bringing the simplicity of digital printing to flexo! · · 2014-06-19bringing the simplicity of...
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BRINGING THE SIMPLICITY OF DIGITAL PRINTING TO FLEXO!
What is REVO Digital Flexo Revolution?
REVO Digital Flexo Revolution is
• A Project Team of leading companies in the printing industry
• Promoting a new manufacturing method
• To create Digital Flexo by “digitising” the flexo process
Who are the REVO Digital Flexo Revolution Partners?
Team Product Revo Activity
Converter of Labels and Packaging Field Test and Validation of the REVO Digital Flexo process
Anilox rollers Anilox rollers suitable for REVO specifications
Helios 100% inspection Press Control & Quality Control
Polymer plates and pre-press HW Flexo plates suitable for REVO specifications
Pre-press software and hardware 7 colours separation SW and control HW suitable for REVO specifications
Printing Inks Flexo inks suitable for REVO specifications
Printing and converting machines Digital automation for REVO printing and converting specifications
Labels and Packaging substrates Substrates suitable for REVO specifications
What is the REVO Digital Flexo Revolution?
• Print with 7 colours (fixed palette) colour separation
• Print with UV Flexo inks
• Use fully automated “digital” Flexo presses
• Use fully automated “digital” Pre-press and plate making
REVO Digital Flexo Revolution is
● Shorter print runs– More products and variants
– “Just in time” production
● Cost efficiency and waste reduction required– Shorter print runs = more
make readies = higher cost– Competition from digital
● In all applications– Labels, Folding Carton,
Flexible packaging…
Market Trends
Source: InfoTrends 2012 survey “What do converters want”. Over 200 converters surveyed in North America, Europe and China
Today’s Market Concerns
“50% - 60% of
production time is washing”
Shrinking Production Time
REVO Digital Flexo Features & Benefits Overview
• Sustainable 10 to 50 meters of waste per job (without operator)
• Consistent Digital colour matching in pre-press (no ink match on press)
Digital print pressures and register (without operator)
Inks and anilox rollers are never changed in the press.
• Flexible hundreds of special colours in one print
1 minute set-up of a press for a new job
Print on all substrates
• Quality driven The most vibrant images ever printed
• Profitable 95% production – 5% set up time on a REVO press
REVO Digital Flexo Revolution is
What do I need for REVO Digital Flexo?
The REVO Team have developed the integrated REVO Set of Technologies, which includes:
• Flexocure® Ancora Low Migration UV inks• Cyrel® DFUV and DPR photopolymer plates• GTT™ anilox rollers• Equinox separation pre-press• Fit™ range of substrates• Infinite Flower™ print units• Helios II pressure control & 100% inspection.
REVO is immediately available as an “off-the-shelf “turnkey” package.
REVO DIGITAL FLEXO Revolutionis accessible to every Labels and Packaging converter worldwide.
What are the REVO benefits?
Cost reduction:
• less substrate, less inks, less time are wasted for colour matching in the press. Up to90% of PMS palette is reproduced with combination of the fixed colours in the press.
• less ink is needed to print PMS colours (up to 50%).
• less substrate is wasted during set-up in the press due to Digital Automation
• more up-time of the press is achieved due to down-time reduction for colourmatching, print and die-cutting cylinders change, press set-up, press inconsistencyduring production.
• no additional cost for substrates pre-treatment
What are the REVO benefits?
Consistency:
• process parameters are digitised throughout the entire workflow “from pre-press toprint”. The full process is under REVO digital control.
• operators skills are not required for colour matching.
• anilox engraving and inks are optimised for consistent performance.
• digital automation on press greatly reduces the variables caused by differing operator’sskills.
• colour density is consistent from 10 m/min to 180 m/min
What are the REVO benefits?
Quality:
• Extended colour gamut with 7 colours (CMYK + Orange, Green, Violet) provide vibranteffects on pictures with natural and realistic images.
• HD Flexo with 80 lines per cm (200 LPI) become standard, taking flexo to a higher printquality level.
What are the benefits?
Digital flexibility:
• the same file can be printed on a Digital or a REVO Digital Flexo press, with similar qualityand costs. Production flow can be similar to a Digital press, with
i. frequent job changes,ii. last minute job planningiii. fast speed to marketiv. reduced minimum order quantity
Graphic flexibility:
• a single job can contain hundreds of PMS colours, without additional print stations.
• REVO allows printers to combine multiple labels on the same plate.
Adare is a UK leading converter who has experiencedREVO technology in “real” production.
“The advantage of REVO technology, which we are beta-testing as a Labels and Packaging converters sincelast year, is inherent to the “digital” control of all variables. We have encountered dramatic cost reductionsin substrate waste, press down-time, ink consumption. It is clear that colour matching for a converter is thegreatest problem, in real life production. With REVO “digitally” optimized technologies we can achieverepeatable and predictable PMS shades. A digitally automated press makes the rest in terms of fast turn-around. Thus we have changed our production structure, proposing much shorter lead times and greaterproduction flexibility to our customers. It is like having a digital press with flexo costs.”
