read more about a greener and better Flexo plate

Planet
Protection.
Print
Perfection.
The Asahi AWP
Water Washable
Flexo Plate.
A greener—and better—flexo plate
While flexography has always been a more efficient
and cost-effective printing process, the challenge
has been to close the quality gap between offset and
gravure printing. Lately, another factor has come into
play—the environmental impact of the product itself.
A low product carbon footprint not only helps a company’s image—it also reduces energy consumption
and its associated operating costs.
However, the challenge has been to create a more environmentally friendly plate without losing the benefits
and advantages of quality or efficiency. Meeting that
challenge, Asahi Photoproducts introduces a new flexo
technology: the Asahi Water washable Plate (AWP). The
Asahi AWP plate is a revolution in photopolymer technology, not only by introducing a new environmentally compliant plate process, but one that exceeds the
print quality of other technologies.
Print quality that matches any flexo plate
technology.
Traditionally, water washable plate quality has been
considered second-best when compared to solvent
plates. The Asahi AWP plate does more than match traditional solvent photopolymer plates—it outperforms
the best digital plates currently available for flexo. For
the first time a digital photopolymer plate can hold
extremely small stable dots— smaller than those of
solvent processed plates—and its stability on press is
superior to solvent plates.
On a typical solvent
type plate, very small
highlights produce
irregular and oval
shaped dots on press,
leading to higher
optical density.
Also quite common is the ‘V shape effect’. Even if the
smallest dots are well formed on the plate, their behavior on press is quite uncontrollable, usually ending up
with the smallest 1% or 2% highlights generating more
dot gain, and printing larger than 3 or 4% dots.
The image on the left shows an actual job. Two arrows indicate the 200x magnification pictures (right). Formed printing
dots fading down to zero can be spotted on impression.
Extensive AWP plate trials and live production jobs
have proven its ability to print down to 2 or 3%, using
classical round dot screening. With the latest screening
technologies, the plate is able to reproduce a vignette
fade to zero. Due to this quality leap, customers already
have been able to successfully transfer production from
offset or gravure to flexographic printing.
Highlight printing dots with AWP (left) and with traditional solvent plates (right)
In flexo, highlights usually cause two potential problems. The first is the highlight ‘breaking point’, which
prevents a vignette from printing smoothly to zero.
Because of dot gain, photopolymer flexo plates usually
start printing highlights at 5 to 8%, in the best cases.
This means that gradations in vignettes suddenly
break at that level, producing a visual contrast with
the substrate—a visible “breaking point” or line, well
known if you print with flexo. Because of smaller dot
size, low dot gain and high dot stability of the new
AWP plate, the breaking point is virtually eliminated,
especially if one uses any of the latest generation of
screening technologies.
A better, longer-lasting plate on press
In the pressroom, the Asahi AWP plate has an extraordinary ink transfer, plate longevity, and dimensional plate
accuracy. It can transfer and release virtually all the ink
it takes from the anilox. Typical problems such as ink
build-up and dot bridging virtually disappear, and the
number of press stops due to plate dirtying is dramatically reduced. Ink release is so good that at the end of
the run, the plate is nearly as clean as before printing.
The Asahi AWP plate also lasts longer, with much greater
abrasion resistance (in fact, three times more resistant
than thermal plates), reducing the amount of times you
have to remake a new plate. Because of the AWP’s wide
latitude, it’s more stable, reducing print deviation during,
A clean AWP plate after printing shows only minor traces
of ink build-up compared to two solvent plates (center
and right).
or between, press runs. The plate is forgiving to changes
in press conditions, like pressure. This leads to easier,
faster and less expensive makereadies. The result? Much
less ink and substrate waste, and more press up-time,
higher press speeds and improved productivity.
An efficient, productive platemaking process
AWP technology has
been designed from
the start with a strong
consideration for the environment, and a commitment to minimizing
any possible waste of
precious resources. For
starters, the system is
water-washable, rather
than relying on harsh solvents.
