marks-3zet News - Label Print Edition

Label Print Edition

Froben Druck: Succesfully printing low migration labels with waterless UV offset

Codimag: Showcases marks-3zet waterless solutions at Labelexpo

Toray thermal CTP plates for high-end label printing

The latest solutions for prepress automation

PrePress iLs: The intelligent software for remote prepress control

marks-3zet news - Label Print Edition - 2013

2 Imprint

marks-3zet GmbH & Co. KG

Lahnstraße 38

D-45478 Mülheim an der Ruhr

Tel. +49 (0) 208 / 999 46 0

Fax +49 (0) 208 / 999 46 29

[email protected]

www.marks-3zet.de

Editorial Staff:

Souscha Verlinde

Hans-Joachim Koch


3

In the coming weeks, our business will be focused on label and package printing, not least

because of the Label Expo, where we will be featured prominently. It runs through this Label

Print edition of marks News like a common thread:

in several regional markets, we are seeing users change from flexographic to waterless

printing: For our customers, the processes are improving in quality and becoming cheaper

at the same time – another sign that these two developments need not be contradictory. It is

critical that the processes also be adapted at the companies as well – a change of technology

always goes hand-in-hand with process changes.

In sheet-fed offset and newspaper printing, the greatest changes are afoot in prepress and in

quality management. Only by continuously standardising the prepress stage while also kee-

ping an eye on process quality can the planned – and potential – cost reductions be realised.

We take these developments into account by continuously expanding our prepress expertise.

In addition to hardware, software is critically important. We follow an „Apple“ instead of a

„Windows“ strategy in our workflow: we are referring not to any operating system, but to our

conscious choice not to offer an endless variety of options, instead providing the user with

those options that are really needed – thereby making things as simple as possible, while

also ensuring high stability (this was precisely the secret to the success of the Apple OS – we

are simply copying the recipe for success!). We succeeded in this attempt in the workflow

software – as many enthusiastic customers will attest!

In package printing, “Low Migration” is a new reality that we all have to deal with. Whether

one views this positively or negatively, ultimately we have to accept what is happening in the

Dr. Gert Sieger

Managing Director marks-3zet

market. It was reassuring for us that Classic Colour‘s UV colours scored the highest in an

independent scientific comparison, and that migration could hardly be detected at all: this

means that we have the lowest migration ink on the market! If your customers request tests

of this type from you, please get in touch, and we will be happy to help you.

I hope that like us, you are also sensing an improvement in the economy. With this in mind,

I wish you continued and ever greater success in business!

Yours sincerely,

Dear customers, dear readers,

• Calibrated underpacking sheets

• Self-adhesive underpacking foils

• Compressible underpacking sheets

underpacking materials www.marks-3zet.de

The Original.

Introduction: Dr. Gert Sieger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seite 3

Producing low migration adhesive labels using waterless UV offset . . . . . . . . . . . . . . Seite 6

Codimag showcases its fully optimized waterless printing process at Labelexpo

using marks-3zet waterless label print solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seite 12

marks-3zet Waterless Label Print Solutions

Classic Colours „Nevada LA“

The low migration ink for waterless UV label printing . . . . . . . . . . . . . . . . . . . . . . . . . Seite 13

Toray TAC VG-5 & LL-7

High-resolution thermal CTP printing plates for maximum label quality. . . . . . . . . . Seite 14

One CTP

For highest flexibility in waterless and conventional label printing . . . . . . . . . . . . . . Seite 16

One Workflow

Optimal automation for the imaging of flexo and offset printing plates . . . . . . . . . . . Seite 20

Producing low migration adhesive labels using waterless UV offset Seite 6

The low migration ink for waterless UV label printing Seite 13

PrePress iLs: The remote monitoring software for your prepress production line Seite 23

Inhaltsverzeichnis

Plate transport systems

The optimal addition to your CTP line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seite 22

Low-chem processing machines

For eco-friendly plate processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seite 25


Producing low migration adhesive labels using waterless UV offset

Foods are indispensable. For protection and for longer shelf life, most of them are pa-

ckaged. Both the packaging and label need to be designed so as to prevent unwanted subs-

tances from migrating from them into the food. The example of Froben Druck near Bremen

shows the lengths that producers of self-adhesive roll labels go to in order to offer „low

migration“ products.