Daragh Whelan - Technical Director of Adare UK
First REVO Testimonial
Conventional REVONo. of Set Ups 5 1No. of Colours 6 7No. of Ink Mixes: (Pantones) 10 0No. of Plates: 30 7Total Make Ready Material Mtrs: 600 501st Job Make Ready Time: 1 hr 30 mins 30 minsRun on Make Ready Time: 30 mins N/ATotal Make Ready time: 3 hrs 30 mins 30 mins
Conventional Flexo Vs REVO Digital Flexo
Conventional REVONo. of Set Ups 2 1No. of Colours: 7 7No. of Ink Mixes: (Pantones) 6 0No. of Plates: 14 7Total Make Ready Material Mtrs: 200 501st Job Make Ready Time: 1 hr 30 mins 30 minsRun on Make Ready Time: 30 mins N/A
Total Make Ready time: 2 hrs 30 mins
Conventional Flexo Vs REVO Digital Flexo
Lots of special colours in one print
The most vibrant images ever printed
REVO Minimum specifications
Extremely accurate register tolerances are needed to print with REVO also small negative types with 2-3 colours on top of each other.
• Accurate plate mounting is needed. • Presses with accurate register performances are needed.
Total colour consistency is a must to achieve PMS matching in production.
• GTT anilox rollers guarantee worldwide that ink transfer tolerance between rollers is limited to less than 1%.
• Infinite Flower print units guarantee 100% colour consistency from 10 to 180 m/min.• Flexocure® ANCORA inks, Cyrel® DFUV/DPR photopolymer plates and FIT substrates guarantee
standardized and tested quality for all the supplies globally, to obtain global colour consistency.• AVT Helios pressure control ensures accurate “operator independent” pressure consistency.
BRINGING THE SIMPLICITY OF DIGITAL PRINTING TO FLEXO!
THANK YOU. QUESTIONS PLEASE?
Can I retrofit my existing flexo press?
No, the REVO Set of Technologies is the best “off-the-shelf” package to start printing with REVOmethod, and getting immediately all the REVO benefits.
REVO Frequently Asked Questions
What is the lifetime of REVO 80 lines plate comparing standard to Digital Flexo?Same or better because the pressure control is fully automated
When I print a 5 colours job (a process job, with only one additional PMS colour), do I need always to use 7 inks and seven plates?NO, REVO will use minimum number of inks and plates. Only a selection (and not all) of the 7 inks available will be required to reproduce the desired PMS.
Can I print with just 4 process colours and print also PMS colours? YES, with REVO Technology you can print with 4 colours process inks and achieve up to 68% of PMS colours.
REVO Frequently Asked Questions
When I print a specific PMS colour, do I always need to print 7 colours on top of each other? NO, any PMS colour will be reproduced with max 3 colours selected between the 7 coloursavailable.
Can I use my existing anilox rollers?NO, you need to buy REVO compatible GTT anilox rollers which can guarantee the consistentand standardized ink transfer needed to achieve REVO quality.
Can I use my existing inks, substrates, press, inspection system?NO, you will not achieve the same accuracy in colour matching, the same quality in printing, thesame consistency in the printed results, and you would not get all the combined, standardizedadvantages of the integrated REVO Set of Technologies and of Digital Automation. In the futurethe REVO Set of Technologies will be further extended.
REVO Frequently Asked Questions
Who is going to make the plate for me?• ADARE REPRO HOUSE can support you on Repro graphic file preparation
for REVO standard.Contact Daragh Whelan ([email protected])
• The REVO Team will identify and propose you the closest REVO Service Point to your company. Please Contact DUPONT PACKAGING GRAPHICS: Mr. Carsten Bastian ([email protected])ESKO : Mr. Fredric Vanvinckenroye ([email protected])
Who is going to consult and qualify me or my service point on REVO?ADARE REPRO HOUSEContact Daragh Whelan ([email protected])
REVO Frequently Asked Questions
Can I make REVO plates in house?Yes, you need to buy Equinox program for 7 color separation and use HD flexo platemanufacturing process for Cyrel® DFUV photopolymer plates.
REVO Frequently Asked Questions
Stay updated and visit occasionally the official REVO web site. (www.revo-digitalflexo.com)
REVO will advertise and publish all the news and technical innovations achieved in the coming months.
The Future of REVO
REVO Contact ListFor all kind of support you can contact the following REVO members:
ADARE : Mr. Daragh Whelan ([email protected])APEX GROUP of COMPANIES : Mrs. Jeanine Graat ([email protected])AVT : Mr. David Naisby ([email protected])DUPONT PACKAGING GRAPHICS: Mr. Carsten Bastian ([email protected])ESKO : Mr. Fredric Vanvinckenroye ([email protected])FLINT GROUP : Mr. Niklas Olsson ([email protected] )Nuova GIDUE : Mrs. Cristina Toffolo ([email protected])UPM RAFLATAC : Mr. Marko Tiainen ([email protected])
www.revo-digitalflexo.com
Thank you!
The Revo Members