Hot Products At PRINT 05

New Printing Technologies For the Packaging Industry

by Noel Jeffrey

Print 05 & Converting 05, held in early September in Chicago, together claim the title as the largest and most comprehensive worldwide trade show and conference for commercial, package printing, and converting this year. It featured more than 4,500 product offerings in 800 exhibits.

The Kongsberg XF10 is a small-format dieless cutting table for signs, decals, and other specialty print applications.

While the show remains a largely commercial printing event, this year's focus on packaging as an opportunity for the commercial segment undeniably created more awareness than in the past. The Packaging Subcommittee for Ghent PDF Workgroup even held its meeting during the show and, as expected, announced the official release of the final Packaging Design PDF Specification V1 and reported on progress for V2, which they hope to release early next year.

For package designers, there were many software and proofing systems of interest. There were prepress systems and digital and offset presses and even inks that offer both efficiencies in production and the ability to handle increasingly creative package designs. PDF workflow and JDF capability were highlighted features. Following is a healthy sampling of what was on hand.

Software workflow solutions Artwork Systems announced four major product launches during its Print 05 press conference. Odystar 2.5 is the new release of its commercial native PDF workflow system that runs on the Mac OSX platform. Now there's Odystar Packaging, a new configuration of this product specifically designed for the label and packaging markets. It allows operators to work in Adobe Illustrator for simple packaging tasks and to use Odystar Packaging for automation of complex, labor-intensive functions like trapping, color mapping, and step-and-repeat.

Two plug-ins are used to facilitate the interaction between Illustrator and Odystar Packaging. The first, called Shuttle, allows job submission, retrieval, and monitoring from any operator workstation. The second plug-in, called InPDF (for "Intelligent PDF"), allows PDF files which have been processed by Odystar Packaging to be returned to the Illustrator environment with full editability. It enhances Illustrator's PDF capabilities by providing support for linked images (OPI), layers, groups, and spot colors represented in the DeviceN color space—all functions which are vital for packaging users.

Artwork's packaging workflow product, Nexus 8.1, called a major upgrade from earlier versions, now supports export of native PDF files specifically for Adobe Illustrator and implements a new JDF-based step-and-repeat mechanism for PDF files. It also offers enhanced color mapping, broader functionality for versioning in packaging applications, and several new screening sets.

One of those sets, the new Concentric Screening, divides traditional AM printers' dots into concentric rings, which allows ink to gain "into" the dot as well as outside of it. Artwork Systems claims that this virtually eliminates dot gain problems on press, allowing much higher AM line screens for improved detail, color saturation, and press latitude.

All of Kodak's recently acquired companies—Creo, Encad, Kodak Polychrome Graphics, NexPress, and Scitex Digital Printing—exhibited under Kodak's Graphic Communications Group (GCG) banner. In addition to an impressive array of digital presses and CTP devices, the company also demonstrated PDF Compare and PDF Merge software, which captured a 2005 GATF InterTech Technology Award for innovation.

These Adobe Acrobat plug-ins for the Prinergy workflow management systems, including the packaging offering, Prinergy Powerpack, provide an automated way for prepress operators to incorporate last-minute changes when preparing files for production. PDF Compare is a quality-control tool that provides the ability to analyze two PDF files and identify the differences between them. PDF Merge is a production tool that allows the operator to extract all of the prior work that was done on the plate-ready file (traps, screening assignment, geometry, overprint settings, etc.) and merge all of those elements into a new revised production file.

Kodak also announced a new version of Pandora, designated 2.8—a step-and-repeat tool designed to create packaging layouts efficiently. According to the company, it is built on open industry standards such as PDF and JDF, enabling seamless integration with a variety of workflow systems. Operators are now allowed to define their own marks and edit the content of these marks within the software environment, eliminating the need to launch another desktop application.

Proofing systems

GMG released version o4.1 of its proofing products. For FlexoProof, which supports the specific needs of the flexo and packaging industries, the new version adds compatibility for the latest Epson inkjet printers; expands the scope of output devices supported with additional large format and laser printer drivers; introduces new media profiles; enables direct RGB file printing; and adds a 1-Bit Creator function for halftone proofing.

GretagMacbeth's vipPAQ is an inline densitometric color measuring system optimized for production and quality control in flexography and gravure printing. The CDI Spark 4260 by Esko-Graphics

is a flexo imager designed for all digital flexo plates up to 42" x 60".