Foods are sensitive goods serving daily needs. They need to be produced in such a way that

they do not pose any health risks to people, i.e. the consumers. This also includes packaging.

Packaging protects the foods, and substances in the packaging must not migrate into the

food. That is to say, no substances of any kind may migrate from folding cartons, foil pou-

ches, other packaging or the applied labels, and in so doing contaminate the food.

The experts at Froben Druck in Ottersberg near Bremen are only too well aware of this. The

self-adhesive roll label specialists take great pains to make sure that the materials they use

pose no risk to human health. That is why they have been using „Low Migration“ (LM) pro-

ducts in their inks and coatings for years.

„LOW MIGRATION“ INKS. The company installed its first machine for printing self-adhesive

roll labels back in 1972. This business segment was continuously expanded. In the begin-

ning, UV production in the area of self-adhesive roll labels was only used in letterpress prin-

ting, with flexographic printing coming somewhat later. The company produces high-quality

labels, adhesive paper, monofilms and adhesive films. The Ottersberg company has now

6

Froben Druck produces many

labels, especially ones subject

to particularly high quality

requirements, using its new

waterless rotation.


Producing low migration adhesive labels using waterless UV offset

been using offset printing for more than five years, and waterless UV offset printing since

the end of 2012. For the latter, the company made a special investment in a new printing

machine equipped with what are called keyless inking units. The Ottersberg company uses

only „Low Migration“ inks by the English manufacturer Classic Colours on this machine. The

English company‘s products are distributed by Germany‘s best-known waterless printing

centre and Toray representative, marks-3zet, headquartered in Mülheim an der Ruhr. Clas-

sic Colours specialises in „Low Migration“ products, and has been formulating waterless

inks for over 20 years.

WHY WATERLESS? That‘s an easy question to answer. The following is a concise list of the

attributes of this type of offset printing: Brilliance, low dot gain, extremely fine screen, high

ink deposit thickness, large density range, or quite simply: very high print quality. A powerful

argument.

In 2002, there were only 100 or so companies offering waterless offset printing in Germany.

Now there are more than 800 – an 800 percent increase! And Froben Druck is one of them.

The company handles all kinds of demanding label jobs using a new narrow-web offset prin-

ting machine equipped with waterless offset printing units.

Given the demand for more and more differentiation in the retail environment, i.e. at the

point-of-sale (POS), along with demand for ever smaller runs, these trends have naturally

had impacts on packaging and label production. Because of frequent order changes, printers

7

are on the lookout for more economical methods of printing than what flexographic printing

allows. „An offset plate costs a fraction of what a flexographic printing form costs, and has

a much shorter way to go during prepress,“ says Frank Hütter, Deputy Managing Director of

Froben Druck. „We do all the printing templates and plate making in-house, including letter-

press, flexographic and offset printing, both conventional and waterless.“

KEYLESS INKING UNITS IN OFFSET. When it came to reprints or extra print runs, flexogra-

phic printing was always one step ahead compared to offset printing because of the simple

keyless inking units. But now the shoe is on the other foot. „Since we acquired our new

web offset rotation for waterless operation, reprints are no longer a problem here, because

The self-adhesive roll label specialists from Ottersberg take great pains to make sure that the materials they use pose

no risk to human health. That is why they have been using „Low Migration“ (LM) products in their inks and coatings for years.

it operates using keyless inking units just like flexographic printing machines,“ continues

Hütter.

„A large number of our customers are from the food industry, which is why we only use low

migration inks. Many of our customers are global brands, while others are small craftsman-

type outfits. We provide comprehensive service and act as a reliable partner to all customers,

whether large or small,“ adds Managing Director Ingwert Froben.

Transition to LM completed. In waterless offset printing, the Ottersberg company operates

using a Codimag Viva 420 Aniflo with keyless inking units (direct inking units, direct colou-

ring) and have (practically) no ink fade from front to back. And there are no longer any zone

screws on the machine. „Once all the data is correct and all temperatures have been deter-

mined, you bring a repeat job to the machine next time and it starts running straight away,“

says Hütter. All of this, in conjunction with factors like the width of the machine, the speed,

the gauge pins (0.05 mm) and the elimination of the ink-water balance (which is much harder

to handle in UV printing than in conventional non-UV offset), argued in favour of a waterless

machine.

