Gallus Rotascreen – customised solutions for screen printing CtP

Gallus Rotascreen – customised solutions for screen printing CtP

Thanks to continued technological developments, computer to plate (CtP) has successfully carved out a niche for itself on the market, but it is predominantly used for flexographic and offset printing. In many companies, CtP makes a valuable contribution to cutting costs and streamlining processes.
The next logical step in this context was to consider the options for using CtP for screen printing. These discussions have now come a long way, and specific solutions are already available on the market.

To meet the goals of

- greater operating efficiency
- less time in prepress
- minimising error sources through an end-to-end process
- and, therefore, achieving a substantial reduction in the overall costs

in their entirety we must take a close look at the technologies available today.
In doing so, we must bear in mind that every printshop has specific requirements, its own processes and expertise, and unique job structures. For this reason, it is clear right from the start that there are no standard, one-size-fits-all solutions that can be applied unconditionally to every company – even if some suppliers may claim that this is the case. It must also be remembered that, in many cases, screen printing is used as a supplementary printing process.
Usually, screen printing does not require the same volume of plates as the main two printing processes, flexographic and offset. An investment in production resources that can only be used for screen printing therefore only pays dividends in the rarest of cases.
Integration is the key in this context – integrating screen printing into the workflows of the main printing processes and the option to use the equipment for mutual backup if necessary.
The diagram below provides an overview of the information required for the reliable assessment of customer-specific CtP solutions.

When assessing the screen printing CtP options for a printing company, particular attention should be paid to the technologies currently used for the main printing processes.
The job structure is also extremely important because, ultimately, it defines the ratio between the various printing plates. In the past, for example, the ratio between flexographic and screen printing has generally been 6:1 on average. This ratio can be used, among other things, to calculate the requisite capacity of the production resources.
A list of the presses and print widths must also form part of the basic data.
The diagram below provides an overview of the entire process – right through to a well thought-out concept proposal for “going CtP” with screen printing.

The first step involves data acquisition and an analysis of the technological structure currently in place at the printing company.
The second step summarises the printer’s requirements. One of the key questions in this case is: Which CtP technologies does the printer want to work with in the future? The definition of the target status and the associated requirements this places on the future technology leads to the third step.

Based on the data collected, a detailed concept for integrating screen printing into a digital workflow can now be drawn up and proposed. In doing so, it is important to compare the printer’s existing technologies with the solutions that are available on the market and adapted for screen printing. This stage requires clarification of the print application (flexographic, offset, screen, letterpress, flatbed) and the plate and imaging technology. For example, there is a whole host of basic technologies for offset printing. Printing plates can be processed through thermal cross-linking or process- and chemical-free products can be offered. The number of plate manufacturers and equipment suppliers increases the complexity. The situation is less complicated for flexographic printing, but the same questions have to be addressed. All this requires a structured approach focusing on the target status defined in step 2.

Screeny Digital is one possible solution. Using a commercially available CDI CtP exposure device from Esko, Screeny Digital can be imaged in the same way as a flexographic plate, for example. Another option is to image Screeny Standard or Screeny S-Line using CtP exposure devices that have UV exposure systems,
e.g. Flexpose from Lüscher in Switzerland.
Thanks to the state-of-the-art technology available today, a solution can be found to suit virtually any printer requirements.

Gallus Rotascreen sees its task in providing printers with customised, process-oriented support with a focus on integration. The company benefits from many years of experience in the screen printing sector and through its cooperation with experienced CtP partners. In this way, we use the wide range of technological options available today to create tailor-made, reliable and sustainable concepts for applying CtP in screen printing.
Give us a call, we’ll be happy to help.

Labelexpo 2009 in Brussels

Gallus Rotascreen will be showcasing the concepts described above at Labelexpo Europe 2009 in Brussels. Rotascreen staff will be demonstrating the digital imaging capability of Screeny Digital using a CDI unit from Esko at the Gallus stand 5B50. Demonstrations can be conducted on request and without an appointment.
In cooperation with Lüscher AG, Gallus Rotascreen will be revealing the imaging capability of Flexpose from Lüscher at Lüscher’s stand. Staff will of course be on hand to answer any questions you may have in this context.

The Gallus Rotascreen team is also looking forward to meeting you at Labelexpo in Brussels.

Dario Urbinati
Produktmanager Gallus Screeny