ТОВ "Лазер Флекс" | Flat Top Dot Flat Point Technology

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Flat Top Dot Flat Point Technology

We offer Nyloflex NExT technology for Flat Top Dots introduced by Flint Group Flexographic Products. It is based on an innovative approach of exposing photopolymer plates in two steps:

High-intensity UV-LEDs exposure burns out oxygen from the plate’s surface, thus reducing the negative effects of oxygen inhibition on polymerisation. The printed elements become flat-topped.
Exposure with UV-A tubes. Formation of a stable substrate of the printed element.

1. Pre-exposure of the reverse side of a photopolymer plate.

Polymerisation of the photopolymer layer on a reverse side and formation of the substrate for the plate printed elements.

2. Record an image on the mask layer.

Image recording to the mask layer of a photopolymer plate at a resolution of 4000 ppi

3. The main exposure.

Main-exposure of the working side of a photopolymer plate without the use of films in the absence of oxygen in the atmosphere. It is performed in two steps (UV LED+UV-А=NExT). At this stage, the relief formation takes place.

4. Washout process.

Removal of photopolymer plate’s areas which were not exposed to polymerisation.

5. Drying.

Evaporation of washout solvent which was absorbed in the relief layer. The thickness of the swollen plate due to the washout process returns to its initial value.

6. Postexposure.

Post-exposure causes complete polymerisation and gives the plate optimum hardness.

7. Finishing.

Finishing eliminates the stickiness of the plate by exposing with UVC-light. Resistance to ink solvents is obtained.

By using the conventional UV tubes the oxygen present in the atmosphere leads to reduction in the size of the printed elements, decrease in the height of dots and formation of a bullet-shaped dot with a bevel top. As a result, unstable printed elements are achieved, which lead to the tone break in the highlights.

Flat Top Dots technology allows us to combine the main advantages of analog and digital technologies, namely, to get halftone and solid elements of the same height without the use of films by recording the information to the mask layer of a photopolymer plate with a laser. Therefore, the flat-topped plate allows us to minimize the dot gain during the printing process due to the same height of all printed elements. It also features an increased runnability due to the ‘steeper’ profile of a dot.

Flat top dot technology is successfully combined with the integrated Pixel+ unit, developed by Esko, which provides:

Tremendous increase of solid density and improvement of ink transfer;
Expanded gamut in halftones and shadows due to microstructure and in lights and highlights due to hybrid screening;
Improvement in the reproduction of texts in small print and fine slur elements.
The usage of higher liniatures due to a higher resolution without rosette and moire;
Printing of the combined images from one plate;
Dot gain minimization;
Increase of plate’s runnability by reducing the pressure during the printing process;
Guarantee of stable and repeatable printing results;
Reduction of gear marks.

Interested in cliches made using Flat Top Dot technology?

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