Chemistry-free CTP: Minnesota State University-Mankato

Doug Fenske’s decision to replace the CTP unit in his in-plant might be characterized as an “It’s not you, it’s me” break-up.

Fenske, the director of printing and photocopy services for Minnesota State University-Mankato, didn’t detest, dislike or even distrust the five-year-old ECRM Mako2 violet laser system.

“The old system was good; nothing was wrong with it besides its age and a messy, hard-to-clean processor,” he admits.

Still, Fenske knew, even from the start, that violet technology wasn’t “the one” for him. “I’ve been looking at chemistry-free [CTP] ever since we bought the first platesetter,” he acknowledges. “I used to tell vendors, ‘When you’re ready to show a chemistry-free system, I’m the guy you want to talk to.’ ”

Last year, Fenske saw and purchased a Fuji-film Dart 4300 thermal CTP system for the self-funded in-plant.

“This was the only one presented to me that was a completely dry system—others required a washer with gum,” he notes. “You can take the plate right out of this platesetter and go to press with no liquids touching it. No odors. No chemicals.”

The machine was installed in December 2008, and Fenske has been thrilled with the results. The shop also invested in a new RIP, the Screen Trueflow.

“The system is working extremely well, beyond my expectations,” he enthuses. “Our motto is ‘Work smarter, not harder.’ And that’s what we’re doing.”

Fenske attributes the smooth transition, in part, to proactive preparation. “We had a trainer spend a week—actually 200 man hours—with us, training everyone,” he recalls. The shop has 11 full-time employees and about three dozen student assistants.

“With the old system,” he continues, “there was only one person fluent in imposition, so if that person was sick or took time off, we were stuck. Now, if one staff member is out or even forgets how to do something, another will remember and step in. Training the whole staff has been the most important part of the process.”

The four-color shop’s runs average between 500 and 1,500, but Fenske has used the system successfully for up to 30,000 to 40,000 impressions with no plate problems.

“We no longer have anyone assigned to be the ‘plate person,’ ” he says. “The designers can put the [Ecomaxx-T] plates in the envelope and take them out to the pressroom. Workflow is much shorter and more direct.”

In addition, plate costs are down and chemistry-related costs have been eliminated. Fenske anticipates a three-and-a-half-year payback.

“Don’t be afraid of the processless plate,” he advises. “The technology is out there and should make [users] more sustainable.” Human resources are also easily redirected: Those ‘plate people’ are now working on quality control.

“Quality is our number-one concern,” Fenske concludes. “This system gives better dot retention; it holds quarter tones and midtones better.” And in contrast to the scrubbing required by the old platesetter, he says, “now, we just have to clean the dust filter once in a while.”