The Perfect Dot Ray Bodwell Du. Pont Packaging Graphics
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3 Expand Scope of Presentation Let’s talk about the quality advantages of the Digi. Corr hybrid dot. . and determine if we can implement in a productive and profitable manner.
4 Agenda • Digi. Corr Recap • Productivity & Workflow Comparisons • Digi. Corr Beyond Corrugated ?
5 The Digi. Corr Solution What is Digi. Corr? • A workflow innovation to produce Digital Cyrel® plate that is optimized for the needs of the corrugated printer. Why Digi. Corr? • The Du. Pont™ Digi. Corr modified workflow produces a hybrid dot profile for corrugated printing resulting in: • Reduced fluting (washboarding) • Maintain good solid ink density • Superior highlights and vignettes • Improved run length
6 How Digi. Corr Works • Digital Cyrel® imaged on CDI in normal manner • The Du. Pont™ Exposure Unit with Digi. Corr retrofit • Unique controlled atmosphere exposure system to produce a modified dot profile • Retrofit includes the controlled atmosphere chamber and control system.
7 Why Does it Reduce Fluting? Hybrid Dot Profile for Corrugated Standard Digital Dot Steep Shoulders & Deeper Reverses Digi. Corr™ Digital Dot Broad Base of Support Digi. Corr™ Digital Dot Uniform Dot Surface 10% Dot Size Benefits throughout tonal range 30% Dot Size
8 SEM Photos of Digital Cyrel® w/Digi. Corr 2% Dot 25% Dot 50% Dot A Unique Hybrid Dot Profile
9 Dot Gain Results
10 Standard Digital – 85 LS
11 Digi. Corr – 85 LS
12 Digi. Corr Installations
13 Digi. Corr Benefits • Simple, cost effective upgrade • Switchable, only use when altered dot profile preferred. • Superior corrugated print quality Du. Pont™ Digi. Corr will provide the Corrugated Tradeshop with a competitive quality advantage So what?
14 Corrugated Times Are Tough! “Our volumes are down” “We’re under tremendous price / cost pressure” “I’ll use Digi. Corr & Cyrel® for high end. . ” “. . . but everyone knows liquid is cheaper, so I’m going back to liquid for my one and two color work !? !”
15 Agreed - Liquid plates are cheaper than Digital Cyrel® on a square inch basis But what about total cost to produce? How do the two workflows compare then?
16 Platemaking Workflow Analysis In Exposure Unit *** Average time study data from on-site customer visits and phone interviews. Data collected and verified by 7 Tradeshops
17 • From Cold Start, time to start of second plate is 1 hr. 10 min. • From Cold Start, time to start of second plate is 30 min. • Rate limiter is Exp Unit @ 50 min. • Rate limiter is CDI @ 30 min. • First plate complete in 2 hr 35 min. • First plate complete in 2 hr 45 min. • Additional plate every 30 min.
18 It’s not just a productivity question Simply producing more digital Cyrel® plates per shift won’t close the cost gap What about plate waste? Liquid platemaking reclaims unused resin. With solid sheet you either have a 1 -piece plate or slugs to be mounted. Either one incurs cost. How will Du. Pont address this? ”
19 Eliminate the plate waste and dramatically reduce the mounting time + + =
20 Digital Imposition - Rapid Mounting
21 Digital Imposition - Rapid Mounting • Fully digital workflow eliminates need for film, film processors and imagesetters • Maximize utilization of all Esko. Artwork, Du. Pont H/W and your mounting / proofing equipment • Eliminate Cyrel® plate waste • De-Skill and accelerate plate mounting with highly productive flat-mount approach • Free up Mounter-proofers to allow rapid proofing on as needed
22 • Suitable for all corrugated segments • Brown Box • Standard Printing • High-end Graphics • Suitable for all quality requirements • Shippers and basic 1 -2 color work • Line and basic screen work • 3 or more color work & Process Printing
23 The Economics
24 Financial Analysis - Digital vs. Analog Rapid Mounting will reduce total cost to produce. • Elimination of all associated film costs: • Elimination of platemaking plate waste • Manufacturing / production efficiency with a single workflow • Reduction in mounting costs: costs - Mounting equipment, labor and space • Lower proofing costs: costs - Registration accuracy may reduce the need for “wet” proof • Lower labor cost: Skill level and headcount higher in liquid platemaking • Higher throughput of sheet versus liquid
ROI Calculation Tool 25
Reference a typical example revenue per year 26
27 A Couple Extra Things of Note
28 Ergonomic Considerations
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30 Sustainability Considerations
31 Future: Remove, Reuse, Ethically Dispose Today: Recover, Reuse, Recycle • Goal: Develop suitable recovery, reuse or recycling outlets for EVERYTHING that we ships to Customers Ø ALL PACKAGING Products & Packaging Ø ALL PLATE WASTE Waste Ø CONSUMABLES Manufacturing Customer Post Manufacturing Reuse Applications New Commercial Applications T O D A Y
32 TR 3: Recover, Reuse, Recycle • Challenges: Non-homogenous streams, separation, efficient collection & handling, simplicity Ongoing Phase I (underway) Developer Rolls Plate Boxes Phase II Unprinted Plate Scrap* *Evaluating pallet systems All Packaging Phase III Obsolete Printed Plates Cover Sheets Phase IV Future Consumables
33 Positive Environmental Impact • Higher productivity • Higher throughput results in lower energy consumption and more efficient plant utilization • With Cyrel® there is no wash water usage and nothing goes down the drain • Du. Pont TR 3 future to handle your waste streams
34 Marketing Plan
35 Du. Pont RSC Program Revolutionary Solutions for Corrugated • Workflow solution covering broad corrugated segment • Digi. Corr for Highest Quality Levels • Rapid Mounting to provide digital benefits to all • Financing • Promote quality and speed of post-print to buyers
