Simultaneous Ablation & UV Exposure for Digital Plates and Sleeves Ian Hole Director for Market Development ESKO

Established Digital Platemaking

3 Established Digital Flexo Platemaking Process Ablative Laser imaging to post processing UV Main Exposure Digital Flexo Plate with LAMS coating Laser Ablation Back Exposure Conventional Solvent Processing Thermal Dry Processing

4 Digital Flexo - Status digitaldigital -Smaller highlight dots and digital consistency -Improved drain in shadow areas giving clean negative print -Stable image throughout print run -Processing not changed for digital plates or sleeves -Dot support issues possible if UV exposure is not well controlled -“Bump Curve” critical to compensate for highlight dot shrinkage on plate - Accepted by many as the way forward in Pack and Labels 14 micron dot

5 ‘ sq. ft ‘ sq. ft ’ sq. ft ’ sq. ft ’ sq. ft (full image 40” x 30” - 12 minutes) (sq.ft/hr) at 2000 dpi- any lpi PLATES AND SLEEVES Digital Ablation through 2005 Advancements in ablation speed and productivity

6 Digital Platemaking through 2005 Advancements in plate processing technologies –Thermal dry processing, saves time and less distortion to the polymer –Thermal dry processing has less emission issues –Extended range of available durometer, thickness and types of polymer Minimal changes to plate main exposure –Point light sources not proven over complete large plate area for dot shape and structure –Bank lights still need compensation from “Bump Curves” to achieve well- formed highlight dots –Inconsistency easily possible, wastage expected

Digital Platemaking Today

8 Digital Flexo Platemaking Workflow - Today Simultaneous Laser Ablation and UV Main exposure Conventional Solvent Processing Thermal Dry Processing UV Main Exposure Laser Ablation

9 Digital Flexo dot shape comparison Simultaneous Digital Digital smaller highlights better formed + dots have good shoulder support + long press life due to dot formation + better ink transfer - smaller highlight dot possible - improved drain of residues - clean negative print - stable throughout press run - no vacuum / OXYGEN inhibition 14 micron dot

10 Speed development of Flexo Imager family 13.2 sq. ft sq. ft sq. ft sq. ft 2000 T WIN B EAM/Optics sq. ft 2002 P OWER B EAM/Optics40 (sq.ft/hr) at 2540 ppi- any lpi PLATES AND SLEEVES 86.1 sq. ft 2005 / Optics sq. ft 2005 / Optics 80 – 50x80=19 minutes

11 Why Simultaneous Ablation and UV Main Exposure? - Possibility for targeted UV light simultaneous with ablation giving higher productivity, less total process time - Rotating plate/sleeve addresses the light exactly perpendicular and very close to polymer surface brings perfect exposure of fine highlight dots - UV light emission is exactly consistent across ENTIRE plate/sleeve surface for highlights and shadows - Easily adapted for plates or sleeves of any size - Reduced handling brings labor down and polymer savings up

12 The Technology (patented) - Liquid cooled mercury capillary source - Pre focused UV reflector

13 The Technology for Plates - Fixed distance from plate surface OPTICS

14 The Technology for Sleeves - Automatic lamp distance adjustment for sleeve repeat sizes - NO Productivity loss for ALL sized sleeves (same as plates) OPTICS

Benefits from the technology

16 time Time Reduction of Platemaking process - before Imaging, UVexposing, processing, drying, finishing Solvent CTP 1.Color 2.Color 3.Color 4.Color Thermal CTP Imaging, UVexposing, processing, (no drying), finishing 1.Color 2.Color 3.Color 4.Color

17 time Time Reduction of Platemaking process - after Imaging/UVexposing, processing, drying, finishing Solvent CTP 1.Color 2.Color 3.Color 4.Color Thermal CTP Imaging/UVexposing, processing, (no drying), finishing 1.Color 2.Color 3.Color 4.Color

18 Elimination of polymer waste – in detail Elimination of waste through Plate to Plate consistency from more digital control of process – UV light exposure was always analog Elimination of polymer waste through reduced polymer handling within process –No carrying of large (thick) plates to and from a UV frame –Once Ablated/UV is exposed, plate image is fixed, damage to mask layer is irrelevant, does not affect the final plate/sleeve image Strong dot shoulder structure from perpendicular light gives support to small isolated highlights

19 Perpendicular UV light forms better dots than Bank Light As UV bank-light is being delivered to the plate, oxygen is being depleted thereby shrinking the dots – Digital Technology What would happen if you could deliver greater amounts of UV to the photopolymer in shorter periods of time? Is oxygen depletion still sharpening the dots? Targeted amounts of UV delivered to the photopolymer at exactly 90 degrees to the polymer Highlights and fine line detail gets almost ALL the light necessary to form a strong dot – Very reduced “Bump” exposure necessary (max 1-3% range) Targeted amounts of light EVENLY delivered to ALL parts of the polymer surface Good quality dots across entire tonal range with good shoulder support

20 time Productivity - Digital Flexo vs Direct Engraving Imaging/UVexposing, processing, drying, finishing Solvent CTP Direct Engraving 1.Color 2.Color 3.Color 4.Color 1.Color 2.Color 3.Color 4.Color Thermal CTP Imaging/UVexposing, processing, (no drying), finishing 1.Color 2.Color 3.Color 4.Color

21 Summary of Cost and Productivity Benefits Reduction in platemaking process time with SIMULTANEOUS ablation and UV main exposure Elimination of waste through Plate to Plate consistency from more digital control across more of the process (no analog exposure frame) Elimination of polymer waste through reduced process steps and handling Reduced Bump Curve plus an extended tonal range – because plate is almost linear Use with Solvent or Thermal / Plates or Sleeves Productivity and quality increased even more versus Direct Engraving

The Results on Press

23 Press Dot Gain comparison 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% FILM DOT % PRINTED DOT Analog Bank Light Digital Dot Gain from Digital is 50% less than analog plates and more predictable Even less Dot Gain from Simultaneous plates Simultaneous Digital DGC curve

24 Benefits on Press This Simultaneous UV dot holds up well on long runs - at least the same as Bank Light UV plates – strong dot formation means press impression has same impact Same shaped dot brings all printing advantages of Digital Flexo Indications of higher Ink Transfer from Simultaneous UV dot – Why?

One application for this technology Improved workflows - Corrugated and Label Market

26 Workflow (Savings in RED) PlatePatcher for optimization of separations Mylar on table register pins, plot “slug” positions Cut and Mount “slugs” Using pins on CDI drum, load mylar carrier (with plate “slugs”) Image, UV expose on CDI Process plates on carrier sheet Attach press barstrips on XL table & onto press PlatePatcher – workflow example - tradeshop XL-Table CDI PlatePatcher *.map 10-15% polymer 70% cutting time saving 10% plate saving Plot slug positions Mounting 90% time saving PRESS Including plate processing 100% mounting time & perfect register on press UV lamp reduces Main exposure time

27 Workflow (Savings in RED) PlatePatcher for optimization of separations Imaging on CDI – ablation and UV together Thermal processing On XL table plates face down for pen ID plot on back of plate Cutting of separations on XL table (still face down) Collating separations into work job tickets Send to Mounting dept. Automatic mounter will use camera position data from graphics file PlatePatcher workflow example – label printer XL-Table Post-Mounter CDI PlatePatcher 10-15% Polymer saving 70% cutting time ID plotting on back of plate PRESS UV lamp eliminates time - 15 minutes Position file cuts mounting time – 10 minutes per color

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