But, because even water can be considered a scarce
commodity, water is reused during the various steps of
the wash out process. Clean water used for the plate
processing is ultimately filtered and recycled. And, as
a water-based system, it is free of any harmful volatile
organic compound (VOC) emissions generated by
solvent and thermal processes.
The entire plate developing process doesn’t generate
any waste other than unexposed polymer residues,
which are collected as dry ‘cake’ and safely disposed as
combustible material.
Because solvent plates systems absorb solvents during processing, they require longer drying times, emit
VOCs, and expend more energy. Thermal plates generate VOCs during the melting and removal of the relief
layer, which are also carried away with the unexposed
photopolymer removed by the blotting material.
AWP plates do not absorb much water, reducing drying time—up to two to three times faster than their
solvent counterparts. It also means a cost and space
saving in the platemaking room, as energy-demanding
hot air dryers aren’t required.
Imaging an AWP plate is quite simple. First, the plate is
back exposed to produce the desired relief depth and
achieve the maximum sensitivity to UV light. After a
protective film is removed, the plate placed in a digital
imager using laser technology, where selected areas
of a thin, black ablative area are removed. Think of it
as imaging its own negative on top of the plate. Asahi
holds the only proprietary patent for digital ablation
masks. AWP’s black mask is more durable than those
of other plates, so it handles, processes and images
more cleanly. From there, the top of the plate is exposed, hardening those areas of the plate where the
thin black layer was removed. The plate is then washed
out, removing the unexposed photopolymer, quickly
dried, and finished with UVA and UVC lights to prepare
the print-ready plate. The plate is press-ready within
an hour—as compared to 2 to 3 hours for solvent
plates—and faster than thermal plates.
The AWP plate:
not only other water-washable plates, • Outperforms
but solvent and thermal digital plates, too.
excellent ink transfer, resulting in outstanding
• Has
ink coverage.
• Has a wider tonal range
balances reproduction of large tonal areas, • Superbly
fine text and halftone elements
compatible—and very durable—with UV, solvent-
• Isbased
and water-based inks
•
Is extremely flexible, so it easily fits on small-diameter
cylinders
a special plate surface that prevents ink filling in • Has
on fine, detailed images
•
Improves registration with low temperature
processing
A greener—and better—flexo plate
While flexography has always been a more efficient
and cost-effective printing process, the challenge
has been to close the quality gap between offset and
gravure printing. Lately, another factor has come into
play—the environmental impact of the product itself.
A low product carbon footprint not only helps a company’s image—it also reduces energy consumption
and its associated operating costs.
However, the challenge has been to create a more environmentally friendly plate without losing the benefits
and advantages of quality or efficiency. Meeting that
challenge, Asahi Photoproducts introduces a new flexo
technology: the Asahi Water washable Plate (AWP). The
Asahi AWP plate is a revolution in photopolymer technology, not only by introducing a new environmentally compliant plate process, but one that exceeds the
print quality of other technologies.
Print quality that matches any flexo plate
technology.
Traditionally, water washable plate quality has been
considered second-best when compared to solvent
plates. The Asahi AWP plate does more than match traditional solvent photopolymer plates—it outperforms
the best digital plates currently available for flexo. For
the first time a digital photopolymer plate can hold
extremely small stable dots— smaller than those of
solvent processed plates—and its stability on press is
superior to solvent plates.
On a typical solvent
type plate, very small
highlights produce
irregular and oval
shaped dots on press,
leading to higher
optical density.
Also quite common is the ‘V shape effect’. Even if the
smallest dots are well formed on the plate, their behavior on press is quite uncontrollable, usually ending up
with the smallest 1% or 2% highlights generating more
dot gain, and printing larger than 3 or 4% dots.
The image on the left shows an actual job. Two arrows indicate the 200x magnification pictures (right). Formed printing
dots fading down to zero can be spotted on impression.