„We converted everything to Low Migration in letterpress, in flexographic and then in offset.

This was a significant expenditure. The inks have an entirely different pigmentation than

non-LM products, and we had to establish completely new colour curves for the machines,“

says Hütter.

8

The narrow-web roller offset

printing machine (width 420

mm) uses waterless printing

plates from the Japanese

manufacturer Toray, which is

represented by marks-3zet.

Since digital printing machines are getting faster and more reliable all the time, and because

repeatability and the range of materials are getting better and better, the future belongs to

digital printing – of this Frank Hütter is convinced. In connection with laser stamping and

many small print runs, this is a very good alternative to conventional printing, he believes.

The team has been following trends very closely.

TRENDS IN THE WATERLESS MARKET. Waterless printing is now a mature technology, ha-

ving emerged from its niche status long ago. All reputable printing machine manufacturers

now at least feature waterless variants as an option in their ranges.


For waterless label printing, the Ottersberg company uses only „Low Migration“ inks by the English manufacturer Classic Colours.

9

The english manufacturer

Classic Colours specialises in

„Low Migration“ products, and

has been formulating waterless

inks for over 20 years.

No migration

EU Regulation 1935/2004 stipulates that materials and articles must be produced in

accordance with good manufacturing practice, so that in normal implementations and

within the context of the intended use, none of their components are able to migrate into

foods, especially not in quantities

• that could be hazardous to human health

• that could bring about an unwanted change in the composition of the food

• or which could lead to a deterioration in

organoleptic properties.

In Switzerland, there has been a regulation in place since 2010 regarding packaging

inks, the stipulations of which have been adopted by many food producers as a guideline.

The new Regulation (EC) No. 2023/2006 on good manufacturing practice for materials

coming into contact with foods stipulates that the printed surface may not transmit any

substances in quantities leading to concentrations in the food not in accordance with the

requirements set out in Article 3 of Regulation (EC) No. 1935/2004. Such transfers occur

either due to migration of particles through the substrate, or due to set-off in the stack.

CLASSICCOLOURS

identity cards and driving licenses in plastic card format are predominantly printed using this

procedure,“ adds Wolnikowski.

For him and for marks-3zet, waterless offset printing is the most environmentally friendly

printing process. In Mülheim an der Ruhr, tackling the issue holistically is seen as a must,

i.e. by also offering Low Migration products.

NO COMPROMISES. Just like the commercial offset printer, the modern label printer would

also prefer to go on producing standardised products for a long time. As is the case in flexo-

graphic printing, an Anilox roller enabling exact, constant colour layer transmission is well-

suited to this purpose. „In conjunction with a keyless inking unit, waterless offset printing is


Given the demand for more and more differentiation in the retail environment, i.e. at the point-of-sale, along with

demand for ever smaller runs, these trends have naturally had impacts on packaging and label production. Because of

frequent order changes, printers are on the lookout for more economical methods of printing than what flexographic printing allows.

With their expanded product portfolio, waterless printers are not as adversely impacted by

crises in the printing industry, since they operate in profitable specialist segments and can

more than compete in a brutal market based on outstanding quality.

So how has waterless offset printing developed over the past 20 years in Germany in parti-

cular? We asked Karol Wolnikowski, who is in charge of process technology, distribution and

quality management at marks-3zet: „Waterless offset printing is undergoing rapid growth

both in Germany and abroad. marks-3zet has seen continuous growth in the number of

square metres in Germany and Europe over the last 20 years. If you compare the figures, the

number of plates sold has increased 20 times over this period. There is no doubt that the

trend is positive and that growth is strong in this segment.

In addition to the new production line at Toray that commenced operations in 2006, it has now

become necessary to expand began. This is why we‘re bringing a new plate factory online in

the Czech city of Olomouc later this year.“

This growth is the result not least of the increasing number of web-based printers, which

are focusing more and more on waterless offset printing based on standardisation trends

that are easy to follow. It is based on new printing machine designs, such as the KBA-Varius,

which was presented at Drupa 2012. Moreover, in the near future two more KBA-Cortina fa-

cilities will be brought online, one of them in Germany. „In sheet-fed printing, we continue to

focus on UV printing, and are growing proportionally. New niches frequently emerge here to

which waterless offset printing is almost ideally suited. Due to the high resolution of the To-

ray plates, nearly all security printers have gone with waterless offset printing. For instance,

10

Due to the high resolution of the

Toray plates, nearly all security

printers have gone with water-

less offset printing.

