CTP-Is It Right For You?

Computer-to-plate systems can reduce your expenses and increase your productivity and quality. Find out if CTP belongs in your in-plant.

Computer-to-plate (CTP) technology has changed drastically over the last two years. The cost of digital workflow systems has dropped dramatically, becoming more affordable to even small in-plants. One benefit of this is the increased availability of thermal CTP systems and printing plates.

A completely digital workflow may seem limiting, but in truth it offers just as many options as a traditional or computer-to-film process. Using digital technology will allow you to use polyester or metal plates or, if required, print out onto film.

Still, with so much information available via trade magazines, vendors and the Internet, it is difficult for even the most savvy professional to filter through it all to make a sound and profitable decision.

The Advantages of CTP

The most notable benefits of CTP are its high quality and the reduction of expense accompanied by an increase in productivity. Implementation can eliminate the need for producing film, decrease your turnaround time and usage of materials, and provide a high-quality end product. The process also allows in-plants to produce short-run materials more economically.

"The whole point in going CTP is to improve productivity and reduce labor in the process," says Ken Newton, senior vice president of sales and marketing at A.B.Dick.

The main reduction in labor comes from printing the plate directly from the computer after proofing, as opposed to the traditional process of shooting a negative then burning a plate. Even with imagesetters, plates have to be made, incurring at least one extra step—and the additional risk of human error.

Along with the elimination of unnecessary steps comes the benefit of perfectly registered plates. These plates reduce the time it takes for traditional makereadies, which means less wasted ink, water and materials before the first sheet is even printed.

Other cost savings come from no longer buying expensive film and processing chemicals. Also, you no longer need to store cumbersome negatives and metal plates for reprint purposes; digital files can be saved to disk for easy access. You also decrease the chance of damaging files by storing them digitally, whereas negatives and metal plates may get scratched if improperly stored.

Are You Ready?

A few simple guidelines will help you determine if CTP is right for your shop.

1. Experience with digital production. If you are not currently using a digital workflow, including a preflighting and digital proofing system, chances are CTP is not for you. As Ben Butera of Fuji says: "If you're not ready workflow wise, you're in a jam."

2. Cost analysis. The best way to determine potential profitability is to perform a workflow study: analog vs. digital workflow. While you will incur expense in going digital, the reduction in time and labor may quickly outweigh the initial cost.

3. Volume. Experts agree that the implementation of CTP is mostly a customer- or volume-driven decision. If your company provides digital files for the majority of work to be printed, CTP could be a great benefit. According to Dean Meyer of Heidelberg, another guideline is the number of plates produced on a monthly basis. If you are producing a minimum of 400 to 600 plates per month, using a completely digital system may be the way to go.

4. Type of work to be performed. Small shops often outsource work because they don't have the in-house capabilities to complete the work efficiently or economically. "Do they plan on doing all their processes in-house or outsourcing them?" asks David Mitchell, vice president of sales at Purup Eskofot. "If they plan on doing everything in-house, they need to update anyway."

5. Keeping up with the Joneses. The popular consensus is that if you want to update simply to keep up with current industry trends, you might want to think again. CTP has a definite future in printing, but not everyone has the need for it. The bottom line, according to Mitchell, is quite simple: "If you're not going to save money or make money, don't do it."

From The Inside

Iowa State University Printing Services recently added a Heidelberg Duosetter poly platesetter. Manager Gary Boyd says cost and labor savings, faster turnaround time and better registration were the main reasons for the changeover.

"In our situation, we looked at conventional costs versus CTP costs and estimated labor savings and throughput," explains Boyd. He offers a series of steps for implementation to help others considering CTP:

• Use a team approach.

• Identify what you want to accomplish.

• Outline current processes.

• Outline CTP processes.

• Identify who will do what.

• Identify training needs.

• Research equipment/capabilities within acceptable price range.

• Perform cost comparisons.

• Purchase equipment.

• Train staff.

• Review after implementation window to make adjustments in processes.

Cost And Other Concerns

Most companies, when considering CTP, must yield to budgetary constraints. While these systems can be expensive, Heidelberg's Meyer points out that prices have dropped considerably over the past couple of years, with systems now available for under $35,000.

Mitchell, of Purup Eskofot, concurs, adding that while CTP used to be one size fits all, that is no longer the case.

"Vendors have come through and targeted many different segments of the market," he says. "Cost is not what it used to be."

Still, the cost can be daunting for small operations, especially when putting an entire system into place. However, as pro-CTP vendors are quick to point out, operators can show that the cost is easily justified when the benefits of reduced labor and materials are realized.

Another factor to consider when contemplating CTP is employee reaction. Employees who are accustomed to traditional methods may balk at the new digital workflow and the training it requires.

The Final Decision

After analyzing all the pertinent information, if you are still unsure if CTP is right for you, do some comparison shopping, and contact vendors for advice and product information. For example, A.B.Dick, which has installed some 1,400 CTP systems, employs implementation specialists who will perform a workflow study for your operation and assist in deciphering the factors needed to make a decision. Having an expert on your side can ease the pressure of trying to fit all the pieces into the puzzle.

by Pamela Mortimer