handles a wide range of products, including film extrusion, bag conversion
and shrink-wrap. Ampac chose to move into HD flexography following the
request of a customer looking to "take their graphics to the next level,"
says Joe Lydic, Ampac's art director. "They wanted more consistent color
management, tighter detail in the screening, and a 150-line screen."
HD Flexo uses high-resolution optics and advanced screening technologies to
deliver 150-line screening at 4000 dpi with a smaller dot size and imaging
quality that rivals offset.
Decision to upgrade
Ampac didn't have to look far when it decided to upgrade. In 2004 the
company migrated from analog platesetting to an Esko CDI Spark XT 46x35 with
2400 dpi 126-line screening, implementing a hybrid dot via a Nexus Rip.
"We always considered ourselves a very good printer with the auto blend
hybrid dot," says Lydic."We don't use an extended gamut--we print very well
with four-color process. The hybrid dot worked well for us. Following our
customer's request, we started researching our options and came to HD Flexo.
Once we showed it to our management group, they were 100% behind the
The installation in June of 2010, which included the existing CDI imager
upgrade to the new optics and implementation of HD Flexo software, went
smoothly. The rest of the workflow remains the same, including the anilox
rollers and flexographic inks and solvents.
Ampac is impressed with HD Flexo's ability to deliver an extended color
gamut, higher contrast, increased tonal range and smoother vignette
reproduction. "HD Flexo has done a great thing for the process image--we see
a lot of positive attributes happening with solids and ink density," says
Lydic. "A good 2400-dpi printer has a highlight dot from 9%-12%. HD Flexo
brings the 9-12% dots down to 3-6% dots. When talking flexo, expanding
highlights 6% is huge. When you image a fade or vignette with 1-2 colors
with the hybrid dot in 2400 dpi, you have a rainbow effect or build-up--not
an issue with HD Flexo. You get a broader gamut range, sharper image, 150
lpi and tighter halftone dots. You get better ink transfer. From the testing
we've done, imaging at 2400 dpi and imaging at 4000 dpi in HD flexo, with
all the same standards and gains, HD Flexo gives you more ink saturation.
That alone is a big plus."
HD Flexo reduces the time Lydic spends on Photoshop file cleanup, a term
he's coined "flexifying,"--a necessity in the pre-HD Flexo days for ensuring
optimal plate performance on press, especially with continuous-tone images.
"With HD Flexo, I have to do a lot less 'flexifying,' such as pushing the
highlights so it meets our tonal range on press or pulling out color out so
it doesn't contaminate the press run," says Lydic.
Customers are taking note of the change. "We had a customer supply us with a
possible project." explains Lydic. "When I received the electronic PDF file
I explained to the customer that we should use HD Flexo; thinking it over,
the customer decided to stay with their current vendor. Since I had the
artwork, I decided to re-separate it and output a target proof using our HD
Flexo color profile. I asked our sales rep that when she came to the
facility again, she should bring a label (the job we didn't get) from the
printer. When I put the sample next to the HD proof, our rep was ecstatic,
'Oh my goodness! I have to show this to my customer!' she exclaimed. A
couple of days later I received an email message form the customer. The
subject line: 'Very Clever!' The job was sent to us, re-separated by us, we
went to press, and the customer approved it on the first pull."
Ampac's customers are also reaping the cost- and time-saving benefits of HD
Flexo technology. Jobs once reserved for 150 line gravure can now move to
150 line flexo, eliminating the increased costs associated with gravure
prepress. Customers now have the option of using lower-cost prepress for
those shorter run packages with surface printed flexo poly or reverse
printed flexo laminates, versus gravure printed packages, without quality
loss. Make ready and time to market are also reduced by avoiding long
gravure prepress backlogs, a benefit for both Ampac and its customers.
Ampac's HD Flexo implementation is a partnership between EskoArtwork and the
packager. A key ingredient in the implementation's success is the facility's
personnel. "EskoArtwork gave us the tools, but it took the whole company to
pull it off," says Lydic. "We have the talented people to pull the plates
and run the press. Our staff, in combination with HD Flexo software and
hardware upgrade, has allowed us to live up to our name and mission. Ampac:
Innovation in Action."
HD Flexo Certified
HD Flexo is the new standard for flexo quality. Companies -- such as Ampac
-- that are HD Flexo certified are among the best in their field. They are
constantly innovating to offer the very best in flexo quality. The HD Flexo
Certified seal is only offered to those companies that have passed
EskoArtwork's strenuous HD Flexo certification program.