Why waterless? That‘s an easy question to answer: Brilliance, low dot gain, extremely fine screen, high ink deposit thickness, large density range, or quite simply: very high print quality.

superior not only because of its print quality, but also because of its extremely high stability

thanks to the elimination of the ink-moistening agent balance,“ Wolnikowski is convinced.

Both in flexographic and in waterless Anilox offset printing, a roller is used to transfer and

meter printing ink, as briefly noted above. Whereas in the waterless process the printer can

control the ink volume via temperature, a flexographic printer can only do so by regulating

the dispensing volume of the roller.

ENVIRONMENTAL ASPECTS. By way of summary, it can be said that waterless offset prin-

ting with keyless inking units combines the benefits of both flexographic and offset printing.

Ink transmission remains stable and consistent using the screen roller, but also indirectly via

a printing blanket. Finally, waterless offset printing is and will remain a planographic prin-

ting method, which is precisely why it permits high-end printing quality. And: For waterless

printing in general, the process is absolutely free of solvents and VOC. All products produced

using waterless offset printing are printed without any alcoholic additives (IPA) which redu-

ces VOC and CO2 emissions, thereby satisfying environmental requirements. In addition,

printers benefit from minimising waste paper and the associated time and cost savings.

Frank Lohmann

11

Frank Hütter (Froben Druck),

Karol Wolnikowski (marks-3zet

GmbH & Co. KG), Souscha

Verlinde (marks-3zet GmbH &

Co. KG), Ingwert Froben (Froben

Druck) and printer Christian

Fritsche in front of the water-

less rotation.

The Aniflo short inking unit of the Viva 340/420 Aniflo from Codimag offers printers new

possibilities and a broad range of advantages:

• Four cylinders of equal diameters

• Guarantees a constant and regular ink volume

• Elimination of variables such as an ink key control

• Saving up to 60% more in waste and time (compared to conventional label printing)

• Waterless offset quality

• 100 % reproducibility

• One-pass inline foiling and embossing

• With the combination of offset quality and anilox stability, Aniflo offers printer more

process stabilization, process control and better colour management


using marks-3zet waterless label print solutions.

Codimag showcases its fully optimized waterless printing

process at Labelexpo

For many years, the French manufacturer Codimag has been actively involved in waterless

offset printing. Nowadays, the printing quality of their VIVA 340 and VIVA 340/420 with its

anilox offset printing unit Aniflo, is highly accepted amongst label printers in various fields

such as wine, cosmetics, food and household.

During Labelexpo Europe in Brussels, two of our core products – the Toray thermal plates

and the Classic Colours waterless inks – will be used “live” on the VIVA 340 Aniflo press, at

the Codimag booth R30 in hall 11.

Codimag will demonstrate its VIVA 340 Aniflo that prints with Multichromy from software

supplier Esko, which enables a high printing quality and reproduction of a great number of

PMS references, without colour changes and wash-up downtimes.

The printing plates will be developed with the marks-3zet KTW 653 plate processor. Also our

low migration ink series “Nevada LA” from Classic Colours with the set of cyan, magenta,

yellow, black, orange, green and violet inks will be used.

In security printing, Codimag will demonstrate high resolution exposed plates that print very

fine lines and guilloches (up to 7620 dpi).

12

The Codimag VIVA 420 Aniflo

for waterless label printing,

using Esko’s Multichromy,

can be seen in full action in

hall 11, booth R30


The low migration ink for waterless UV label printing

13

Let us convince you of the quality of our low migration ink

series „Nevada LA“ for waterless label printing by sending

us your request for a free product sample of Nevada LA

process inks to [email protected].

Nevada LA is an ink specially developed for roll label printing. Nevada LA is silicone-free, and

is used especially in cases where the printed surface needs to be further processed.

The continuous development and ease of handling of the printing machine make the Nevada

LA series one of the most popular UV inks in waterless label printing. It is not only ideally

suited to Anilox and conventional inking systems, but also to various printing materials like

coated/uncoated papers and plastics.

