With a steady flow of new technology entering the computer-to-plate market, Catherine Carter takes a look at some of the latest equipment that could help your company improve workflow and efficiency.

The careful mix of digital and litho capabilities by an increasing number of printers has resulted in demand for workflow solutions that create smoother prepress throughput for effective job preparation and planning. This includes creating highly reactive workflow solutions that enable conventional presses to be more responsive to short-run demands. While digital retains the competitive edge, developments, particularly in computer-to-plate (CtP), are helping litho to reduce run lengths.

Drupa saw a number of CtP debuts, particularly for flexo such as Luscher’s 8-page UV CtP system, the XDrum!, which has been designed for commercial print and packaging providers. It offers an economical platesetter for mid-format offset plates and is capable of outputting plates up to 25 plates—measuring 930 x 1050mm—an hour.

Screen has developed the Screen PlateRite FX range of thermal platesetters to image all market-leading solvent and water-wash photopolymer plates for flexo and letterpress applications. The open-platform PlateRite FX systems can use FlexoDot software to create a powerful imaging solution for flexible packaging, labels, cartons and corrugated packaging applications.

“We are encouraging print firms to take a closer look, not only at the impressive capabilities of Screen’s expert workflow and digital presses, but also at the considerable benefits these can bring to their business,” comments president of Dainippon Screen’s media and precision technology company, Katsuhiko Aoki.

BasysPrint unveiled its next generation of 4-up and 8-up CtP UV platesetters for the digital exposure of UV-sensitive offset printing plates. The UV-Setter Series 460x and Series 860x offer resolutions of up to 2400dpi and a unique flatbed design for the digital imaging of a wide variety of plate sizes and formats. Both are equipped with the unique Dynamic Autofocus system to cope seamlessly with plate undulation.

BasyPrint’s director of sales and marketing, Christophe Lievens, says the ability to image coating plates for spot varnish printing, image photoengraving magnesium or copper plates of thicknesses up to 10 mm for hot-foil stamping or embossing, image screen meshes and even image dies for flexible die-cutting ‘offers the opportunity to generate additional revenue – all from one and the same engine’.

Flint Group demonstrated its Nyloflex Next UV CtP with daily live print runs on a Comexi Flexo F2 press using its and PremoFilm SXS water-based flexo inks. Nyloflex Next uses Esko’s Pixel+ flexo screening technology to support flat-top dot creation, and is compatible with all digital plates regardless of type, thickness and format. Also using Esko’s Pixel+ is DuPont’s workflow enhancement for its Cyrel DigiFlow flexo CtP system. DuPont said the upgrade delivers superior print quality and productivity to Cyrel DigiFlow users.

Developing and emerging

In the VLF market, Chinese manufacturer Cron will use its exclusive UK distributor, HighWater CtP, to launch the European debut of its G-Class range of platesetters—including two devices capable of imaging plates up to 1,670 x 1,290mm and 1,850 x 1,422mm. Luscher will also highlight its large-format MultiDX! 240 system that can process plates up to 1300 x 1100mm and is designed for use with rigid and flexible screen printing forms, and the Accent coating plate for offset applications.

Kodak’s Achieve is an all-in-one CtP System aimed at helping printers in emerging markets to affordably achieve transition to CtP with thermal imaging and plate technologies. Initially introduced in the Asia-Pacific region, it will expand into emerging markets in Eastern Europe, Russia, the Middle East, Africa and Latin America.

“Kodak’s portfolio of solutions and services optimise the delivery of higher-value images for our print customers to better serve their clients and grow business,” says Kodak’s director and vice president marketing, commercial business  Chris Payne.

Kodak has also developed the Sonora XP process free plates. They provide mainstream quality and print capability without a processor or chemistry, offering streamlined platemaking, removal of operational costs, and a reduced environmental footprint. Sonora XP process free plates are also non-ablative—removing the need for debris removal equipment to protect both employees and the CtP equipment. They are also capable of running recycled stocks, soy-based inks, IPA free founts and other press setups to help operations reduce their environmental impact.

Elsewhere, Fujifilm Graphic Systems UK’s product manager, offset solutions, Sean Lane, believes the key trends in the pre-media sector will focus on how current technologies have evolved to offer end users enhancements within the different product ranges, as well as highlighting their environmental characteristics through reducing their carbon footprint.

This may be by developing inks that contain less hazardous chemicals, or by introducing plates that use less chemistry, such as Fujifilm’s new Brillia HD LH-PXE plate and XR-1200F waste developer reduction system. Minimised environmental impact and increased productivity and efficiency are core to solutions such as FLENEX DLE flexo plate and multi-channel CtP platesetter. It offers packaging printers an alternative to laser ablation mask (LAM) method of plate production and allows printers to benefit from further digitisation of the print process.

