The pre-owned ECRM Stingray 63 imagesetter has been combined by Marlowe with a StudioRIP software RIP to image TIFF files to film, which are subsequently exposed to flexographic printing plates. The new system replaces an ageing Agfa Accuset and RIP which was not suited to the format required by the recently acquired Uteco Emerald 1200mm wide flexographic press.

Paul Mainwairing, Operations Director at Single Source, said: “We might not be a true print house, but print is still an integral part of what we produce. Each single serve portion is held within a printed sleeve of some description, and 25 million of these are produced on site via our flexo printing press every single day. The recent upgrade in the press required a re-think in the platemaking department, and whilst a computer-to-plate product might have been ideal, we could not justify the expense required for such a machine. However, our pre-press support partner, Marlowe Graphic Services, suggested a wider format imagesetter coupled with the excellent StudioRIP software product. The software gives us significantly more control over the production of files. We have now calibrated the new press and imagesetter solution and we are getting significantly improved results against our previous equipment.”

The extremely versatile StudioRIP incorporates a number of important flexo features. For example, reproducing highlights can be a problem in flexography, as there is often huge dot gain in this area (typically 2% will print as 10-15%). The standard SGSS hybrid screening offers the desired colour depth, but even though it is stochastic, the FM part isn't entirely pattern free. This isn't a problem in offset, where the hybrid screening protects only the highlights under 2-3%, and the slight pattern of the SGSS FM part is practically invisible. However, with the huge dot gain of flexo it may become visible and therefore offensive.

StudioRIP provides SGSS hybrid screening optimized for flexo. Using a principle that allows the centres of the halftone dots to slowly drift away when the percentage falls below a given level (typically 30-35%), reaching an entirely stochastic structure at 3-5%. Removing dots from this stochastic grid will become practically imperceptible, thus visible patterns will disappear almost entirely.

Commenting on the equipment supplied, Marlowe Graphic Services, Andy Hemmings, Sales Director, said: “We had been servicing the existing equipment at Single Source, but with the new press purchase it was essential for the company to move forward with its pre-press equipment. The Stingray provides a 630mm film width, which is ideal to produce half-width plates for the new 1200mm wide flexo press. It was also a great opportunity for the business to move forward with the latest RIP technology, and the team at Single Source could see the significant benefits offered by StudioRIP immediately.”

More info:
www.singlesourceportions.com