1. Flint Group A re-introduction
Rich Emmerling
Technical Manager
Flint Group Flexographic Products
Having the speaking slot right after lunch can be a challange but this is a better slot as compared to the last two times I have skoken at the FPPA these slots were the last talk of the FPPA and the golf outing followed.
By reintroduction I mean that we have had a a strong corrugated product for several years but have not gained a signficant market share in the US. In Europe we are the market leader with this product line. Our US market share can be attributed to a number of reasons but but plate material quality or print quality are not factors.
Today I will go over our correugated product line. Followed by our thin plate technology and end with Flint Groups managing the platemaking waste stream program.
But first a quick FG overvciew.

2. ? A History BASF Morrison Inks Inks Chemicals B&T CQIB Temple Inks
News/Publication

3. Flint Group Divisions Packaging & Narrow Web Pigments Print Media
Flexo Inks
Gravure Inks
Offset Inks
Packaging
Pigments
Print Media
Pigments
Coatings
Plates
Sleeves
Plate Making Equipment
Offset Inks
Blankets
Pressroom Chemicals
News Inks
Commercial Printing

4. Quick Facts 140 Facilities, in over 40 countries worldwide
~ 7,500 People
Revenues of $3.5 billion in 2009
100% derived from sales to the printing and packaging industry
#1 or #2 in all markets served
Flint Group was formed from the merger of XSYS Print Solutions and Flint Ink in 2005
XSYS was the combined companies of ANI and BASF Printing Products (2004)
Flint Group acquired Day International/Rotec in 2007

5. North American Plates Facility
North American Technical & Training Center In Charlotte, NC with nyloflex® FV flowliner, drier, top lift exposure unit, image analysis systems, and ablative lasers.
Team of experienced Technical Service people for plates set up and equipment installation & training.

6. Product Portfolio Flexo Plates Letterpress Plates Equipment & Solvents
Sleeves, Service & More!

7. Differentiate to Thrive Offer something different to your customers
Rich Emmerling
Technical Manager
Flint Group Flexographic Products
Now to move into the corrugated section

8. Surviving in a challenging economy requires differentiating yourself in the market. Offering new products to your customers – ones that address their need for quality and value – set you apart from your competition.
In the spirit of differentiation, Flint Group is introducing two new products for the corrugated market, and a new, thinner plate that will address both quality and sustainability concerns.

9. Corrugated Industry Focus
For too long it’s been a " me too" world for corrugated post print plate products
Everyone was after the formidable leader to duplicate the performance of the market leading product
Each supplier has developed a product that is essentially similar to that market leader
But now it’s time to do something different
Flint Group has refocused its product development on the corrugated post print market to introduce new products that take the print performance for corrugated to new levels
Our R&D department took some unique steps to learn more concerning the plate needs of the corrugated market, besides the usual required physical properties like solvent swell resistance, high chip resistance in the W/O unit, and robust finished plate storage properties. The development group actually decided to leave the labs and look into non traditional areas for ideas and they were good enough to share a couple of these with me.

12. nyloflex® FAC
The premium, high quality plate for corrugated post print
Available in digital and conventional
Wide market share globally
Proven high quality printing plate
Conventional up to 52x80"
32 Shore A

13. nyloflex® FCC The " economic" alternative to FAC
Durable, ideal for line and halftone work on a variety of boards
Very good ink transfer and solids coverage, even on coarse liners
32 Shore A

14. Requirements of Corrugated Post Print
Print Quality
Dealing with the trend to lower liner quality
Lower board quality demands a plate that will work with low impression to avoid compression of flute
The market needs a plate that will provide excellent solids coverage, print clean, open reverses, and minimize dot gain
Can these requirements be filled with one plate type?
What would be the effect of using a harder plate?
Would a softer plate be able to reduce impression while still providing smooth ink lay down and still print with low level of dot gain?

