Flat-Top Dots
Let’s start by stating what is meant by the term flat-top dot. A flat-top dot on a photopolymer plate is one that accepts the transfer of data from an imaging device to the finished plate at a 1:1 ratio. The 1:1 imaging ratio is measured in the file, post-CDI imaging, and ultimately on the final plate.
Now, let's dive into the details of what we have identified as the most frequent questions people ask about flat-top dots. We will release one question and answer over this 10-week timeframe.
Part 2. Flat-top dots use less ink and less substrate and thereby minimize the cost of raw materials. How?
A. It's easy to explain the savings in set up substrate just from the plates pulling up faster, with more evenness and consistency. Whether saving set-up stock or the amount of time, you STAY up and running and not stopping to clean plates or re-adjust ink and plate settings will save valuable substrate.
B. The lowest hanging fruit in regards to ink consumption is the reduction of ink wasted during the press set up. Re-setting print stations throughout the press run adds to waste. As for ink savings, flat-top polymers enhance the variety of screening technologies available for improving highlight fades and solid ink laydown and density. Couple this with the improved impression latitude of flat-top technology, this superior ink transfer becomes a game-changer.
C. The engineered screened or textured surfaces of solid screening technologies like MicroCell and Pixel+ enable the potential for the printer to apply less ink, yet achieve more density. This improved ink laydown is visually smoother, with less mottling and pinholing. Much of this screening technology is a result of resolution output devices like the Esko CDI Spark and Crystal devices. Esko's Crystal Screening is said to reduce ink consumption in as much as 15% with these FTD materials.
Check us out next week when we answer, "Are flat-top plates less susceptible to damage, wear, offer longer press runs?"
If you want to learn more about this subject, please feel free to reach out to us by calling 1-800-445-4017, or by e-mail at [email protected].
All Printing Resources has formed our Technical Solutions Group (TSG) to encompass our full range of expertise in all critical areas of the flexo process. This team is made up of industry professionals dedicated to being up-to-date on new technologies along with best practices. They are armed with the latest in diagnostic tools and are experienced in problem-solving that can achieve sustainable results. The TSG has walked in your shoes, and have felt your pain.
Click here to read: Part 1, Part 2, Part 3, Part 4, Part 5, Part 6, Part 7, Part 8, Part 9, Part 10.