Automation in Flexo Plate Making
July 28, 2020The corona crisis has left shock waves in global economy, the effects of which will be felt for quite some time. One can speculate on the extent and details, but some (mega) trends can already be seen.
- Telework
This means much more than working in a home office, which will certainly be used increasingly in the future. Telework also includes a new way of internal communication, as well as external communication with customers and partners. Internally, compliance with distance rules and the avoidance of larger gatherings will favour new forms of communication. Up to now, business trips have been considered from a cost / benefit perspective, which was mainly related to time expenditure, travel costs and potential business success. Now in-addition health risks have to be considered. A Corona infection will not only affect the travelers, but also the wider workforce, because if an infection is introduced, a further Covid-19 outbreak can only be kept under control by company shutdowns, personal quarantine, thus, considerable effects on employees as well as business development.
- Automation
Of course, this trend is not new, especially the automation of business processes through improved software is a continued trend. But particularly at the level of physical work steps, automation will experience a new boost from the Corona pandemic. While in the past times of general economic growth, automation was mainly considered while looking into capacity expansion and making the best use of new investments. It is now also a question of minimizing risk and increasing competitiveness. This affects not only pure cost optimization, but also the possibility of maintaining business operations with reduced personnel. In addition, it is easier to ensure social distancing during remote monitoring activities than for manual activities that requires co-operation with others close-by.
- Digitalisation
This trend is also experiencing a new impetus, and in conjunction with the topic “Automation in flexo plate making”, the term means the convergence of two trends mentioned above: when online conferences and telework become the new normal, online control of flexo plate production should also be part of this, as well as online access to production data and online support for maintenance. This means that the automation of individual plate production steps is not enough. The automation must also be monitored by sensors, remotely controllable and accessible at any time.
Will these trends also show up in flexo plate production, and what would they look like in practice?
Xeikon
has been working on new, visionary solutions for flexo pre-press operations for
some time. Starting with the highly productive ThermoFlexX flexo plate imagers and the new Woodpecker NANO surface structuring technology, Xeikon Prepress has
presented new devices for flexo plate processing in recent months. A new
product line was launched under the name Catena,
which includes the following modules for flexo plate processing:
– Catena-E:
UV LED exposure module
– Catena-W: solvent-based plate processor
– Catena-DL:
dryer/light finisher module
– Catena-DLS:
dryer/light finisher/stacker module, for combination with Catena-W
Each of these modules has unique features to
ensure optimal processing of flexo plates. A smart design and a carefully
considered software architecture also enable easy connection of the modules in
different combinations with very limited effort. Plate imaging and exposure
steps can be partially automated by the combination of ThermoFlexX imager and Catena-E
UV LED exposure, the washing, drying and post-treatment steps by the
combination of Catena-WDLS.
Fig. 1: ThermoFlexX imager and Catena-E combination for semi-automated flexo plate imaging and exposure | Fig. 2: Catena-WDLS combination for semi-automated flexo plate processing, drying and light finishing |
Such
semi-automated processing devices from various suppliers have been known in the
market for a long time. However, they do not mean a breakthrough in fully
automated flexo plate production, or even providing an answer to the challenges
described previously.
With the ThermoFlexX
Catena+ system, Xeikon is the first to present a zero touch fully automated
solution, guarantying integrated flexo plate processing with the highest
standards in quality, reliability and safety.
Productivity
All process steps are aligned to each
other. The completely redesigned Catena-E UV LED
exposure hasgenerally speaking the same productivity as the ThermoFlexX
imager and the Catena-W processor, so that there is hardly any production
bottleneck when standard resolutions and relief depths are used. The ability to
process all plate thicknesses is unique on the market. Therefore, almost no
restriction exists for the selection and use of digitally imaged flexographic
printing plates.
Variability
As mentioned above, almost every digitally imaged
flexo plate available on the market can be processed with the Catena system. In
addition, various “side-feed” possibilities are provided where special plate types can be
introduced into the processing line. A first option is inserting plates after
the imager, so that they can be processed fully automatically starting with the
Catena-E exposure. After exposure, there is a second possibility of side-feeding
plates into the system, thus, at least benefiting from automation after
plate washing. However, the lateral introduction of plates has a disadvantage:
the steps processed outside are naturally not recorded, and missing data will either
have to be entered manually or simply are not available. But more on that later.
Quality
All Catena devices have a robust design, thanks to the enormous experience of Flint Group Flexographic’s equipment service team. Only high-quality components are used, which have a low susceptibility to wear and also enable remote control and monitoring. Further, design principles are easy access for maintenance, as well as easy replacement of consumables such as filters, UV LEDs, brushes, etc. Many new solutions in details are implemented, such as the separation of the transport mechanism and the plate washing zone in the Catena-W in order to avoid contamination with solvents including dissolved polymers, and consequently to prolong maintenance cycles.
