digital photopolymer plate making. 

The facility began its journey in 1999 with one of the first digital plate workflows in North America, and since then doubled yearly the amount of jobs created with digital plates.  This enabled us to streamline our operation with faster speed to market, operate with lower costs by lowering make-ready waste, and improve the consistency and grade level of printed products.  The chart shows the time frame as well as growth pattern we endured to get to such a goal.  Along the way we have received numerous printing awards such as FFTA “Best of show” 3 years in a row as well as FPPA Inaugural Best of Show in 2002 and year 2003.