Extensive AWP plate trials and live production jobs
have proven its ability to print down to 2 or 3%, using
classical round dot screening. With the latest screening
technologies, the plate is able to reproduce a vignette
fade to zero. Due to this quality leap, customers already
have been able to successfully transfer production from
offset or gravure to flexographic printing.
Highlight printing dots with AWP (left) and with traditional solvent plates (right)
In flexo, highlights usually cause two potential problems. The first is the highlight ‘breaking point’, which
prevents a vignette from printing smoothly to zero.
Because of dot gain, photopolymer flexo plates usually
start printing highlights at 5 to 8%, in the best cases.
This means that gradations in vignettes suddenly
break at that level, producing a visual contrast with
the substrate—a visible “breaking point” or line, well
known if you print with flexo. Because of smaller dot
size, low dot gain and high dot stability of the new
AWP plate, the breaking point is virtually eliminated,
especially if one uses any of the latest generation of
screening technologies.
A better, longer-lasting plate on press
In the pressroom, the Asahi AWP plate has an extraordinary ink transfer, plate longevity, and dimensional plate
accuracy. It can transfer and release virtually all the ink
it takes from the anilox. Typical problems such as ink
build-up and dot bridging virtually disappear, and the
number of press stops due to plate dirtying is dramatically reduced. Ink release is so good that at the end of
the run, the plate is nearly as clean as before printing.
The Asahi AWP plate also lasts longer, with much greater
abrasion resistance (in fact, three times more resistant
than thermal plates), reducing the amount of times you
have to remake a new plate. Because of the AWP’s wide
latitude, it’s more stable, reducing print deviation during,
A clean AWP plate after printing shows only minor traces
of ink build-up compared to two solvent plates (center
and right).
or between, press runs. The plate is forgiving to changes
in press conditions, like pressure. This leads to easier,
faster and less expensive makereadies. The result? Much
less ink and substrate waste, and more press up-time,
higher press speeds and improved productivity.
An efficient, productive platemaking process
AWP technology has
been designed from
the start with a strong
consideration for the environment, and a commitment to minimizing
any possible waste of
precious resources. For
starters, the system is
water-washable, rather
than relying on harsh solvents.
But, because even water can be considered a scarce
commodity, water is reused during the various steps of
the wash out process. Clean water used for the plate
processing is ultimately filtered and recycled. And, as
a water-based system, it is free of any harmful volatile
organic compound (VOC) emissions generated by
solvent and thermal processes.
The entire plate developing process doesn’t generate
any waste other than unexposed polymer residues,
which are collected as dry ‘cake’ and safely disposed as
combustible material.
Because solvent plates systems absorb solvents during processing, they require longer drying times, emit
VOCs, and expend more energy. Thermal plates generate VOCs during the melting and removal of the relief
layer, which are also carried away with the unexposed
photopolymer removed by the blotting material.
AWP plates do not absorb much water, reducing drying time—up to two to three times faster than their
solvent counterparts. It also means a cost and space
saving in the platemaking room, as energy-demanding
hot air dryers aren’t required.
Imaging an AWP plate is quite simple. First, the plate is
back exposed to produce the desired relief depth and
achieve the maximum sensitivity to UV light. After a
protective film is removed, the plate placed in a digital
imager using laser technology, where selected areas
of a thin, black ablative area are removed. Think of it
as imaging its own negative on top of the plate. Asahi
holds the only proprietary patent for digital ablation
masks. AWP’s black mask is more durable than those
of other plates, so it handles, processes and images
more cleanly. From there, the top of the plate is exposed, hardening those areas of the plate where the
thin black layer was removed. The plate is then washed
out, removing the unexposed photopolymer, quickly
dried, and finished with UVA and UVC lights to prepare
the print-ready plate. The plate is press-ready within
an hour—as compared to 2 to 3 hours for solvent
plates—and faster than thermal plates.
The AWP plate:
not only other water-washable plates, • Outperforms
but solvent and thermal digital plates, too.
excellent ink transfer, resulting in outstanding
• Has
ink coverage.
