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FLEXO Magazine : October 2011
october 2011 VOLUME 36, NO. 10 In this Issue color in Focus: FtA technical Innovation Award Demo Project Color: from crispness to clarity, calibration to control techniques, and customer- furnished materials to client satisfaction; it’s all in this very special issue. We devote its pages to FTA’s 2011 Technical Innovation Award winners and demonstrate their use in a live printrun—FLEXO’s cover. From the cover, we move to FTA’s Fall Conference and preview several presentations covering calibration, standardization, ICC profiling and Lean production. FtA toDAY 50 Innovation & excellence Robert Moran Award-winning printer, press and platemaking system put to the test. tecHNoLoGIeS & tecHNIQUeS 5 2nd Annual Plate & Platemaking Selection Guide Technical data sheets galore spell out the latest offerings from leading manufacturers. 14 control the Atmosphere for controlled Platemaking Ray Bodwell Perfecting plate profiles requires improving solid ink coverage, without trading off the benefits of the digital dot. 23 FtA Member/North American trade Shop Locator Prepress providers and their capabilities outlined. 29 the Flying Splice Joe Prunier Straight-line splicing tapes and techniques are keeping presses running, while building a reputation for delivering consistent, measurable and auditable results. FLEXO® Magazine (ISSN-1051-7324) is published monthly by the Foundation of Flexographic Technical Association. Address all correspondence to FLEXO® Magazine, 3929 Veterans Memorial Highway, Suite 9, Bohemia, NY 11716-1074. Telephone: 631-737-6020. Fax: 631-737-6813. Copyright ©2011. All rights reserved. Subscriptions: 1 year: $55 U.S ./$76 foreign; 2 years: $92 U.S./$125 foreign; 3 years: $125 U.S ./$170 foreign. Single copies: $7 U.S./$10 foreign. Periodicals postage rates paid at Bohemia, NY 11716, and at additional mailing offices. POSTMASTER: Send address changes to FLEXO® Magazine, 3929 Veterans Memorial Highway, Suite 9, Bohemia, NY 11716-1074, USA. Printed in USA. Publications Mail Sales Agreement No. 1558153. FLEXO® Magazine is the official journal of the Foundation of Flexographic Technical Association, devoted to education, technical and research support to advance flexographic technology. Acceptance of advertising in FLEXO® Magazine does not imply endorsement of the product or service by the FFTA. Opinions expressed in bylined articles are not necessarily those of the FFTA. FTA HEAdquArTErs & FLEXO EdiTOriAL, AdvErTising, subscribEr sErvicEs 3920 Veterans Memorial Highway, Suite 9 Bohemia, NY 11716-1074 Phone: 631-737-6020 Fax: 631-737-6813 PubLisHEr robert Moran, ext. 17 email@example.com dirEcTOr OF businEss dEvELOPMEnT Jay Kaible, ext. 20 firstname.lastname@example.org EducATiOn dirEcTOr Joe Tuccitto Phone: 651-319-5003 email@example.com grAPHic/WEb dEsignEr Katie dubois firstname.lastname@example.org FTA TODAY Excellence & Innovation Award-Winning Printer, Press & Prepress System Put to the Test By Robert Moran Job #100114. Theticketreads1108FLEXOCover. Pa- rametersstate,“4/4with cold foiladhesiveandtactile varnish.” AtPublishersPrintingCo.,Shepherdsville,KY, thework orderdoesnotscreamout,“Thisisnoordinaryflexojob!” Instead,it specifiesarrivalon Sept. 16andsetsTuesday,Sept. 20, 2011astherundate.Quantiyis17,000sheeted pieces. Dimension foreachsheet:19-in. longX12.5-in. wide. Detailsofthecomplexityoftheworkathand,laidoutfar earlier, are nowclearlyunderstoodbyall.Giventheactivityin thepressroom, even before8:00am—specificallythenumber of visitorsturningout—it isapparent that thewholeindustryis watching,and withgoodreasontoo. Thisrelativelynew flexoestablishment,withjust underone year’slabeland packagingprintingexperience,facesthe chargeof orchestratinga livedemonstrationofcutting-edge SPECTACULAR RESULTS IN A SINGLE SHIFT • FLEXO’scoverprojectamountsto ademonstration ofaward-winningtechnologiesandaward-winning execution on theproductionfloor. • Itshowcasescapabilitiesofthe 2011NarrowWeb BestofShowprinter, aswellasthetwo Flexographic Technical Association2011Technical Innovation Awardwinners. • The themeforthejob, “ColorinFocus,” issharedby FTA’s2011Fall Conference. • Specialeffectson the17,000sheetedpieces—em- bossing,coldfoiling, tactile varnishing. • Ourindustry’sexpectation:quality,consistent, print; plusminimal waste,quicksetupandstate-of-the-art operatingefficiencies. 50 FLEXO OCTOBER 2011 www.flexography.org FALL CONFER EN CE E DIT ION Cover on press. Monitoringthejobonpress. TECHNOLOGIES & TECHNIQUES Thecontrolledatmospherechamberis mountedinthelidoftheexposureunit.Atmospheric purge andexposurecontrolis managedthoughatouchpad.Theunitiscapableofsupportingstandard analoganddigitalexposure workflows as wellascontrolledatmosphereattheflipofaswitch. Digitalplatesurfaceshowinganunscreened solidareaexposedinairandprocessed throughsolventprocessor. Photos1–3 aretakenwithaHirox cameraat350X magnification. All samplesprintedon opaq ue whi te pol yethyl ene. Art:DuPontPackagingGraphics. 1 2 3 4 5 6 Digitalplatesurfaceshowingsolidthat has hadsolidscreeningapplied.Platewas exposedinairandprocessedthrough solventprocessor. Digitalplatesurfaceshowingsolidwiththe samesolidscreeningappliedasinphoto#2. Platewasexposedincontrolledatmosphere andprocessedthroughsolventprocessor. Printedresultfromunscreenedsolidarea ofathermalprocessdigitalplate.Sample showsunevencoverageandpinholing. Photos 4–6aretakenthroughastereo microscopeat50Xmagnification. Printedresultfromscreenedsolidareaof thermalprocessdigitalplatewhich was exposedincontrolledatmosphere. Printedresultofthermalplateshowing resolutionoftextelementsdowntoone point. 14 FLEXO OCTOBER 2011 www.flexography.org 2ND ANN UAL PL ATE /PLATEM AK ING GUID E