4000dpi - Is it really revolutionary for flexo?
So how is 4000dpi laser imaging and hybrid screening revolutionary for flexo? Hybrid screening has been in use for many years and there are lasers that are used for imaging flexo at 9600 and 12400 dpi.
Matching offset with flexo. Well that's nothing new either. The Kodak Flexcel NX System has been doing that for the last 18 months with a 2400dpi Squarespot imaging device. It achieves 1:1 image transfer from the digital file to the plate from 10 microns up to 300lpi using AM, hybrid and FM screening, the same as they use in offset.
And about square pixels in the data file and a round laser beam, even John's three year old Lilly knows that the round block does not fit properly in the square hole. This means that a 1:1 digital pixel to dot on plate can never be achieved with a round laser beam.
Irrespective of this "revolution" in resolution and screening technology (which as we said before is really nothing new) the fact that it is applied to traditional digital black mask flexo plates still remains, resulting in oxygen inhibition and rounded bullet shaped dots. These rounded bullet shaped dots are clearly accepted by some of the statements in the press release as causing variation in the press room, delays in press set up, reduced plate life and production inconsistency. This means that the plate is a major cause for variation in existing digital black mask flexo plate systems (here at Kodak we have been saying that for more than a year). The new imaging and screening does not change the profile of the printing dots, so how can it significantly affect their performance on press? High resolution and hybrid screening can certainly help your highlight and fine line performance; we have technology to do this too. Keeping the rounded dots there and keeping them consistent in real world production is the challenge, and only a flat top dot can enable the stability and wide impression latitude that we all desire for true consistency - it is simple physics 101!
Lilly also loves to draw with an ultrafine pencil, which is comparable to small dots, but even Lilly knows that coloring in the shapes in her coloring book takes a long time with such a fine pencil. It is just lucky that as a Flexo industry we don't need to do large solid areas on our plates, otherwise that could slow imaging down greatly.
ESKO claims that more than 90% of all digital flexo plates and sleeves are imaged on CDI imagers. We know this is not true. Kodak is a major supplier of flexo imaging devices and unless none of our customers are actually using their Thermoflex and Trendsetter NX devices to image flexo plates, then the statement must be false. I have actually visited and seen them working in trade shops and printers all around the world. When you see clearly overstated claims like this in a press release it makes you start to question all of the other claims.
Their sustainability statements are a little questionable too. Once again others seem to be hung up primarily in the solvent vs thermal debate instead of looking at the big picture, where industry data indicates that the greatest environmental impact that can be affected by flexo plate choice is in print production. So it's clear that the flexo plate should be chosen to reduce the actual number of plates used, optimize productivity and minimize waste in the pressroom.
Esko's statements throughout the press release indicate that the current digital black mask flexo plate system has a whole series of issues that need addressing - issues that have a serious effect on production performance, resulting in higher levels of waste. It's hard to see how just smoothing the dot edge of a round top dot will have the significant effect that they claim in all but the exceptional cases.
Wide impression latitude, significantly extended plate life and consistency are key parameters in minimizing this environmental impact. Sort these issues out and you really start to see the environmental benefits. The improved predictability, reliability and consistency that Kodak's plates deliver, with their 1:1 image reproduction and flat top dots, enable printers to achieve significantly improved waste reduction in production.
The Flexcel NX plate system was built for superior press performance, addressing many of the significant weaknesses of traditional digital flexo. The inherent weaknesses of digital flexo just can not be overcome with 4000 dpi imaging and hybrid screening alone, although they can do a nice job of masking some of the issues!
At best Esko's step forward is evolutionary for them..... it's certainly not revolutionary for flexo!
This post was co-written by Emma Schlotthauer, Global Current Marketing for Flexo at Eastman Kodak.
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Comments
Posted By: me (10/20/2009)
Comment: Funny there were several entries of NX printed plates that won some type of award but an analog plate at 175 won best of show. As a percent more NX plate were not winners than those that were - digital - LAMS plates overal won the most.
