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FLEXO Magazine : September 2011
Our desire to develop new products and offer our customers choice is demonstrated by the rate of growth. PRESS CABABILITIES Our ability to coat film in-house puts us at a great advan- tage, as it provides total quality control when producing hot melts and UV hot-melt adhesives for specialty applications— e.g. the peel and reseal market. Our Deeside facility also enables us to apply silicon in-line onto backing liners and provides a test platform for new product development trials. That’s a benefit utilized by many partners. Cost savings are directly passed on. We’ve got 10, eight-color, UV flexographic printing presses that run around the clock and can print on 400 mm-width substrates. All presses have dedicated finishing units and can accommodate a variety of substrates. Two blank label presses provide large volume capability with the recent installation of a high speed Omega label converter tripling capacity. A multiple turret rewind enables continuous produc- tion. The type of work varies from straightforward spot and/or four-color process with halftones and options to metallic, hot/ cold foil, lam/de-lam and holographic stamps. Label products include self-adhesive, wrap-around, cut- and-stack, peel and reseal and in-mold labels. NEW TECHNOLOGIES Systems Labelling offers a variety of budding technologies to help stay one-step ahead of the competition. Advancements in solvent-free platemaking and PDF/print-to-proof matching have been embraced and are proving advantageous. What works for offset or gravure, may not work for flexo and vice versa. With this in mind, we are always happy to advise and guide clients through the design process. Our ethos is to produce the best possible results from our customer’s art- work. Systems Labelling Reprographics (prepress) operators are fully conversant with all print disciplines and are able to offer best practice advice. In addition, we provide an industry-recognized artwork guide that helps designers consider the technicalities of pre- paring artwork for the flexo printing process, ensuring we get that best possible result achievable for the client. Advanced screening techniques enable us to extract the very best results from our clients’ designs. • Kodak Hyperflex resolution enhancement technology achieves excellent halftones and vignettes, enabling cus- tomers to submit complex designs to achieve maximum stand-out. • Kodak Maxtone Hybrid Screening is modulated tech- nology that delivers enhanced detail, smooth vignettes and improved highlight reproduction by allowing our prepress operators to restrict the minimum dot size and control the number of highlight dots in a frequency modulated-like manner. • Production of our solvent-free flexographic plates has been revolutionized following the commissioning of a Kodak Thermoflex platesetter. • The installation has been accompanied by the new DuPont Cyrel FAST system, which eliminates the use of solvents during the platemaking process. Makeready times and waste have been reduced and run-lengths increased, providing obvious benefits to our customers. The working environment for our prepress team has improved, as there are no solvents to handle, store or recycle. GETTING IT RIGHT One of the challenges Systems Labelling’s prepress department faces on a daily basis is managing the multitude of job files submitted by customers. “ T he quality of the Adobe Illustrator® files we receive varies widely,” explained Robin Barker, Systems Label- ling’s reprographics director. “Approximately 50 percent of them contain improperly prepared artwork and em- bedded images requiring corrections and adjustments before they can be truly print ready. We were struggling along, dealing with these issues, and it was laborious and time consuming.” With a goal of finding a tool that could help simplify and streamline the management of the Illustrator job files, Systems Labelling started to research the available products in the market. The search led to Astute Graph- ics’ Phantasm CS Publisher plug-in for Adobe Illustrator. “ Using the Relink Embedded Images tool has allowed us to correct problems without having to lose time and increase costs by returning the files to the agency or customer for corrections,” Barker commented. “ T he soft- ware links to the image and allows us to quickly check the ppc, make conversions if necessary, and move on. ” In flexo, drop-off levels (minimum dot) can lead to visu- ally poor cut-off areas in artwork, especially in commonly used vignettes and drop shadows. Barker explained that Systems Labelling can hold process to a 1 percent dot, but settings below that can create problems. An ongoing issue was drop-off levels set at .4 to .8 percent, but reading as 1 percent in the Illustrator files, giving the impression that Systems Labelling’s stan- dards were being met. As Illustrator doesn’t provide a method to check for ink coverage or flexo-related drop-off levels, the workflow had to be disrupted, export- ing artwork to alternative systems and cross-matching areas of concern for correction within Illustrator. “ Now, items such as drop-off levels literally ‘jump out’ at us,” Barker stated, “helping us eliminate potential issues further on in the workflow.” The ability to produce labels for a wide range of industries has helped Systems Labelling become one of Europe’s largest manufacturers. 48 FLEXO SEpTEmbEr 2011 www.flexography.org EBECRYL® 571 Resin A New Benchmark in Shrink Sleeve Performance & Productivity Email: email@example.com l Worldwide Contact information: www.cytec.com Contact Us Today : US Toll Free: 800-652-6013 l Tel: 973-357-3193 l Belgium: +32 2 560 4511 Trademark Notice: The ® indicates a Registered Trademark in the United States and the TM or * indicates a Trademark in the United States. The mark may also be registered, the subject of an application for registration or a trademark in other countries. © 2011 Cytec Industries Inc. All Rights Reserved. Introducing EBECRYL® 571, Cytec Industries’ newest resin system for UV/EB curable flexographic shrink sleeve printing ink and coating applications. EBECRYL® 571 has excellent pigment wetting, is suitable for process colors and is compatible with metallic and white pigments. Find out more about how EBECRYL® 571 can reduce cost and time while increasing the overall performance of your narrow web energy curable printing by contacting us at the e-mail address and phone numbers listed below.