Presstek also revealed a chemistry-free CtP plate for sheetfed and web waterless printing applications. It claims to help raise the efficiency of prepress departments by eliminating the time-consuming steps, variables and costs associated with production of other waterless plates. Presstek will also feature Aurora EXP, a true chemistry-free daylight-safe metal plate that can be imaged on a range of thermal platesetters. It requires only a water wash after imaging with no need for chemistry before mounting on press.

Workflow that works

A key trend at Drupa 2008 was the increased development of automated IT solutions in prepress, press and postpress with the focus on file handling, press colour reproduction and JDF technology. This saw Fujifilm adopting Adobe PDF Print Engine for its JDF based XMF workflow. Agfa’s ApogeeX, Screen’s TrueFlow, Kodak’s Prinergy and Xerox’s FreeFlow Print Server followed.  As a result, solutions that deliver output consistency, enable true conventional and digital print hybrid workflows as well as crossmedia workflows are under development.

Agfa Graphics’ Ralph Hilsdon agrees there will be a shift in workflow towards more integration both at input, through management information systems (MIS) and web interface and output, to support a wider range of output devices, digital presses, CtP or handheld devices. This will largely driven by the increased number of printers offering both litho and digital capabilities and the need for the most productive and smoothest workflow to be quickly identified.

Continued growth

Premier Print and Digital Mail Group invested in Agfa’s Avalon CtP system that images Azura TZ chemistry-free plates and Apogee workflow to help the company create a stronger operational footing for today as well as add capacity for the future.

Established in 1984, the ￡2.7 turnover firm specialises in magazine and journal production and runs Komori Lithrone and Heidelberg SpeedMaster presses. It chose the Agfa solution because it was easy to use and offered strong servicing and support.

“We wanted to increase turnover and keep the same level of staffing. We invested in technology that enabled us to improve our operations today and provide us with extra capacity for the future so we can continue to grow,” explains director Darren Goodson, who runs the business with his brother Gary.

In the main, these solutions are the result of separate systems for different stages in the production process being brought together. One example is Kodak’s Unified workflow solution. Upgrades  include Kodak Prinergy 6 software, Kodak Insite prepress portal software and App for iPad Devices, plus new versions of Kodak Colorflow software and Kodak Preps imposition software. Collectively these are aimed at increasing profitability by automating manual production processes in customers’ digital and hybrid printing environments.

“Efficiency improvements are required long before the actual print production process,” says Kodak’s general manager of unified workflow solutions, Jon Bracken, who adds: “Prinergy Workflow 6 takes optimisation further to address the entire production planning process, driving equipment and manufacturing capabilities based on customer intent.”

With Prinergy Workflow, jobs are now planned with a customisable interface, automated and easily monitored across multiple devices through the user-driven workflow solution for blended production environments.

Screen has also introduced a complete Equios universal workflow designed for conventional and personalised printing environments. Featured on Screen’s Drupa-launched Truepress JetSX inkjet press, the single workflow with a single interface drives streamlined production from web to print to the delivery of the finished item automatically and there is no need to operate different device-dependent workflows, to drive Screen and third party CtP, toner and inkjet devices. The Equios Autoflow function will allow users to define print workflows according to the product type selected. Screen will also introduce a cloud-based variable data application that simplifies the production of variable jobs and enables designers and data owners to collaborate on projects via a standard web browser.

Lane expects cloud-based solutions are a prominent trend, as systems become more sophisticated and relevant as the demand for online services increases. Fujifilm’s XMF Workflow has recently benefited from the addition of XMF Remote, a submission and approval module, and XMF PrintCentre, a cloud-based web-to-print system. The firm also recently saw the addition of XMF ColorPath, a new cloud-based system designed to help maintain consistent colour standards.

Heidelberg acquired software specialist Cerm to, in combination with Prinect, create a fully integrated MIS solution. Esko extends this credibility to suppliers too with software that allows brand owners, designers and retailers to collaborate on artwork creation with packaging manufacturers and printers. Using softproofing and virtual 3D modelling allows greater co-operation and quality assurance—delivering automation and efficiency, and reduces costs and time related to miscommunication and technical errors.

These improvements to CtP and plates improve production quality and workflow but it is the advent of smartphone and the ability to review jobs progress throughout the whole process chain delivers a greater level of accountability. Heidelberg has Prinect Mobile app and Agfa’s :Apogee Prepress App that lets users check a specific job during production. It is technology like this that will help companies adapt to the modern market and continue to succeed.