Computer-to-plate is still important for many businesses’ setups
Classic computing
While computer-to-plate (CtP) has been around for some time now, and despite it facing all sorts of competition from new launches and techniques, the technology is still a common feature in plenty of printrooms right across the UK.
Development with CtP is also ongoing, with the manufacturers behind the technology that has played such an important role in the growth and success of many print companies over the past few decades, still working hard to make even more improvements to kit that has proved so reliable.
Here, we look at some of the latest advancements with CtP kit and find out what this might mean for those companies that have stayed true to CtP.
Optimum performance
First up, with more than 6,000 installations around the world, Cron is a producer of CtP equipment, with its kit available in the UK through Service Offset Supplies (SOS). Mike Ryan, CtP sales specialist at SOS, says CtP should be regarded as an essential component for all litho printers and, thanks to ongoing development by the likes of Cron, will remain part of the industry for many years to come.
Mike Ryan, CtP sales specialist at SOS, says CtP is regarded as an essential component for all litho printers
“Unlike many of its rivals, Cron manufactures every component itself – with the exception of the lasers – and extensive investment in R&D [research and development] has led to several innovative features, common to all Cron models,” Ryan comments.
“For example, the laser head transport system employs a friction less magnetic laser carriage for greater accuracy and reliability, requiring no maintenance – a big improvement on the ‘worm screw’ design found on rival machines. Cron has patented automatic laser focusing, patented internal temperature control, and a patented side gauge system – all of which add up to a reliable plate registration accuracy to within 10 microns.
“At SOS, we are confident that Cron offers the optimum performance and value for every market sector.”
The Cron range spans all formats from B3 up to very-large-format, the latter of which is used mainly in specialist packaging applications, though Ryan explains the more popular formats are the 26 (B3) and 36 (SRA1) models.
“Cron equipment is compatible with most major plate types including processless and they will also fit seamlessly into all existing PDF workflows – although SOS will supply its own workflow if required,” Ryan says.
Cron equipment is compatible with most major plate types including processless; and they will also fit seamlessly into all existing PDF workflows”
The ‘H’ variant from Cron offers a space-saving three-in-one design, with autoloader, de-interleaving and punching built in. According to Ryan, this means it is around two-thirds the size of equivalent alternatives.
Meanwhile, Ryan says the ‘G+’ variant has greater modularity; it is available with a range of autoloaders with a high-capacity single size tray, or multiple trays depending on work profile. Manual loading is also an option while switching between plate sizes, plate thickness and punch configuration is entirely automatic.
In terms of new developments, Cron recently launched a new CtP system it claims to be the world’s first dual-drum machines, as well as the fastest in the industry. A unique design means the new DD858 and DD870 are able to process two plates simultaneously, making them capable of producing up to 70 plates per hour.
Cron recently launched a new CtP system that it claims to be the world’s first dual-drum machines
The DD858 and DD870 are compatible with all offset plates including processed, processless, low-chem and chemistry free, in sizes up to 1193 x 940mm (B1) and down to 450 x 370mm (B3) with resolutions up to 9600dpi. Both machines come with a 500-capacity autoloader as standard and are also available from SOS with a 1500-capacity loader.
“It’s a niche market but these machines will appeal greatly to any high volume, high speed printer who needs high volume, high speed platemaking to match,” Ryan says, adding: “Examples would include trade or ‘internet’ print production companies looking for an imaging unit to meet platemaking demands for a day shift or 24/7 operation.”
Automation equation
Elsewhere and another name in the CtP segment is Agfa. Iris Bogunovic, product manager for plate and CtP systems at Agfa, says one of the main reasons why offset remains – and will remain – a dominant print technology is the continued development in pre-press, press and post-press, including within the CtP space.
“Advanced automation, interconnectivity, increased productivity – all these elements add up to make offset the most cost efficient technology for reproduction in many areas,” Bogunovic says, adding: “Agfa has one of the broadest portfolio’s in the industry, offering computer-to-plate engines for the commercial, packaging and newspaper segments.
“Agfa is the absolute market leader in newspaper CtP, with more than 1,500 Advantage violet engines installed. These engines can deliver up to 400 plates per hour and have different levels of automation – ranging from manual loading up to delivery from pallets coming straight out of Agfa’s production facilities.”
This automation is also available for Agfa’s Avalon thermal CtP line, which is mainly used by commercial and packaging printers. The Expert Loader can hold multiple pallets of plates, which the manufacturer says allows for an almost operator-free production for multiple days. The fastest Avalon CTP is capable of producing more than 70 B1 plates per hour.
