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FLEXO Magazine : October 2011
files go off to all for review and comment. Notes, or more ac- curately, the concise instructions on the job ticket reflect the collective solution. Joining the list of partner suppliers as the design plan becomes final are API Foils, Environmental Inks and Coatings division of Siegwerk, 3M and Rotometrics. All furnish materi- als specifically for use on demo day. Familiar products made by Harper Corporation of America—XLT anilox rolls—and Max Daetwyler—standard lamella-tipped (MDCDB) doctor blades—play critical roles as well. Step #3: Customize files in prepress before proceeding to platemaking. With Publishers handling the ordering of the embossing cylinders from Rotometrics and the tactile varnish sleeve from Stork Prints, the cold foil application was done with a MacDermid DMAX .045-in. plate with an adhesive for applying the cold foil in the outline of the word FLEXO. 3M comes on board here, contributing a special tape for the embossing plate station—3M 2205—and a second special tape for cold foil—3M 1515. The responsibility for art file adjustments for special effects; namely embossing, cold foiling and tactile varnishing, come with formal hand-off to Dixie Graphics. The trade shop has been handling prepress and platemaking for Publishers since installation of its first flexo press in November 2010. Coffman reports, “Repeat for this job is 19-in. Plates are mounted one around/one across. Plate thickness is.045-in. Screen is 161 lpi. Adhesive material is 3M E 1315 tape. The embossing plate is a Miraclon, measuring .037-in. thick.” Talking to the rotary screen application, Coffman says, “Mesh is 0.75 and the open area is 40 percent. ” He notes, “Stork Prints, Charlotte, NC is furnishing the tactile varnish sleeve. Plate material is MacDermid DMAX with LUX technology. Esko’s HD flexo screening is in use. GMG certified proofs are output using specific color profiles for the press, substrate, plate, and dot gain curves, and the Delta E value averages 0.7. ” FLEXO MEETS FLEXO Dispatched to the plant to witness the proceedings, as FLEXO, the magazine, meets flexo, the process it reports on: PRINT LIKE NEVER BEFORE LUX platemaking technology allows plate- makers and printers to achieve higher quality, consistency, and versatility in their operations, while enhancing the value of their existing investment in digital flexo hardware and soft- ware. According to its developer, MacDermid Printing So- lutions, it amounts to controlled engineering of dot shapes and capitalizes on coverage afforded by flat-top dots. The technology entails lamination of a membrane over the top of an already image-ablated digital flexo plate, followed by standard UV exposure of the pho- topolymer through the membrane, and subsequent removal of the membrane prior to processing. The LUX Platemaking process offers unique benefits to both printers and plate makers. For printers, credits to its use include: • Better Highlight Detail: LUX highlight dots print much smaller than those of standard digital plates. • Smoother vignettes: Smaller dots result in reduced hard edges • Accommodation of higher line screens: No addition- al investment in current print environment needed. • Reduced Dot Gain: LUX reduces dot gain caused by plate wear due to unique shape of flat-top dot. For platemakers, the benefits are as follows: • Greater consistency: 1:1 mask:plate imaging eliminates the traditional digital bump curve, which is a ‘fix’ for the oxygen inhibition inherent in the standard digital plate workflow. • Format versatility: LUX can be used with plates from .045-in./1.14 -mm to .250-in./6.35-mm thickness and any plate size up to 52-in. x 80-in. • Wide plate compatibility: LUX can be used with any digital plate from MacDermid. Publishers Print- ing used DMAX plates for the FLEXO cover job. MacDermid says the LUX platemaking process offers printers the opportunity to print like never before. It produces digital plates with expanded print capabilities and can be used with all flexo lasers. It does not require modification to existing exposure equipment. By add- ing this quick step, printers produce an enhanced dot profile, resulting in cleaner, sharper print. Mounting the embossing plate. Cold Foiling...The API dieLESS® System The API dieLESS® system is recognized as the market leader for cold foiling technology. The process allows foil to be applied in-line on a web-fed press without the need for expensive rotary dies. A free radical UV adhesive is used in conjunction with API’s exclusive thruCARRIER® foil to produce the highest level of print quality at speeds up to 400 feet/minute. For samples or additional information about our rotary foil products, please call Customer Service at: 800-255-4605. Hot Foil or Cold Foil... API Foils is Raising the Standard High Speed Rotary Hot Stamping Foils Need a foil that will keep up with your rotary press speeds or adhere to difficult inks or coatings? GR Series provides excellent stamping definition and adhesion to a variety of coated, printed, uncoated and film stocks at print speeds of 600 feet/ minute for web fed machinery and up to 12,000 sheets/hour for sheet fed equipment. OR Series is considered the most overprintable foil in the industry. Known for its’ excellent surface tension of 44-46 dynes, no primers or sealers are necessary when printing with most conventional and UV inks. API FOILS New Jersey • KaNsas • CaliforNia 800.255.4605 • 785.842.7674 www.apifoils.com 52 FLEXO october 2011 www.flexography.org