Do more with Flexo

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Do more with Flexo

• Grant Blewett
• Segment marketing manager EAMER

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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.

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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

1930
Laser Ablative Flexo System
Today Kodak Flexcel NX
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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 resultsjob-to-job, and
  run-to-run
• Flexo has to move forward to meet the demands of
  brand owners and printers

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Typical LAMS plate processing and results
Original tonal values 0 - 100
Flexo tries to match the original image
Uncorrected plate loses dots in highlights, first
dots at 10 area (example for 150lpi)
Without adjustment it fails, leaving hard edges
Uncorrected print shows hard edge
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Typical LAMS plate processing and results
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
Compensated plate values range 2-3-100
Flexo tries to match the original image
Final compensated print
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LAMS plates a renown limitation
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Effects of round top surface
Considering a typical LAMS dot profile cross
section

• Measurability
• Inking Printing predictability

Kiss impression ? dot
3 µ Impression 4 dot
6 µ impression 9 dot

• How do we calibrate?
• What will it print?

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Results with the Flexcel NX System
Original Tonal Range 0 - 100
Original offset separation
Plate tonal range 0 (0.4) 100 Up to 300 lpi
120 lpcm
Result gravure class reproduction of the original
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How do we solve this with Flexcel NX
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LAMS plate vs. Flexcel NX plate

• Flexcel NX System achieves stable flat top dot
  structure
• Provides consistent structure and repeatability
  on press

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LAMS plate vs. Flexcel NX plate

• Flexcel NX System achieves stable flat top dot
  structure
• Provides consistent structure and repeatability
  on press

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Kodak DigiCap NX Screening

• Deliver greater shelf impact at the same or lower
  price

Boosting ink transfer in flexo printing
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An additional Flexo challenge

• Especially when printing on filmswith 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

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Whats wrong with traditional digital flexo?

• Efficient ink transfer is always an issue,
  especially with solvent inks on flexible
  substrates

Traditional Digital Flexo Black

• 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

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Previous attempts to improve ink transfer

• Plate surface texturization has long been thought
  to hold the key to improved ink transfer

Traditional plate cell patterning

• 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
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Take a closer look 4pt Text _at_ 30X magnification
Kodak DigiCap NX Screening Applied
No surface texturization
Traditional Plate Cell Patterning Applied
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Now at 60X magnification
Kodak DigiCap NX Screening Applied
No surface texturization
Traditional Plate Cell Patterning Applied
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A 70 tint at 250X magnification
Kodak DigiCap NX Screening Applied
No surface texturization
Traditional Plate Cell Patterning Applied
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Real prints show the power of Kodak DigiCap NX
Screening
Flexcel NX Plate with Kodak DigiCap NX Screening
applied
Traditional Digital Flexo
Smooth ink laydown
Same press, same ink, same anilox, same substrate
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Higher density gives increased color gamut
Kodak DigiCap NX Screening is not just for solid
areas Higher densities throughout the FULL tonal
range enable significantly expanded color gamut
Measured densities in this example Measured densities in this example Measured densities in this example
Traditional Digital Flexo Flexcel NX withDigiCap NX
C 1.30 1.50
M 1.25 1.45
Y 1.00 1.20
K 1.40 1.70
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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.
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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.
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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 co-printed designs

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In summary

• Trends and Realities of Today
• Brand integrity
• Complex graphics
• Print inconsistencies
• Price pressures
• Increasing costs
• Production complexity
• Global competition
• Environmental pressures

• Flexcel NX System Opportunities
• Greater visual impact
• Differentiated print offerings
• Stable, consistent, robust printing
• Profitable, shorter runs
• Ink and substrate savings
• Simplified production
• More billable hours
• Sustainability improvements

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Questions?
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Thank you for your attention