1. Corrugated Post-print: Conventional or Digital?
Dan Rosen
Accounts Manager
BASF Printing Systems
BASF

2. A Frequently Asked Question:
With CTP growing rapidly in other flexo markets, are there any benefits to using CTP in Corrugated Post-print?
Does it improve workflow?
Does it make better plates?
Does it yield better print capability?

3. Indeed, CTP Is Growing Rapidly
Installation of Laser Systems - World wide 2 10 30 80
125
175
250
320
420

4. Do The Benefits Of CTP Apply To Corrugated?

5. Some Qualifying Comments
This is a real world discussion:
B flute, not E flute or micro flute boards
Kraft and mottle white, not “high holdout” specialty liners
Average presses with standard aniloxes
Thicker plates (.155”), not ultra-thin with foam
Line Screens in the range of 42, 65 and 85 LPI

6. Just One Commercial…
BASF

7. Yes, We Have The Digital Plates!
62°
ACE DII 58
FAH DII
42°
ART DII
32°
FAC DII 0°
10°
20°
30°
40°
50°
60°
70°
Shore A
Hardness

8. End Of Commercial.
BASF

9. CTP Handling
Today's laser imagers are well suited for thicker photopolymers (.125” ”)
RPMs are now lower, high throughput
Plate loading & gripper bars are improved
Vacuum assist is very effective
Ergonomic designs allow for single operator loading of very large plates
                                                                                 

10. Let’s Look At A Few Aspects:
The standard points about film elimination
Pre-flight workflow, Mounting
Imaging / Printing – “where the rubber hits the road”
Summary

11. Let’s Look At A Few Aspects:
The standard points about film elimination
Pre-flight workflow, Mounting
Imaging / Printing – “where the rubber hits the road”
Summary

12. Film Elimination With CTP
No films to file or strip
No dings, dust, or film quality issues
Set-up of plate exposing is simple
A big plus, since most platemaking for corrugated involves large films that are difficult to handle.

13. Image Layout
Some strong advantages to using digital layout – compared to traditional film stripping
Some aspects of digital layout can be done with film image setters today
Other aspects, such as last minute image changes, plus pre-mounting techniques are better suited for CTP
The Following Three Slides Are
Courtesy of Esko Graphics

14. PlatePatcher Software For Post-mounted Jobs
Post-mounting support for corrugated workflow
Automatic reduction of full-format jobs with scattered images - into patches, saving polymer
Automatic generation of cut marks – for higher/easier accuracy
Parameter file sent to cutting & post-mounting video devices
Decreases post-mounting time

15. PlatePatcher Software For Post-mounted Jobs
Time savings opportunity:
Allows for accurate post mounting using coordinates from the graphics file… less guessing
Workflow description:
Job File PlatePatcher  Datafile (plate cutting)  CAD CAM table  Datafile (positioning)  Post Mounting Device
Video / Electronic Mounting Device

16. Productivity In Pre-Mounting Images Before Platemaking
Unimaged polymer pieces pre-mounted on the carrier sheet using templates generated by the job file
NO “image” mounting, ONLY blank pieces
Laser imaging time managed by “Superskip” software
Image placement on the mount is digital-perfect
Normal plate processing on the carrier, die sealer added afterward
Best on large mounts
* Used at Rudolf, Schawrtz and Tiesen

17. The Print Test…
BASF

18. Team Involved BASF Printing Systems: Plates, Data, & Reporting
Fox Valley Technical: Printing
Schawk Chicago: File Prep., Platemaking, Mounting, & Data

19. Materials & Conditions
BASF’s nyloflex FAC Conventional & Digital
Imaged on Esko 5080 Power Beam
Mounted on 30 pt. Carrier with 2 mils tape and underpacked with 90 mils foam
Printed on FVTC Workhorse Industries 3-color press with a Harper 400 line, 3.8 bcm anilox roll
Menasha Corp. KLA white & Kraft b-flute substrate
INX Brite II Process Black 9.7 ph and 24s with #4 DIN
Speed was 50 sheets / minute
equal SIDs and Impression levels

20. Image Target Designed

21. Image Target Designed

22. Keeping Things Fair…
BASF

23. Light Scattering Light (UV) Scattering area Scattering area
Vacuum film
Film base
Silver emulsion
Release layer
Relief layer
Black mask
Relief layer
Scattering area
Scattering area
Conventional plate
Digital plate

24. Dot Reduction From O2
UV Light
Black mask
ablation
Polymer

25. Dot Reduction From O2
Ø conventional
Ø digital O2

26. Dot Reduction From O2

27. We Worked To Make All Dots Physically Equal On The Plates
File
Film
Plate =

28. In Other Words, A 10% Dot Is The Size Of A 10% Dot
Mask
Plate
File

29. Measured Dot Physical Surface Diameters On Plates

30. The Print Results…
BASF

31. Solid Ink Density Comparison

32. Side By Side Comparisons

33. Side By Side Comparisons

34. Side By Side Comparisons
Digital
Conventional

35. Side By Side Comparisons
Conventional
Digital

36. Dot Gain: 42 LPI White

37. Dot Gain: 65 LPI White

38. Dot Gain: 85 LPI White

39. Dot Gain: 42 LPI Kraft

40. Dot Gain: 65 LPI Kraft

41. Dot Gain: 85 LPI Kraft

42. Side By Side Comparisons
Digital
Conventional

43. This was one test. Many more should be done!
Summary of Advantages
Filmless Output, Layout And Imaging
Possibilities For Imposition Digital Mounting
Ability To Hold Finer
Highlights
Shadows
Fine Type & Reverses
Less Dot Gain on 85, 65, even 42 LPI White
Marginal Print Improvement on Kraft
This was one test. Many more should be done!

44. Dan Rosen Accounts Manager BASF Printing Systems rosend@basf.com
Thank You!
Dan Rosen
Accounts Manager
BASF Printing Systems
BASF