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Newspaper Solutions - medium volume

What is medium volume printing?

Why are there so many processor variants?

What is the difference between different plate technologies?

What are the benefits of integration and automation?

What is the Preventive Maintenance Program?

 

What is medium volume printing?

To achieve optimal performance, it is practical that a processor best matches a printer’s production volume, so at Glunz & Jensen we have segmented our equipment for high, medium and low volume printers.

Medium volume equipment offers the same high Glunz & Jensen processing quality as the high volume equipment, but is available at a lower cost, as the components aren’t required to withstand the rigors of continuous high volume production.

As a printer you should consult your dealer for proper guidance to the best match of processor for your business.

 

Why are there so many processor variants?

No one processor can cover the need of every printer, because every printer is special in his own way. Therefore, we make it our business to assure that we offer solutions which are just as dedicated in design and performance as the products delivered by a printer.

There are several parameters which influence the design of a plate processor. The main parameters which should be considered are:

  • Plate technology/type of CtP plate - There are many plate CtP plate technologies on the market today and Glunz & Jensen has a processing solution for every dominant technology
  • Width of the CtP plate - Glunz & Jensen processors are capable of handling plate widths in the range 680, 850, 1250, 1500 or 1650 mm (26.8”, 33.5”, 49.2”, 59.1” or 65.0”)
  • Speed of the image setter - A faster CtP require a faster processor, i.e. a longer dip tank to maintain same dwell time at a higher linear speeds
  • Yearly consumption of CtP plates - All equipment becomes worn with use; higher volumes require more robust equipment to give acceptable lifetime
  • Required level of automation in the prepress room - With a fully automated prepress line the printer is able to attend to other important matters while plates are prepared in the prepress room

Other parameters of importance for the printer are:

  • Dedicated or open system
  • Cost of ownership
  • Service and support

Glunz & Jensen supplies processors for every type and size of CtP plate and for every production volume and price niveau. Experience shows that the cost of owning a Glunz & Jensen processor is on average lower than other brands, due to the robust build quality and the added value of highly qualified customer service.

 

What is the difference between different plate technologies?

Below is a brief description of some of the different plate technologies which are available in the market today. The choice of plate technology must be made by the printer based on his preferences. Glunz & Jensen is able to offer a premium solution for every dominant plate technology.

Thermal

Thermal systems use heat or energy from a laser to image the plate, altering the plate’s coating once the temperature threshold is reached. It is a slower process compared to e.g. Violet systems, but there is in principle no overexposure. They offer a high resolution image without the risk of overexposure and the plates are not light sensitive, so daylight in the prepress area is not a problem. However, the thermal lasers require a much higher energy output, so are more expensive. Plates require developing and finishing, similar to the traditional film process, and some Thermal plates require a pre-heat step before developing.

The traditional Thermal processor has 3 steps: development, rinse & gumming, though different brands of Thermal plates differ, so the configuration of the processor must be considered when a printer wishes to have premium printing quality. 

 

Violet Photopolymer

Violet Photopolymer plates have a light-sensitive coating which are imaged by laser on a Violet light CtP. Imaging the plate is faster, compared to Thermal systems, but a pre-heat stage is needed prior to development in order to complete the photo-initiated polymerization process. Because the plate is light sensitive, it must be handled in an environment without ambient light. Violet systems are more sensitive to variations, compared to Thermal systems, so consistency and accuracy of the pre-heat step is important. On the other hand, they tend to be less expensive than Thermal systems because the laser technology is widely available and less costly. Violet photopolymer systems are often preferred by newspapers because of the very high imaging speed.

The traditional Violet Photopolymer processor has 5 steps: pre-heat, pre-wash, development, rinse & gumming.

Processors for traditional Violet Photopolymer applications may be converted easily to work with Violet low-chemistry applications.

 

Low Chemistry or Chemfree

The “Chemfree” name comes from the fact that traditional chemical processing is replaced by a simplified process which includes washing the plate in a gum solution in either one or two steps. Chemfree plates are available for both Thermal and Violet CtP systems, and the plate is imaged in a similar manner to the traditional counterpart, but the subsequent processing steps are simplified. For the Violet Chemfree systems, there is still a need for the pre-heat step in order to complete cross-linking of the image.

The Chemfree Violet Photopolymer processor has 2-3 steps: pre-heat and 1-2 gum/wash steps.

 

Processless

These plates are only available for Thermal CtP systems. The plate is mounted on press without any additional processing. As the press starts up, the fountain solution dissolves the non-imaged areas of the plate, transferring the dissolving coating to the blanket and then onto the first sheets of paper. The plate is fully developed by the time the press has been calibrated.

Concerns about contaminating the press and the fountain water can be eliminated by dissolving the plate coating in a simple wash-out unit before putting the plate to the press.

 

Silver Halide

Introduced in 1993, the Silver Halide plates are highly sensitive and offer very high resolution. The plate is imaged with visible light CtP (Violet). Silver halide plates require a special development process which includes development and a subsequent diffusion process. The waste from the development process contains relatively high concentrations of silver in metallic form and is considered or classified as a hazardous waste. The system may be complemented by a silver recovery unit, which separates the metallic silver content from the waste. Glunz & Jensen no longer offers processing equipment for the Silver Halide plate technology.

 

What are the benefits of integration and automation?

Are you familiar with picking up damaged plates from the floor of the prepress room?

With a fully integrated and automated prepress line, you will be able to attend to other important matters while plates are made ready for the press, without the fear of plates or material being wasted. The full integration of equipment in your prepress line means that the CtP will only send new plates to the processor and futher down the line, if all components after the processor are ready to accept the plates. If the processor is also configured for automatic monitoring and reporting, then it will only accept plates from the CtP if all processing steps are available and able to process the plate with good results.

WebConnect makes it further possible to monitor the status of the processor from a remote computer. Read more about WebConnect under Relevant Products at the bottom of the page.

 

What is the Preventive Maintenance Program?

By definition, all equipment becomes worn when it is used. A CtP processor is no exception, but with proper care and maintenance the processor will support a printer for many years. We have developed the Preventive Maintenance Program to make it easy for the printer to keep the processor in optimal condition, increase uptime and reduce the risk of failure.

The Preventive Maintenance Program is a series of dedicated kits containing a few carefully selected wear-and-tear components which are unique to the processor model. At certain intervals, either based on time or production hours, these components are replaced on the processor as a preventive measure.

The Preventive Maintenance Kits give your customers peace-of-mind, maximize vital uptime and minimize the risk of unexpected breakdowns. Your service technician always has what he needs with him, saving you time and money and letting the customer plan the service call to match his schedule.

The Preventive Maintenance Kit is available for all our processors. Read more about them under Relevant Products at the bottom of the page.

Relevant products

Plateline Equipment
PlateLink 46-XR
Plate Transport
PlateLink 46-XR
Accessories
PlateLink 46-XR
WaterClean
Cooling Unit
Processors
WaterClean
Offset Accessories and Services
WaterClean
iCtP
PlateWriter 3600 Pro
PlateWriter
PlateWriter 3600 Pro
Thermal
Kylin 85P
Monitoring Software
WebConnect
Remote Enabling System
Spare Parts
Preventive Maintenance Kits
Violet Photopolymer
Raptor+ P