Classic Colours Nevada LA is a low migration printing ink which is UV-cured. Only permitted

raw materials are used in its manufacturing, and we devote the most meticulous attention

to the dosing. The challenge is to succeed in actually retaining the positive characteristics

of a good printing ink. This requires many tests, analyses and sustainable production, but

ultimately makes the ink much easier and suitable to use in the food industry.

The Nevada LA printing inks are constantly being further developed in order to offer our cus-

tomers the very best quality. From trial printing at printing machine manufacturers, to the

numerous ink tests conducted at marks-3zet‘s Waterless Printing Centre, to the customer‘s

own experiments with various recipes – all these measures make the printing ink what it is

today: a good, established product fully adapted to the needs of users in the label segment.

Classic Colours „Nevada LA“

CLASSICCOLOURS

TAC VG-5 & LL-7

TAC VG-5 & LL-7

The TAC VG-5 and TAC LL-7 plates are based on Toray‘s patented technology for waterless

printing and introduce a new approach to the digital printing plate production. Using thermal

energy, longchain silicone rubber molecules are broken down („cracked“), thus exposing the

image area.

Both plates are especially suited for high-end label printing where print quality is of extra im-

portance. The difference between the two plate types lies in the protective plate foil. The LL-7

does not have a protective foil and therefore is excellently suited for autoloader systems. The

VG-5 does have a protective film, which increases the service life and increases the protection

agains mechanical damages and scratches.

14


Imaging

The LL-7 and VG-5 are thermal negative-working-type printing plates and do not require pre-

heating. The image area surface is generated through irradiation with an infrared laser having

a wavelength of 830 nm, exposing the emulsion on the printing plate to thermal energy. The IR

sensitive agent in the exposure layer absorbs the heat and releases the silicon rubber from the

image area and adheres only loosely on the polymer image area. The nominal sensitivity of the

VG-5 and LL-7 is 150 mJ/cm2, resp. 130mJ/cm2. However, this value depends upon the type

and quality of the laser being used. The printing plates can be imaged with almost any thermal

CTP system on the market. Since the printing plate works non-ablative, no suction system is

required in the image setter. The VG-5 can be imaged both with and without the cover film.

High-resolution thermal CTP printing plates for maximum label quality.

Basic Processing

Both plates work according to a purely physical development process, ie. this process does

not affect the imaged areas. The special mild activator merely serves to support the separa-

tion process of the silicone rubber. Prior to processing, the cover film of the VG-5 needs to be

removed.

Conserving

Generally, a conservation of the plates is not required. In case of longer dwell times between

plate production and printing process (as of approx. 3 days) as well as for archiving, we recom-

mend using our conserving agent CS-1 to maintain the good ink receptivity of the printing layer.

Baking

Since both plates are resistant to UV printing inks as well as UV washing agents, the baking of

the printing plates is not required. Baking will not increase the print run length.

Run length VG-5 Run length LL-7

Coated paper 120,000 Coated paper 150,000

Uncoated paper 80,000 Uncoated paper 100,000

UV inks 60,000 UV inks 50,000

15

The TAC-Concept

The TAC approach differs significantly from traditional thermal printing plates. Since the TAC

uses a physical washout method, the dot size remains unchanged by the developing process.

Due to the combination of a minimum consumption of chemicals, no conservation and no

regeneration, this system offers ecological and economic advantages to the ser. The real user

benefit, however, is based on the absolute reliability of the system: it is robust and noncritical,

particularly in terms of imgaging and processing.

The fast throughput speed and the absence of a preheating stage ensure a quick imaging of

the printing plates, resulting in the reduction of downtimes. Moreover, the premium quality

ensures that usable prints are being produced after only a very short time and with minimum

waste paper.


MultipleRES®

The integration of security features in a print product is of great significance, particularly in

label, card and packaging printing.

Using microtexts or the finest screens, there are many ways for the print shop to increase

security against counterfeits while also improving quality. MultipleRES® was developed es-

pecially for the requirements of security printing.

This special option allows highest flexibility, for the operator can switch between various

resolutions. If a higher production speed is required, 2540 dpi ensure a maximum plate

throughput. If a job requires security features, a total of 7620 dpi provide the finest elements

and the highest screen ruling (also ideal for lenticular printing).