Further automation comes in the form of Agfa’s unique Robot Loader, a robot arm that can feed multiple CtP engines at a time, picking plates from multiple plate pallet stations. One of Agfa’s customers in Scandinavia, for instance, uses the Robot Loader to feed two very-large-format CtP lines with five different plate sizes.
Agfa’s unique Robot Loader is a robot arm that can feed multiple CtP engines at a time, picking plates from multiple plate pallet stations
“The result is a completely operator-independent production flow with improved efficiency, stability and productivity,” Bogunovic says.
Aside from specific CtP kit, Agfa also continues to enhance its range of digital offset plates. One of the latest developments from its Ecology, Economy, Extra Convenience (ECO³) philosophy is the Eclipse process-free printing plate.
“In addition to the advantage of not having to spend pre-press CAPEX anymore, Eclipse has the benefit of a strong and stable image contrast and excellent scratch resistance,” Bogunovic says, adding: “Its dedicated on-press processing technology opens up opportunities for printers to save time and money.”
Elsewhere and Adamas is Agfa’s latest chem-free solution for the more demanding part of the commercial and packaging segment. According to Bogunovic, this combines efficiency – both in plate throughput and in run length – with sustainability, as it uses zero water and generates up to 75% less waste compared to similar products.
In the newspaper segment, the N95-VCF chem-free plate is Agfa’s flagship, delivering night-after-night run lengths of several hundred thousand copies.
“The introduction of an automatic cleaning module on the Attiro clean-out unit allows newspaper companies to work for almost half a year without any intervention on the chem-free processing line,” Bogunovic says.
Faster and more efficient
Finally, a CtP feature would not be complete without a mention of Kodak. Nathanael Eijbersen, WW product manager for output devices at Kodak, says in a world of shorter runs and increased price pressures, CtP is an “indispensable prerequisite” for highly efficient, cost effective, high quality offset printing, as well as for minimising errors and waste in platemaking and on press.
“When state-of-the-art platesetters are combined with process-free plates and high-capacity plate loading and unloading automation, CtP becomes a fully automated, compact process that requires almost no manual intervention,” Eijbersen says, adding: “This also enables printers to position CtP systems closer to the printing presses or even to integrate them directly into the pressroom.
“Thanks to these capabilities and the availability of high-speed CtP platesetters, jobs can move faster than ever from prepress to press which reduces turnaround times.”
O Factoid: A recent study from Smithers Pira predicted that by 2030, more than 60% of all printed matter in the world will still be printed in offset O
Eijbersen goes on to say that CtP imaging of process-free plates like the Kodak Sonota XTRA Process Free Plate enables printers to produce in a more sustainable way and leave a smaller carbon footprint. The sustainability advantage here, Eijbersen says, is that the entire consumption of electricity, water, developer, replenisher and gumming solution, and clean-out finisher associated with conventional plate processing is reduced to zero.
“Since there is no longer any chemistry to contend with, and no plate processor in need of cleaning and maintenance, there are also no spent chemicals or contaminated residual liquids to be disposed of,” Eijbersen adds.
In terms of new developments, one of the latest launches from Kodak is the T-Speed Magnus Q800 Platesetter, which images up to 80 process-free plates (B1/ eight-page size category) per hour. This high-speed CtP device is supported by different automation options such as Single Cassette Unit, Multi-Cassette Unit, Single Pallet Loader, and Multi-Pallet Loader, the latter of which holds up to 3,200 plates in as many as four formats.
Kodak’s new T-Speed Magnus Q800 Platesetter can image up to 80 process-free plates (B1/ eight-page size category) per hour
Also new from Kodak is the Kodak Magnus Q4800 Platesetter which offers what Eijbersen describes as market-leading speed and productivity for extra-large-format plates. It is capable of imaging plate sizes up to 1,600 x 2,900mm for 96-page web offset presses (32 plates per hour at 2,900mm).
“The Magnus Q4800 also supports dual plate imaging. It is the only CTP device available in the market capable of imaging two 1,650mm wide plates simultaneously, with a maximum plate size of 1,650 x 1,600mm at a throughput of up to 50 plates per hour,” Eijbersen says.
“With its custom-configurable pallet automation options, this platesetter provides online capacity for up to 4,800 plates in up to eight different formats.”
While CtP technology has been around for some time now, speaking to some of the major players in the market makes it clear that development is ongoing and new solutions are coming to market on a regular basis. CtP is here to stay and will continue to play a huge part in the future of print.
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