36 Part II: Hybrid Dots Beyond Corrugated ?
37 You’ll Remember. . Problem When printing on the uneven surfaces and non-uniform compressibility associated with corrugated board, the shape of the dot in combination with the composition of the plate material has a significant impact on the appearance and intensity of fluting Solution Develop a process to produce an analog dot in a digital workflow; a "hybrid" dot. This workflow solution has been commercialized now as Du. Pont™ Cyrel® Digi. Corr. Sample printed at 150 LPI with typical “ 5 over” impression settings
38 The Obvious Question There is an advantage to a hybrid dot in corrugated printing. Is there any advantage to a hybrid dot in other market segments? 100% 90% 80% To determine, we must compare dots of equivalent size. dot % printed 70% 60% digital 50% 40% conventional 30% 20% 10% 0% 0% 10% 20% 30% 40% 50% 60% dot % in file 70% 80% 90% 100%
39 The Test measure the difference between the physical size on the plate and the physical size printed; compare hybrid dots to standard digital dots; smaller is better. delta 19 m 18. 3 m 37. 3 m
40 Design Factors Test Target Variables § x 1: dot shape* hybrid - round § x 2: line screen 175 ls - 250 ls § x 3: resolution 2400 - 4000 S 1 T 1 U 1 V 1 W 1 X 1 Y 1 Z 1 S 2 T 2 U 2 V 2 W 2 X 2 Y 2 Z 2 4 te r Pr in te r 2 Pr in te r 1 te r Pr in Hybrid, 2540 dpi, 175 LS Hybrid, 2540 dpi, 250 LS Hybrid, 4000 dpi, 175 LS Hybrid, 4000 dpi, 250 LS Round, 2540 dpi, 175 LS Round, 2540 dpi, 250 LS Round, 4000 dpi, 175 LS Round, 4000 dpi, 250 LS 3 Four Printers S 3 T 3 U 3 V 3 W 3 X 3 Y 3 Z 3 S 4 T 4 U 4 V 4 W 4 X 4 Y 4 Z 4
41 Dot Measurement Hybrid dots are very easy to measure under a microscope. Digital dots; not so easy.
42 Lots of Data 56 gray levels 8 plates (8 prints) 4 printers 1, 792 measurements
43 Plate Measurements S 1 -01 18. 7 m W 1 -15 18. 3 m U 1 -02 22. 9 m Y 1 -22 18. 9 m T 1 -01 17. 8 m X 1 -25 17. 1 m V 1 -03 18. 7 m Z 1 -34 18. 3 m
44 Print Measurement S 1 -01 53. 6 m W 1 -15 37. 3 m U 1 -02 36. 7 m Y 1 -22 43. 5 m T 1 -01 39. 0 m X 1 -25 37. 6 m V 1 -03 24. 2 m Z 1 -34 43. 0 m
45 Printer 1 Printer 3 Printer 2 Printer 4
46 Conclusion Hybrid dots, on average, have less physical gain on press. However smallest hybrid dot smallest digital dot
47 Smallest Printable Dot smallest printed hybrid dot smallest printed digital dot
48 Our Tests Show • No clear improvement with a hybrid dot. • Some printers may benefit from a hybrid dot. • Unlikely to achieve anything you couldn’t also get with a digital dot and sophisticated screening (i. e. HD Flexo)
49 Observations & Market Feedback • Hybrid dot may have benefits in T & L and security printing market. • Wide Web flexo less likely to benefit • Always interest in new technologies • Best solution is a hybrid workflow that can be switched on & off
50 Cyrel® XD - The Market Will Decide • XD is for smaller format workflows • External Evaluation in April • Like Digi. Corr, system will be on / off • Maintain existing equipment investment • Use as needed • Keep workflow options open
51 Questions?
52 Thank You
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