Rice initiated his presentation with a video on football to epitomise team-work in a flexo unit.

Rice described flexography as a continually advancing technology by chronologically citing the technological developments since 1970 to 2015, from analog platemaking using films to digital to thermal to flat-top dots and engineered surfaces. “With time, flexographic platemaking has moved from being an analog solvent-based process to become more sustainable, fast and precise process,” said Rice.

Rice explained the difference in dot formation using conventional exposure and LAMS technology and the side effects of presence of oxygen during the exposure in digital platemaking. Rice said, “Without vacuum, the oxygen inhibits polymerisation at surface, giving rise to the round-top digital dot.”

With different approaches, digital flat-top dot can be achieved using various technologies such as exposing in inert atmosphere using nitrogen or using UV radiations to expose the laminated plate or exposing the plate using UV LEDs instead of UV lamps or tubes.

According to Rice, there are several advantages of using flat-top dots. He said, “It provides improved solid ink densities without the requirement of any additional steps during platemaking. The initial investment is low, consumable cost is minimal and still remains in digital filmless workflow. And above all provides a better plate life.”

Then, the second part of Rice’s presentation discussed Dupont’s Digital Solvent Performance (DSP) series plates, which feature an engineered surface for better ink transfer. According to Dupont’s study, the engineered surface plates witness a consistent 10-20% improvement in densities.   

Rice said, “DSP delivers higher ink on the substrate. Even with UV inks (100% solid inks ) there is a significant increase in solid ink densities, which enables the converter to use a finer anilox and move to print with higher print resolution. It also results in ink savings on solid colour.”

He stated that the DSP and Digiflow are under testing in India. “In the competitive climate of today’s printing market, flexographers need to be able to continuously improve quality while taking out cost. This can be achieved with a combination of Digiflow with DSP,” added Rice.

The final part of Rice’s presentation put lights on thermal plate making technology, which has been adopted by 15 users in India including five trade-shops.  Thermal platemaking process is dry thermal technology that allows the development of flexographic plates without any solvent. Rice said, “Since it is a solvent-less technique, it eliminates the rate determining step of drying, which takes up to three hours. Hence the process of platemaking requires merely 45 mins as opposed to 3-4hours with solvent process.”

Rice concluded his presentation by highlighting Dupont’s thermal platemaking products. He said, "These products can deliver four sleeves per hour. The thermal processing technique is based on loose-fit concept wherein a movable arc enables ‘one size fits all’ funda."