Do more with Flexo
Grant Blewett
Segment marketing manager EAMER
Agenda
 Why the need for a new digital plate making system.
 Understanding the limitations of modern CTP for Flexo.
 Introducing the Kodak Flexcel NX system.
 Introducing a breakthrough for Aqueous and Solvent printing.
 Business benefits.
Why invent a new digital flexo plate system?
 Flexo had a significant constant growth in packaging printing
since its introduction more than 75 years ago
 Digital flexo plates have been available for over a decade
 Flexo is now the leading print process for packaging
The challenge
Yet the most common complaints from
printers are still based on technical
limitations such as:
Unacceptable color matching to
proof and other print processes.
Inconsistency in the process
Unpredictability of results
job-to-job, and run-to-run
Flexo has to move forward to meet the
demands of brand owners and printers
Typical LAMS plate processing and results
File
Original tonal values 0% - 100%
Flexo tries to match
the original image
Without adjustment it
fails, leaving hard
edges
Plate
Uncorrected plate loses dots in highlights,
first dots at 10% area (example for 150lpi)
Print
Uncorrected print shows hard edge
Typical LAMS plate processing and results
File
Bump is applied to compensate highlight loss,
tonal range is compressed to 10% - 100%
A bump curve is used
to set the minimum
dot size
Plate
Compensated plate values range 2-3%-100%
Flexo tries to match
the original image
Print
Final compensated print
LAMS plates: a renown limitation
Effects of “round top” surface
 Measurability
 Inking & Printing predictability
Kiss impression
= ? % dot
3 µ Impression
= 4% dot
• How do we calibrate?
• What will it print?
Considering a
typical LAMS
dot profile
cross section
6 µ impression
= 9% dot
Results with the Flexcel NX System
File
Original Tonal Range 0% - 100%
Original offset
separation
Plate
Plate tonal range 0% (0.4%) – 100%
Up to 300 lpi – 120 lpcm
Result: gravure class reproduction of the original
Print
How do we solve this with Flexcel NX
LAMS plate vs. Flexcel NX plate
 Flexcel NX System achieves stable flat top dot structure
 Provides consistent structure and repeatability on press
LAMS plate vs. Flexcel NX plate
 Flexcel NX System achieves stable flat top dot structure
 Provides consistent structure and repeatability on press
Kodak DigiCap NX
Screening
 Deliver greater shelf impact at
the same or lower price
Boosting ink transfer in flexo printing
An additional Flexo challenge
Especially when printing on films
with solvent inks:
 Insufficient density
 Uneven ink laydown
 Narrow color gamut
Limitations in these areas mean:
 Flexo print lacks the visual impact of gravure
 Print that lacks brilliance
 Many special colors are used
 Split plates are common
 More expensive inks and higher volume anilox
What’s wrong with traditional digital flexo?
Efficient ink transfer is always an
issue, especially with solvent inks on
flexible substrates
 Split plates and high volume
anilox are often required to
get required opacity
 Poor ink transfer throughout
tonal scale contributes to
reduced color gamut
 Voids in printed solids
reduce the visual impact
Traditional Digital Flexo Black
Previous attempts to improve ink transfer
Plate surface texturization has long
been thought to hold the key to
improved ink transfer:
 Mechanical methods have
been tried
 Plate coatings have been
tried
 Digitally imaged plate cell
patterning has been tried
But none have delivered dramatic
improvements or been consistently
successful
Traditional plate cell patterning
Take a closer look: 4pt Text @ 30X magnification
No surface texturization
Traditional Plate Cell
Patterning Applied
Kodak DigiCap NX Screening Applied
Now at 60X magnification
No surface texturization
Traditional Plate Cell
Patterning Applied
Kodak DigiCap NX Screening Applied
A 70% tint at 250X magnification
No surface texturization
Traditional Plate Cell
Patterning Applied
Kodak DigiCap NX Screening Applied
Real prints show the power of
Kodak DigiCap NX Screening
Traditional Digital Flexo
Flexcel NX Plate with Kodak
DigiCap NX Screening applied
Smooth ink laydown
Same press, same ink, same anilox, same substrate
Higher density gives increased color gamut
Kodak DigiCap NX Screening
is not just for solid areas…
Expanded color gamut
delivered by Flexcel NX
System with Kodak DigiCap
NX Screening applied
Higher densities throughout the
FULL tonal range enable
significantly expanded color gamut
Traditional Digital
Flexo color gamut
Measured densities in this
example
Traditional
Digital Flexo
Flexcel NX
with
DigiCap NX
C
1.30
1.50
M
1.25
1.45
Y
1.00
1.20
K
1.40
1.70
Differentiated
Print
Achieve better printing today
 Deliver print with greater visual impact
 Same print conditions:




Higher densities
Cleaner tones
Finer detail
Greater contrast
At standard print conditions and line
screens Flexcel NX Plates
dramatically improve the visual impact
of your print. Print Buyers are
impressed with the strong colors and
clean tones.
Differentiated
Print
Explore new opportunities tomorrow
 Do more with process color printing
 Make co-printed designs a reality
 Open the door for gravure class quality
 Optimize your press
 Print up to 175 lpi in regular production
 Give brand owners greater design freedom
Designs that were previously only achievable
with roto-gravure are now in regular flexo
production with Flexcel NX Plates.
Co-printing designs can restore profitability to
short runs jobs.
Kodak DigiCap NX Screening
Business Benefit
Taking flexo where it has
never been before:
 Gravure like print quality at
175lpi
 Impactful densities
 High contrast for maximum
shelf impact
 Expanded color gamut,
more
4 color process
 Opening the door for coprinted designs
In summary
Trends and Realities of Today
Differentiated
Print
Flexcel NX System Opportunities
 Brand integrity
 Greater visual impact
 Complex graphics
 Differentiated print offerings
 Print inconsistencies
 Stable, consistent, robust printing
 Price pressures
Production
Efficiencies
 Profitable, shorter runs
 Increasing costs
 Ink and substrate savings
 Production complexity
 Simplified production
 Global competition
 More billable hours
 Environmental pressures
 Sustainability improvements
Waste
Reduction
Questions?
Thank you for your
attention