For highest flexibility in waterless and conventional label printing

One CTP with MultipleRES® and MultipleRIP®

For highest flexibility in waterless and conventional label printing

Optotec One CTP is an innovative computer-to-plate concept where configuration and degree

of automation can be adapted at any time. The modular built system is adjustable to the in-

dividual requirements of a pre-press stage by means of an interchangeable laser head (ILH).

The external drum system works with register pins, thus enabling an extremely accura-

te imaging with up to 650 rpm. The balancing and oscillatory control system guarantees

smooth and vibration-free running. Fixation of the printing plate is carried out with the aid of

a magnetic clamping system and pneumatically powered push down rollers.

One ILH – Interchangeable Laser Head

The interchangeable laser head provides maximum flexibility for the operator. If market re-

quirements change, the thermal laser head can be easily replaced with a violet laser head. By

default, all laser modules work with an addressable resolution of 2540 dpi and a very reliable

laser-array technology Dual Pitch. In connection with the special option MultipleRES®, this

CTP system also allows an increased definition of up to 7620 dpi. All parts and components

correspond to the applicable ISO standards, are easy to install and can be quickly replaced.

16

The special option Multiple-

RES® allows highest flexibility,

for the operator can switch

between various resolutions.

One CTP with MultipleRES® and MultipleRIP®

Highlights:

• Switchable 2400*/2540/4800*/5080*/7620 dpi, laser spot diameter approx. 11 μm

• The ideal solution for a high plate throughput and when high resolution is required

• Very smooth edges achieved through high addressable resolution

• Easy start-up of security printing with low investment costs

*Not in combination with the Dual Pitch laser.

One® High-Resolution

This special option has been particularly designed for customers requiring high security

printing. Very fine and smooth elements can be achieved through a modification of the laser

module with a laser spot of < 4 μm in diameter.

Highlights:

• Use of a special laser module (thermal laser)

• Genuine 7620 dpi enabling for finest positive and negative elements

• Combination of high addressable resolution and a very fine laser spot

17



MultipleRIP®

Very small plate formats make it particularly difficult to use a CTP system in narrow-web

label printing. In most cases, customary CTP systems can only be used by modifying the

stamping/drum to work with the smallest formats.

The special option MultipleRIP® was developed especially for this market segment. This

feature makes it possible to illuminate multiple inks on just one plate format. For instance,

all four process inks are imaged on a mother plate in one pass to increase the output speed

by fourfold. Special colours (Pantone) are also possible. An automated or manual stamping

and cutting system then completes the pre-press production process.


With fully automatic, multi-compatible transport and stacking systems, the CTP system can

be expanded to a production line: The transport table is designed for a safe and smooth

transport of the printing plates. The plate is detected by means of a sensor. Optionally, a

transport table with colour sensor allows feeding of a wet offset and a waterless offset pro-

cessing machine with a CTP imagesetter.

More information about our plate transport systems can be found on page 22.

18

Keeping a constant eye on the pre-press area

Available for:Apple, Windows, Android, Linux.

Remote Monitoring Software www.marks-3zet.de

PrePress iLs

iLs Basic::: Status request for CtP, transport table,

processor and stacker (including web interface usage depending on model)

::: Notification via email in case of emergency

::: Room control via a robotic camera

::: Control of room temperature and humidity

::: Control of room light e.g. yellow light / UV light or process-free plates

• Output format: 1-bit TIFF (Packbits, LZW, CCITT4, uncompressed)

• Connectable to nearly every CTP and CTF system

• Multiprocessor support for optimum computer performance

• Client/Server option for sharing the software on multiple workstations

• System requirements: Windows XP Pro or Windows 7 (32-bit / 64-bit)


One Workflow

One Workflow is known for its outstanding quality, various screen types, user-friendly inter-

faces and high speed. An additional important feature is One Workflow‘s flexibility: it can be

configured to suit customer needs, with an optional integration of all the available functions.

In addition, our highly qualified team is continuously working on the further development of

One Workflow.

All functions of One Workflow can be used in full automatic mode and at multiple work

stations through the use of the Client/Server option. Depending on your requirements, One

Workflow can be expanded through special editions and options.

One Workflow is a conclusive concept that guarantees you a high degree of production safety.