15. Introducing New products for the corrugated post print market
FSC – a soft durometer (25 Shore A) plate for excellent solids coverage with fine, detailed reverse and positive printing on A-, B-, C-Flute, rough surfaces, recycled, and low quality liners
FHC – a higher durometer (38 Shore A) product for high end post print applications on C-, E-, Micro-Flute coated and uncoated liners

16. nyloflex® FSC – High Quality Print
Conventional and Digital
Excellent solids coverage, particularly on low cost liners
Very good ink transfer
Deep, sharp reverses, for excellent print results
Superior performance in line work
Also suitable for halftone work

17. nyloflex® FSC Digital – Cost Efficient & Reliable
Standard solid plate processing
Superior durability and long lifetime, no chipping
Processes in standard equipment
Established, proven technology
Easy handling – fast processing
Reduced plate cleaning
Excellent plate thickness tolerance

18. nyloflex® FHC Conventional and Digital Excellent dot reproduction
Fine line and reverse printing
Excellent ink transfer
Wide exposure latitude
Longer press life
Excellent impression latitude

19. Print Trials
Two separate print trials were conducted with all products
Trials were done at Clemson University on the Bobst press and at Fox Valley Technical College on their Grant International Workhorse press

20. Print Results – Hard Plate/Coated Board

21. Hard Plate – Coated/Dot Gain
Standard
Hard
Sharper detail
More open shadows
Comparable solid coverage
Slightly sharper reverses
Standard

22. Hard Plate – Coated/Solid
Standard

23. Hard Plate/Reverse Print Coated
Standard

24. Print Results – Soft Plate/Coated Board

25. Soft Plate – Coated/Dot Gain
Standard
Soft
Equal dot gain.
Better solid coverage
The ultra fine reverses were slightly more closed
Standard

26. Soft Plate – Coated/Solid
Standard
Soft

27. Soft Plate – Reverse Print/Coated
Standard
Soft

28. Print Results – Soft Plate/Uncoated Board

29. Soft Plate – Uncoated/Dot Gain
Standard
Soft
Less image gain
Standard
Soft

30. Soft Plate – Uncoated/Kraft/Solid
Standard
Soft

31. Soft Plate – Reverse Print/Uncoated
Standard
Soft

32. The broadest product line for corrugated
Conventional and Digital
Conventional and Digital
Conventional
Conventional and Digital
Hardness (Shore A)

33. nyloflex® Product Range
Product Application Board Quality Hardness
Shore A
FHC/FHC D
Pre-, Post Print
Very High 38
FAC/FAC D
Post Print
High 32
FCC
Standard
FSC/FSC D
Basic, Low 25

34. nylosolv ® Low odor Rarely requires balancing
Low plate swell for shorter drying times
Low plate swell prevents chipping in washout unit
Largest market share of washout solvents in Europe

35. Conclusions
The softer plate produces excellent solids coverage at lower impressions levels, with clean, open reverses, and comparable dot gain to harder plates
The harder plate prints as well as current 32 Shore A products but has the durability of a harder plate
The harder plate provided a higher impression latitude without showing distortion of the finer detail

36. Ultra Thin Plates

37. What are Ultra Thin Plates?
Flexographic plates with a thickness of .030" (0.76 mm)
Have a relief depth/polymer layer of .023" (0.58 mm)
Have a base PET film thickness of .007" (0.18 mm)
Have no " floor" polymer, plates are washed down to the PET layer
Typically a hard plate, 62 Shore A, (ASTM)
Polymer Layer
PET Base Layer 37

38. Why Ultra Thin Plates Now?
Flexo platemakers and printers are looking for technology/quality advancements
Speed to press, up to color time, registration, print quality are at measured by higher standards
Platemakers and even packaging buyers want to use eco-efficient technologies to reduce waste and carbon footprint
Most wide web presses are fitted with sleeves, allowing for the necessary change in tooling 38

39. So What Are The Advantages Of Going Thin?39

40. Weight Raw material has about ½ the weight
40% more plates per box = less packaging
Less handling boxes, crates, skids
Easier to carry sheets of material 40

41. Weight Finished plates have 1/3rd the weight Easier handling
Lower shipping costs
Example: 7 color job, 42x60" plates, shipped UPS Next Day from Chicago to Dallas:
0.067" plates cost $191.85
0.030" plates cost $138.70
Savings per shipment of $53.15
5 Shipments per 50 weeks would be a savings of $13,288
Source: UPS.com June 41

42. Productivity Comparison of a Single Plate
Solvent Processed 0.067"
Exposure – 10 min.
Processing – 8 min.
Drying – 120 min.
Light Finishing – 10 min.
Total – 148 min.
Solvent Processed .030"
Exposure – 8 min.
Processing – 6 min.
Drying – 30 min.
Light Finishing – 6 min.
Total – 50 min.