The 1-Bit Creator feature allows users, such as ad agencies and design firms that do not own a RIP or workflow system, to create and proof 1-bit screened data from their continuous tone files. This produces "a true representation" of how a final printed item, or package, will look on different media—complete with screening structures and color rosettes. Version o4.1 is a free downloadable upgrade for users of o.4 products.

DALiM demonstrated DiALOGUE v3.1 for remote and collaborative viewing and soft proofing files on all current client operating systems via the Internet. It is the only standalone SWOP-certified soft proofing application that runs on a Macintosh. DiALOGUE integrates with a wide range of third-party automated workflows either via "hot folders" or directly using JDF. Users view files in high resolution to approve single and imposed pages from any location in real time. The system does not require client side plug-ins and is not an ASP solution.

Integrated Color Solutions (ICS) recently upgraded Remote Director, its monitor-based proofing system. Version 3.1 includes a suite of tools for printers, allowing them to easily integrate Remote Director 3.1 in the pressroom, as well as a new API interface, enabling Remote Director to work with any open or JDF-compliant workflow. ICS and Pantone, Inc. also announced a strategic partnership to incorporate the Pantone Color Library in Remote Director.

High impact opportunities

HumanEyes software was shown in the Xpedx booth. This product enables the simple creation of 3D, lenticular, and special effects using existing images, cameras, and printing equipment. Digital press vendor HP, for example, was touting the software for its Indigo line.

Shown for the first time in the U.S. last year, this year's upgrade is a 2D to 3D conversion tool which company literature says lets "untold hundreds of thousands of conventional, flat, 2D images be reconsidered for numerous new uses in advertising, POP, packaging, direct mail, and more." The tool will be offered as an upgradeable option to current users and new customers. The company also says that, in contrast to other methods, HumanEyes does not use layers. Therefore, its technology permits a more natural looking, continuous 3D effect not tainted by layering.

MetalFX Technology demonstrated its technology for the first time at a U.S. trade show, although Texas-headquartered Consolidated Graphics has already adopted it for its various locations. A U.K. company, MetalFX offers a base silver ink that, when run in the first unit of a printing press followed by measured values of CMYK inks in the other press units, can create hundreds of metallic colors as well as special effects. At the show, the company introduced a new gold base ink, MetalFX Version 2, printed live in the Heidelberg booth. In addition, the company debuted a soft proofing solution called PrintDevizor.

Kodak's PDF Merge is a production tool that allows the operator to extract and merge all of the prior work that was done on a plate-ready file.

Color quality control tools

GretagMacbeth featured vipPAQ, its first inline densitometric color measuring system optimized for production control and quality assurance in flexography and gravure printing. The vipPAQ system performs quality checking in the actual print situation at the control console for true real-time job control with no need to slow down the press or extract pages. It displays any deviations in substrate, viscosity, speed, pressure temperature, and ink impurities while the job is running so immediate corrective action can be taken.

Pantone, Inc. introduced Color Cue 2, the next generation of its award-winning handheld colorimeter. According to the company, "The device saves designers time and money when capturing color inspiration by drastically reducing the time for color identification." Color Cue 2 provides additional formulas for reproduction including CMYK, CMYK EURO, sRGB, Adobe RGB 255, HTML, L*a*b, PANTONE Hexachrome, and XYZ values. It also enables users to simulate a number of different lighting conditions like daylight and fluorescent.

X-Rite introduced the DTP45, a fast, highly flexible, automated spectrophotometer, designed for precise calibration, profiling, and quality control. The DTP45 spectrophotometer is unique in its ability to calculate color by strip or spot measurement. The new spot-checking capability is excellent for applications such as large-format media and uncommon color patterns. DTP45 will be part of the new X-Rite Color Ensembles Plus system, which includes highly robust professional level control hardware and advanced profiling software.

Brand owners look to the latest flatbed inkjet technology from companies such as Scitex Vision for¬Ýshort-run packages and prototypes as well as corrugated boxes and POP displays.

Esko-Graphics extends lines

Esko-Graphics demonstrated all the elements of its Design Life-Cycle Management Initiative (see October 2005 Package Design), as well as several pieces of new hardware, such as the debut of the Kongsberg XF10. The FX10 is a small-format dieless cutting table based on the technology and robust architecture of the Kongsberg cutting and creasing table. It is designed to offer a fast, productive solution for sign, decal, and other specialty print applications, as well as for making samples of folding carton boxes.