Occupational safety
All Catena devices are equipped with dual safety circuits to ensure redundancy
and immediate shutdown, and to avoid environmental contamination should
any unforeseen events or accidents occur. The requirements of the CE label for
tested safety are by far exceeded, and reach a level that basically
enables a TUV certification. The compliance with the highest safety standards
is particularly important for a fully automated process in order to be able to monitor activity remotely without being physically present in the
plate room.
Automation
A
digital flexo plate is processed by putting it first onto the ThermoFlexX imagerFlextray. As soon as the job data is available, the plate is automatically
loaded and the imaging process starts. At this time, the next plate can be
prepared on the Flextray. After imaging, the plate is automatically transferred
to the UV LED exposure via the Catena-B bridge. Further, progress of the plate
in the Catena modules is tracked by means of a sensor system, and all
processing parameters are automatically stored in a database. In addition to
pre-set parameters, such as exposure time and washout speed, also actual
processing parameters, such as UV intensity, temperature, solid content of the
solvent etc., are linked to the respective job and design, stored in an
external database, and can be reviewed at any time. This explains why a
side-feed of flexo plates is possible, but less convenient.
With the help of Catena-R, a robot arm, the
exposed plate is transferred to the new Catena-W solvent washer with automated
punching. Sensors ensure that the auto punching takes place parallel to the
plate edge, so that the flexo plate is pulled through the washer without
distortion. The pin bar for transportation is detached from the plate inside the
washer. The pin bar remains and circulates solely in the washer, thus, solvent
residue on the transport bar does not dry and remain, making complex cleaning
unnecessary. The flexo plate is then transferred into one of ten existing dryer
drawers, and finished in the light finishing section after drying. If
necessary, the plate can be cooled down before finishing in the stacker with
individual rest times as required. Thanks to an extremely compact design, the
total length of the ThermoFlexX Catena+
system is only 13 meters (40 ft).
Network and data exchange
Pre-press
data in TIFF or LEN format can be transferred on the ThermoFlexX imager with
the the highest quality and productivity to digital LAMS flexographic printing
plates. Thanks to the Woodpecker software solution, surface microstructures can
be created that achieve comparable results for all levels of quality known in
printing on flexible packaging materials.
Integration of software modules from external
providers, such as Tectonics from Hybrid Software, in Multiplate (ThermoFlexX
GUI) ensures that flexo plates are used efficiently by smart grouping of job
data on a plate. Furthermore, integrated cutting tables data also helps to
reduce waste on high levels. Catena
Cockpit, developed in co-operation with Hybrid Software, ensures
overarching planning of workflows, including options for integration into
external ERP and MIS systems by means of standardized API’s.
Great emphasis is put onto high availability of
the entire plate processing line. For this purpose, the functions of all
modules are externally accessible in order to be able to carry out an immediate
error analysis and correction by remotely connected service technicians. All
serviceable components are also easily accessible and easily exchangeable by
the user. Very latest technology, provided by our partner
Schneider Electric, is the possibility of using VR glasses with a virtual section
through the modules to visually show any errors. Supported by videos or the
direct connection to service technicians, it is also possible for in-house
staff to carry out complex maintenance directly and immediately with only
minimal training.
By feeding data into a database, Xeikon Prepress
is in a position to perform an AI-based analysis of machine data from all
installations worldwide. In this way, minimal deviations from the norm can be
detected and analyzed in real time, and appropriate predictive service
activities can be initiated on site.
At the best of times no-one appreciates unscheduled down-time or the expense of a service visit. Of course, this data can also be used for increasing efficiency in plate room operations or installation of a comprehensive plate room management system.
All these new service provisions and possibilities are summarized under the Catena ProServX brand. The strategic partnerships with Hybrid Software and Schneider Electric ensure that users of Catena processing devices will have continued access to the latest web-based network and database technologies.
Fig. 3: ThermoFlex Catena+ with Catena-Cockpit and Catena-ProServX software for process integration
Xeikon Prepress is the first company to offer a fully automated zero touch flexo plate processing line from a single source. After several years of development, we are proud to present our ThermoFlexX Catena system solution to a broader audience. However, the time of publication also creates ambiguous feelings: On one hand, we are aware of the difficulties caused by the Corona pandemic, which, in addition to uncertain business perspectives, has also caused hardship due to Covid-19 infections, and the economic consequences of the pandemic. We would have also liked to have the first public presentation live at Drupa in front of a specialist audience. On the other hand, we are certain that the ThermoFlexX Catena product line, in combination with the expanded service options and the well-known high quality of Flint Group flexo plates, will provide an answer to the future challenges mentioned, whether it is planning for a new start after the Corona crisis under modified conditions, planning for efficiency increases, or also the development of new business models by using the comprehensive software integration capabilities. Flint Group is once again proving that it is not only a leading provider in packaging printing, but also, thanks to the close cooperation between the Xeikon and Flexographic divisions, the innovation driver in flexo pre-press operations.