43. Even more flexible than .045" plates!

44. Reduced Cupping, Thanks To Being Thinner
Cupping on solids happens
more on thick plates
Thinner plates cup less,
print more even,
require less impression

45. Print Quality
In 1996, the FQC Program had leading suppliers and printers evaluate the optimum plate thickness for flexography in wide web printing. 45

46. Print Quality 46

47. Print Quality 2009: Equal or Better with .030"
SID 1.1
SID 1.4

48. Print Quality: Conclusions
As was concluded in the 1996 FQC Study, the 0.030" plates still print with less dot gain than 0.067“ plates.
Medium to firm cushions tapes and sleeves are recommended for use with 0.030" plates. 48

49. Eco Efficiency
Eco Efficiency was calculated from 0.045" and 0.067" plates with a degree of solvent recycling at 87.5%
Data was not specially optimised for better processing conditions (exposure) for 0.030" plates
GWP incl. plate, packaging and transport contribution is estimated to be 32% lower for 0.030" plates compared to 0.067" plates
Energy consumption incl. plate, packaging and transport contribution is estimated to be 40% lower for 0.030" plates compared to 0.067" plates
FG commissioned a third party to complete an EEA comparing solvent washed plates with thermal plates. The results of this study were presented last year. The main conclusions were the carbon foot print of the solvent washed plate was either smaller of equivalent to the thermal process depending on the blotting towel used in the thermal processor. Also, the solvent process provides approximately 13% savings.
CO 2 emission are used to measure GWP

50. Eco Efficiency
GWP of 0.030" plates (.76mm) versus " plates (1.70mm) extrapolated estimate
0.067"
.030" 50

51. Eco Efficiency
Energy of 0.030" plates (.76mm) versus " plates (1.70mm) extrapolated estimate
0.067"
.030" 51

52. Summary of Benefits with 0.030" Plates
Plates process about 60% FASTER than 0.067" plates
Lighter weight can save thousands $$$ per year in shipping
Flatter plates with less cupping = durability, fast up-to-color
Less packaging due to more plates per box
Perfect relief consistency, easier to process and print with
Estimated 32% reduction in Global Warming Potential
Estimated 40% reduction energy consumption
Prints with less dot gain than 0.067" plates 52

53. Managing the Plate Making Waste Stream
A new program in development at Flint Group

54. nyloflex® Sustainable Solutions
Thinner Plates to reduce time, energy and material consumption by up to 40%. Let Flint show you how and provide the materials and tooling, along with a detailed transition plan
Compressible sleeves to reduce the waste and cost of disposable cushion tapes. Improves run consistency while allowing for higher run speeds
Plate room and pressroom audits, plus technique training to reduce production waste
High efficiency process equipment. Use less chemistry, energy and time
Recovery of plate packaging. Services available to recycle empty containers
Recovery of used plates and distillation material. Services to remove plate materials and convert them into energy will be available soon
Rotec compressible sleeves reusable compressibility, available in three cushion levels the foam layer is extremely durable and provide equivalent print quality when compared to tradition cushion tapes.

55. An offer to our Customers
In our opinion the least that should be done with products after they have done their job in the Flexographic Process is to get part of the energy back that has been put into them during manufacturing
Flint Group offers customized Solutions for a responsible way to handle Flexographic waste other than just land-fill
" Waste to Energy" is one of the solutions that Flint will be offering to customers in a "removal and disposal" service
Flint Group FP benefits from experiences with similar services that have been successfully offered to our ink customers over the years

56. nyloflex® Sustainable Solutions
More information will be available soon!

57. Wrap Up Doing something different for your customer
A new, softer plate for direct print corrugated that offers improved solid coverage, sharp and open reverses, and comparable dot gain to 32 durometer plates
A harder plate that demonstrates sharp detail, low dot gain
Thin plates to improve print quality, reduce waste, minimize environmental impact
A proactive program to reduce the environmental footprint of plate making operations
And now a closing photograph taken during a brain storming session during the development of the new corrugated products of our R&D director.
Differentiate to thrive = offer something different to your customer.
FSC = smooth solids
And
FHC = low dot gain

59. Thank You