Posted By: Stephen Zmetana (4/15/2009)
Comment: Just a quick response to David's comment at the bottom of the thread: "have you calculated the number of gray levels you can reproduce with 300 lpi at 2400 dpi? 65!!!"
This comment would have been true for early RIPs (circa 20 years ago), which did not use supercell technology. Kodak has been using supercell screening in all its workflows for a very long time (and I would be very surprised if there are any workflow vendors left that do not).
Rather than calculating grey levels at the individual halftone cell level, supercell screening calculates grey levels over an area consisting of many halftone cells and uses pixel dithering to render very accurate tones within the supercell area, no matter how high the frequency.
The only limitation to imaging grey levels on a Kodak system is the underlying data in the input file. 8-bit contone and 8-bit vector objects can only be rendered at 256 grey levels, but objects created with smooth shade operators can be rendered with 16-bits, which produces 65,536 grey levels.
Of course, in real life, TIFF measuring tools can only distinquish tones to about 0.1% accuracy. But even with this limitation, I can demonstrate 1000 grey levels in a device-ready TIFF rendered at 300 lines at 2400 dpi, from any of our workflow systems.
Stephen Zmetana
Technical Specialist, Packaging Workflows, Kodak Product Development
Posted By: Dan (4/7/2009)
Comment: I was curious after reading about Flexcel NX. If Flexcel NX is so superior to digital imaging, will Kodak discontinue the Thermoflex product line?
Posted By: John Anderson (4/2/2009)
Comment: Thank you for the comments, I can assure you this was not an April Fools joke, but your reaction does not surprise me. The most common reaction when talking to Flexo printers is that 300 lpi is impossible, and we must be crazy. Flexcel NX is a real "show me" product where people don't believe unless they see it with their own eyes, and then they want to see it on their own equipment. There are lots of people out there that even on older flexo presses, where people often put the Flexcel NX plates first because if it works here it will certainly work on the new presses, that they are amazed and shocked at what is now possible.
In reality if you're printing solvent based inks on flexible packaging with Flexcel NX your limit is around 200 lpi with current equipment, but for the industries printing with UV inks, like labels and folding cartons, 300 lpi is not only possible, but it is a daily occurrence somewhere in the world. If you want to read more visit the page for an article from the January issue of Package Printing on Trisoft Graphics who are supplying Flexcel NX plates at 250-300 lpi daily to the label industry on the West Coast of the United States.
http://graphics.kodak.com/KodakGCG/uploadedFiles/1219pp_0109.pdf
One of the best ways to answer your doubts is to send you samples, so that we can "show you" Flexo prints at 300lpi or maybe 21 micron FM screening, and confirm that what we are saying is true and not just marketing hype. Rather than being a "special Kodak" lab sample, please send me your contact details to my email below and I'll have samples mailed to you that are printed by one of the label printers doing this every day. Then if you still want to see it on your own equipment I can arrange for a local contact to get you test plates, and then plates for a job of your own choice on your own press (if you're a printer).
Another place to watch for proof of what we are saying is true, is the FTA's print awards coming up May 3rd. We already know from several of our customers that they have won awards for jobs printed with Flexcel NX at 250-300 lpi.
For print samples or to arrange test plates email me at john.anderson3@kodak.com
For more information and to see the specifications of the plates, and imaging device, or read the Trisoft article visit www.kodak.com/go/flexo
With regards, Dr John
Posted By: Michael Jahn (4/1/2009)
Comment: Maybe it was just an April Fools joke like this one --> http://members.whattheythink.com/home/af/eyecamera.cfm
Posted By: Paul (3/31/2009)
Comment: sounds logical to me. I'm not sure why your factual disection of a press release is called a "rant." It's simply uncovering unqualified claims in a very logical, sequential order.
Posted By: David (3/31/2009)
Comment: I think this is far from objective and some of the things you are pointing out don't make any sense. 300 lpi for Flexo doesn't seem very realistic to me, have you calculated the number of gray levels you can reproduce with 300 lpi at 2400 dpi?
65!!!
I think it's sad to be ranting against the competition like this, it is a sign of weakness.