The work area of the XF10 is 31.5" x 43.3", and it can accept material as large as 35.4" x 47.2". The XF10's new feature set includes rack-and-pinion X/Y drive with precise motion control, new and fast servo system and an entirely new, faster toolset. The i-XF10 tooling system also features the integrated MGE i-cut camera, a key component of the patented i-cut vision system for obtaining perfect cut-to-print alignment.

Esko-Graphics also introduced the Cyrel Digital Imager (CDI) Spark 4260, a flexo imager designed for all digital flexo plates up to 42" x 60". The 4260 provides variable resolutions from 2000 to 4000 ppi on a job-to-job basis and is capable of screen rulings up to 200 lpi, depending on imaging resolution. It is built to accept optional In-line UV main exposure units.

Packages on offset presses

Offset press manufacturers such as Heidelberg, KBA, Komori, MAN Roland, Mitsubishi offer presses to package printers—many equipped with inline finishing like diecutting and UV coating. What stood out at the show was the emphasis that these companies placed on addressing the needs of packaging. MAN Roland, who claims to have started the "wider is better" trend to increase package printing productivity, emphasized the efficiencies of their presses over 40" wide.

MAN Roland's 65" version of its extra-extra large press—the ROLAND 900 XXL—made its North American premiere as a six-color-with-coater configuration. Company literature states that the XXL is poised to significantly boost the popularity of mini-flute and micro-flute package printing. The press can be equipped to handle board thicknesses up to 1.6 mm or 63 pt., positioning it as a highly productive E-flute, F-flute, and G-flute printing solution.

Heidelberg demonstrated the breadth of its packaging solutions with a wide range of prepress, press, post press, and consumables solutions for simple folding boxes to premium-quality finished cartons for luxury goods. In addition to running the new MetalFX gold base, Heidelberg also featured the newest member its Speedmaster family.

The Speedmaster XL 105 can attain a maximum speed of up to 18,000 sheets per hour with the largest maximum sheet in its class 29.53" x 41.34" with an imaging area of 29.13" x 41.34". The company designates it as "the ideal production tool for label and packaging printers handling large volumes of multiple-up work," noting that it offers additional automation features that are attractive for high-end printers, especially packaging printers.

Human Eyes transforms regular, flat 2D images into spectacular 3D easily without cumbersome layering and tracing.

Superwide flatbed inkjets

Superwide flatbed digital inkjet printers capable of running UV inks have been encroaching on the screen printing market and playing a role in short run package printing and prototyping because they can print on paper, board, wood, textiles, glass, plus flexible and rigid plastic, and even get excellent results on single-faced corrugated board and foam. The machines typically have format bed sizes of 126" x 63" and can handle materials from 1.2 to 1.75-inches thick.

What was also intriguing at Print 05 is that large graphic arts vendors have acquired a number of once-independent manufacturers, who were nonetheless exhibiting under their own brand names. The U.K.'s Inca, the flatbed pioneer, now belongs to Dainippon Screen. EFI acquired VUTEk earlier this year, and HP acquired Scitex Vision not long before the show. MacDermid ColorSpan and NUR Macroprinters, among the other most widely known flatbed vendors, remain independent.

Inca Digital Printers Ltd. showed its mid-priced flatbed offering Spyder 320 ($300-$400K) for the first time in the U.S. VUTEk debuted its PressVu UV 320/400, a UV curing flatbed machine with a two-in-one capability that lets it handle sheetfed or roll-to-roll printing. Scitex Vision displayed an extensive portfolio of products. Its flatbed, the CORjet Premium, incorporates a print controller and RIP, a fully automated loader, the press and drying unit, and an automated un-loader.

Wide format inkjet manufacturer Roland DGA Corp. introduced its Packaging Prototyping System, which it promotes as an efficient in-house solution for producing professional blister packaging prototypes in less than one day. The system incorporates the following Roland equipment: LPX-1200 3D laser scanner; MDX-40 3D milling machine; and SOLJET PRO II V SC-545EX 54"-wide integrated printer/cutter into a complete solution for creating precision, custom packaging prototypes. Total retail pricing for the necessary components is around $60,000.