• Has a wider tonal range
balances reproduction of large tonal areas, • Superbly
fine text and halftone elements
compatible—and very durable—with UV, solvent-
• Isbased
and water-based inks
•
Is extremely flexible, so it easily fits on small-diameter
cylinders
a special plate surface that prevents ink filling in • Has
on fine, detailed images
•
Improves registration with low temperature
processing
A green environmental impact
Asahi has always kept its focus on the environmental
impact of its AWP technology. The basic prerequisite
used to measure and manage greenhouse gas emissions is to have a scientifically substantiated, transparent
and internationally coordinated assessment framework
in place. A CO2 Footprint comparison between AWP
and other plate technologies was based on a methodology used by JEMAI (Japan Environmental Management
Association for Industry).
According to the quantitative studies, the primary
advantages of the AWP platemaking process are:
to the AWP water wash technology and re
• Thanks
duced water consumption, the AWP plate processor
uses basic resources like water and electricity in their
most efficient way. There are no VOC emissions and a
lower CO2 footprint than solvent and thermal
technologies.
reduces natural resources by re-using the wash
• AWP
water during plate processing
quality and consistency are both assured
• Production
by the automated process.
AWP-DEF digital plate specifications
AWP-DEF 1.14 AWP-DEF 1.70
Plate thickness
0.045”
0.067”
Color
Yellow
Yellow
Hardness/Shore A
77
70
K factor
5.98
9.89
Resolution @175 lpi
1-98%
1-98%
Isolated line
.003”
.003”
Isolated dot
.005
.005
Ink compatibility
UV/Water/Solvent
Asahi Kasei: A global materials-technology
leader
The Asahi Kasei Corporation, founded in Japan in 1931
and based in Tokyo with consolidated sales of $16 bil llion,
is one of the leading global chemical companies.
Its 28,000 employees work in research, production,
sales and application technology, providing innovative
chemistry and materials science solutions to a diverse
range of markets, including fibers, chemicals, consumer
products, housing, construction, electronics, and health
care.
Asahi Photoproducts, a business unit of Asahi Kasei
Corporation, is a leading global supplier of photopolymer printing plates, with facilities serving the Americas,
Europe and Asia.
Asahi Kasei America, Inc.
Photoproducts Division
3800 Camp Creek Parkway, Building 2400, Suite 122, GA 30331, USA
Tel: 1-877-344-1223 (Toll Free) +1-404-344-1223 Fax: +1-404-344-1224
info@asahi-photoproducts.com
www.asahi-afp.com
Asahi Photoproducts Europe n.v. /s.a
Paepsem Business Park Boulevard Paepsem 22 1070 Brussels / Belgium
Tel: +32 25260530 Fax: +32 25260545
planning@asahi-photoproducts.be
Asahi Photoproducts (UK) Ltd.
1 Prospect Way Hutton Industrial Estate Shenfield CM 13 1XA
Phone: +44-1277-23 28 77 Fax: +44-1277-22 44 14
asahi-photoproducts.co.uk
Asahi Photoproducts Europe n.v. /s.a. – Deutschland
07, 18 68181 Mannheim / Deutschland
Telefon: +49(0)621/401713-0 Telefax: +49(0)621/401713-17
info@asahi-photoproducts.de
Asahi Photoproducts Europe n.v. /s.a. – France
13, rue du 4 Septembre 75002 Paris / France
Tél.: +33-1-41 39 93 20 Fax: +33-1-47 77 08 22
info@asahi-photoproducts.fr
Asahi Photoproducts Europe n.v. /s.a. – Italy
Via Garibaldi 51 20013 Milano / Italia
Tel.: +39-02-38001260 Fax: +39-02-38002680
info@asahi-photoproducts.it
Asahi Kasei E-materials Corporation
1-105 Kanda Jinbocho, Chiyoda-ku, Tokyo 101-8101 Japan
Tel: 00 81-3-3296-3350 Fax: 00 81-3-3296-3466
www.asahi-afp.com