Through modular expansions, the simple adaptation to future production techniques can be

easily realized.

One® Workflow

An Overview of the Most Important Functions:

• Clearly arranged, English user interface (also available in other languages)

• Adobe compatible up to PDF 1.7, PS Level 3; works with PS, EPS, PRN, TIFF, BMP, and

JPEG

• Current PDF variations including transparencies and PDF‐X

• Special client version available for multiple users with Windows

• Data input using printers, network printers, hot folders, or manually

20

Optimal automation for the imaging of flexo and offset printing plates

Additional Workflow Options:

One Imposition

One Imposition is a simple to operate PDF or screen imposition software, with a user-friend-

ly interface that fulfills even the highest requirements.

One Commit Management

Internet-based software for the administration of the entire work process. All production

steps are monitored. One Commit Management can be tailored to the size of every company

and to all customer requirements.

One Preflight Checking

This option enables the automatic testing and certification into PDF format, in advance of

exposure.

One CIP 3

This option calculates the colour zone data of your typeset data. In the manual mode, all

printing machines can be preset with regard to plate size and the setting range of the colour

zone controller.

One Stochastic

One Stodhastic is the extension of the standard screening programme of RIPs, with a fre-

quency modulated screen of the second generation. One Stochastics suppresses undesira-

ble moiré and cloud effects.

21

One Color Flow

This expansion provides universal and centralised control of colour profiles for all output

units.

One Trapping

One Trapping is a quick, pixel-based trapping with well-organised functionality. The result

can be checked directly on the monitor. Trapping behaviour can be individually defined for

every colour (RGB, CMYK, CieLab).




In order to cope with the growing pressure – especially cost pressure - in the label market,

we offer you an automation and cost-reduction solution in the plate making process.

We support our clients with innovative technologies and products in the planning, configu-

ration and installation of building blocks for their CTP line: from the transport table to the

turntable and the plate stacker. We will be happy to assist you in equipping your CTP line for

optimised plate transport, offering the right solution for every need and plate size, tailored to

accord with the site‘s available space.

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The transport table is designed for a safe and smooth transport of the printing plates. An

integrated sensor makes plate identification possible and ensures a safe plate transport.

A turntable is used, when control of two different processors is required. Plate detection

is carried out with a colour sensor, while the transport to a wet offset or a waterless offset

processor depends on the material. A plate stacking unit is located behind the processor,

as a last component. It is characterized by a highly compact and flexible construction, an

excellent suitability for waterless plates and represents an ideal solution for automated pro-

duction processes.

The optimal addition to your CTP line

The Conveyor MDT transport table, which is available in different versions, and the PST plate

stacker are the most popular products in this area. Of course, this is only a small selection

of what we can offer in plate transport systems.

Just contact us, and we will be happy to draw up your individualised installation plan, free of

charge and without any obligation.

For even more efficiency, safety and cost reduction, discover our new concept “PrePress iLs”.

This remote monitoring software will allow you an overview of your prepress production at a

glance on your mobile device – at any time:

iLs basic

• Status request for CTP, transport table, processor and stacker (including web interface

usage depending on model)

• Notification via email in case of emergency

• Room control via a robotic camera

• Control of room temperature and humidity

• Control of room light e.g. yellow light / UV light or process-free plates

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Benefits and uses:

Cost reduction

• Process optimisation

• Acoustic / optical status report

• Recording of temperature and humidity values

• Remote process termination

• Ready-job notice to printer and workflow

• Avoidance of error productions in-between paper recognition



PrePress iLs

Safety

• Interface connection for all machines

• Acoustic and optical signalling

• System error via sms, email or telephone report

• Liquid level control

• Room control

• Smoke alarm

• Co2 measure when using ovens

Job management

• Job allocation / job separation

• Individual plate labelling

• Job backfill when stacking

• Job control

• Real-time job-monitoring

• XML gateway to megalith, SAP and others

• Barcode / 2D Data matrix

• Notification of ready-printed jobs

• Plate quality control PQCS

Environment

• Energy monitor

• Economy mode

• Ovens’ stand-by control

• Regulation of heating and air conditioning

• Control of the room light e.g. yellow light / UV light or process-free plates

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Low-chem processing machines 25

For eco-friendly plate processing

In order to achieve best processing results we recommend using our processing machines,

especially designed for waterless offset printing plates. An appropriate processing machine

is available for every format, every application and every requirement

The most important benefits at a glance:

• constantly high processing quality

• expedited supply of spare parts

• up to 400 plates/hour with MWP 863-HS

• industrial materials, made in Germany

• economical consumption of energy and chemicals

• intuitive operation, space-saving design

• integrated water-saving system

• long service life due to low-wear components

• solid construction

• low maintenance required

Low-chem processing machines

The length of the inserting and exit tables can be modified according to customer demands.

In general, inserting tables for inline applications have a shorter length (150 mm) because

the imaged printing plate is fed to the processing machine via a transfer table. If the printing

plate is manually (offline) fed to the processing machine, a longer inserting table is required.

When using an automatic stacker, a shorter exit table is no longer required. In newspaper

production, no exit table is used and the printing plate is directly fed to the bending machine.

26

Technical setupSupporting

constructionFolded and pressed sheet steel, welded profiled tubes and chemi-cally resistant stainless steel

Bearings High-quality bearings for drive and squeezing rollers, low-wear plain bearings on brushes

Rubber rollers Steel cores and stainless steel shafts, rubberised with special rubber coating

Brush rollers Stainless steel cores and shafts with one brush, fine calibration

Drives Feed with DC gear motor (electronic speed control), brush drive with three-phase AC worm gear motor

Pumps Low-wear submersible and magnetic centrifugal pumps

Chemical and water tanks

Separately integrated in the machine, easily accessible with feed filter, heating in the activator tank (electronically controlled)

Water consumption

Approx. 0.5 to 2 liters, chemicals circulating within a circuit

For eco-friendly plate processing

Operating principle

An exposed waterless printing plate is processed in 5 steps – except for models KTW 450 (3

processing steps) and KTW 650 (4 processing steps).

1. Pre-treatment

The plate passes through a tempered pre-treatment bath to soften the silicon in the image

areas.

2. Brushing out

After squeezing off the pre-treatment solution, the macerated silicone layer is removed with

a rotating and oscillating brush. Pure tap water is used, the consumption of which is reduced

to 0.5 to 2 litres per plate thanks to the implementation of a water saving system. The silicone

rubber remnants are then washed out through the overflow.

3. Brushing out

Step 2 is repeated to remove any remaining silicone residues.

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4. After-treatment

Once the silicone is removed, the printing plate is dyed with a special after-treatment soluti-

on by means of rotating and oscillating brushes, making the image area visible.

5. Rinsing

The fully developed plate is rinsed with water in order to remove any residual dye. After a

final squeezing, the printing plate is now dry and ready for printing. All processing machines

feature a high level of workmanship and conform to German demands on quality. Spare parts

for all types of processing machines are available immediately and for the long-term.

Interested buyers are welcome to visit and test our development machines at any time at our

Waterless Printing Centre in Mülheim an der Ruhr. Just call us on +49 (0)208 999 46 0 or send

an e-mail to [email protected] to schedule an appointment.

1 2 3 4 5


World market leader with over 220 distributors and branches world-

wide. marks-3zet is the inventor of the internationally known calibrated

underpacking sheet − a real high tech product.

UNDERPACKING MATERIALS

• Calibrated underpacking sheets

• Compressible underpacking sheets

• Self-adhesive underpacking foils

• Tympan paper

WATERLESS OFFSET PRINTING

• TORAY printing plates

• Printing inks & auxiliary equipment

• Chemical and cleaning agents

PRE-PRESS STAGE

• CTP systems

• Workflow software

• Developing machines

• Plate transport systems

WATERLESS PRINTING CENTRE

• Seminars & training courses

• Research and development

• Extended printing hall

PRINT & MEDIA CONSULT

• Prepress configuration

• Quality management

• Cost reduction

• Print job management

• Environment

• Security

You can find further information on waterless offset printing on the

following listed websites:

www.marks-3zet.de

www.ewpa.org

marks-3zet GmbH & Co. KG

Lahnstraße 38 · D-45478 Mülheim an der Ruhr

Tel. +49 (0) 208 / 999 46 0 · Fax +49 (0) 208 / 999 46 29

[email protected] · www.marks-3zet.de

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