The Quest For CTP

Many in-plant managers are finding that computer-to-plate isn't the wave of the future—they need it right now.

By Mike Llewellyn

IT ISN'T easy to convince management to invest in large equipment, particularly not when it transforms an in-plant's workflow. But it was just that vigilant attention to the bottom line that led Ken Volz to prepare his in-plant's offset operation for a digital workflow.

"We were still doing small-format film and we wanted to get a large-format platesetter," says Volz, director of Printing Services at the University of Cincinnati. So just over a year ago, the Ohio in-plant brought in an Agfa Apogee prepress system with a Palladio platesetter. The acquisition followed the installation of a four-color Heidelberg Speedmaster 74.

As the in-plant for the second-largest school in Ohio (the university comprises 15 colleges), Printing Services sees a large volume of work. Volz says the magnitude of work demanded he rethink the way jobs were processed. Still, it was a bit of a challenge to get university administration to see things his way.

"It was fairly difficult to justify the purchase because everyone's budget is really tight right now," Volz says of the state institution. "But we hadn't bought a new piece of equipment for quite some time, so that helped with our request."

The selling point? Keeping work in the shop. It was clear that, in the long run, going CTP would save money. And combined with the new four-color capabilities of the Heidelberg, the Palladio represented a big boost in customer satisfaction as color work that had slowly trickled away from the shop returned in force as customers learned not only about the quality work the in-plant could produce, but the speed with which it could turn around color jobs.

"Customers love it," Volz says. "The quality and speed have improved tremendously."

Volz says the biggest challenge the in-plant faced when introducing digital technology was training his 17 employees.

"Getting everybody accustomed to the new, all-digital technology was the big learning curve," he says. It took about six months for the in-plant to iron all the kinks out of its workflow. But now that the Palladio has a year under its belt, Volz says it's been smooth sailing.

One In Two In-plants Run CTP

Under constant pressure to show cost reduction, managers have had to ask not if their in-plants can afford CTP, but if they can afford to run without it.

A recent IPG market survey revealed that 51 percent of in-plants use computer-to-plate systems, and 95 percent plan to expand their prepress operations within the next two years. To help find the system ideal for your shop, check out these vendors' flagship platesetters:

New from A.B.Dick, the DPM34 SC/HSC is the latest generation of Digital Plate Makers. Reportedly the first CTP device to use ThinDrum technology, it offers high-speed production, outstanding resolution and other benefits to help streamline workflow.

Agfa's Palladio offers violet imaging in a flatbed format and handles plates to 25x29.68˝. The company's Polaris 100/200 are flatbed, FD-YAG laser platesetters with a maximum 36x25.6˝ format. They output 160 and 235 plates/hour, respectively, at 1,016 dpi. Polaris 100V/200V are violet laser versions. The Advantage DL3850 is the newest violet laser platesetter from Autologic, an Agfa company. It can be configured for multiple plate sizes without requiring customization.

The Panther FasTRAK/HS from alfaQuest Technologies is a metal platesetter that images aluminum plates up to 24.625x36˝. Featuring eight standard resolutions from 1,016 to 2,540 dpi with imaging speeds up to 180 plates/hour, it has a 350-plate capacity. An automatic plate loader is available, as are both violet and YAG laser versions.

Creo's Lotem 400 Quantum features SQUAREspot thermal imaging, high throughput, efficient plate handling, ease of use and image quality for four-page printers. The device images 27 plates/hour with advanced automation and proofing.

ECRM Imaging Systems offers the DesertCat 8, an eight-page thermal platesetter that images both eight- and four-up work in 44-1⁄2x35-2⁄5˝ format. The DesertCat 8 offers resolutions from 1,800 to 2,540 dpi and can output up to 12 plates/hour.

The Cobalt violet laser diode CTP systems from Escher-Grad Technologies image up to 40 plates/hour. Cobalt-4 can handle variable sizes from 8-1⁄2x11˝ to 24x29˝. Cobalt-8 images sizes from 16x19˝ to 32x42˝. Cobalt-32 images sizes from 50x60˝ to 60x80˝. All feature variable resolutions and can expose both silver-halide and photopolymer plates.

The PlateDriver 4 is a high performance, affordable four-up (24.4x31˝) platesetter from Esko-Graphics. The internal drum system supports all current metal plate technologies, including 30mW violet. PlateDriver models can load, expose and punch plates in landscape and portrait modes. The flexible design allows for the customization of format, punch configuration and plate type. The PlateDriver is compatible with any CTP workflow, including EskoGraphics' FlowDrive and FastLane.

Fujifilm offers the Dart Luxel T6000 CTP II and III thermal platesetters. Dart II has a 3221⁄32x253⁄8˝ maximum plate size, while Dart III features a 32-21⁄32x26˝ maximum size. Both Dart II and Dart III offer automatic, continuous operation with auto-loading options and a processor bridge. Dart II outputs 17 four-up plates per hour at 2,400 dpi, while Dart III produces 20 four-up plates per hour at 2,400 dpi.

The Heidelberg Prosetter family of internal-drum platesetters supports violet (405nm) imaging. It includes the two-page (26.37x20.66˝) Prosetter 52, four-page (26.37x29.52˝) Prosetter 74/F and eight-page (31.92x41.53˝) Prosetter 102/F 102. The 'F' versions are higher speed machines. All models feature automatic plate punching and built-in temperature compensation. Semi-automatic machines operate in yellow safelight conditions and can be field-retrofitted to an automatic mode.

The SDP Eco 1630II environmentally friendly digital platesetting system from Mitsubishi Imaging is for black-and-white, spot-color and process-color applications up to 16-5⁄16x22-13⁄16˝. It features high-speed capstan technology that allows an output of 78 plates per hour at 1,200 dpi. Resolutions reach 1,200, 1,500 and 1,800 dpi. The SDP Eco 1630II uses two-thirds less processing chemistry than current analog and digital systems and is a self-contained processor operating with two processing chemistries.

Presstek offers CTP and plate products that eliminate the use of darkrooms, film and processing chemicals. While reducing turnaround time and lowering production costs, Applause CTP plates provide process-free imaging. Chemistry-free Anthem plates require a rinse with water. Dimension CTP systems offer easy-to-use features and a compact footprint.

OLEC's ink-jet CTP systems are based on phase-change technology and accurately place an oleophilic (ink retaining) image directly onto multi-grained anodized aluminum at up to 133 lpi. The plate is ready for press following UV curing.

The PlateStream platesetters from Printware image, cut, process, dry and punch silver-halide plates in one step. Two-up (13.4x22˝) and four-up (18.1x27˝) models are available. They image four-mil to eight-mil polyester plates at two plates/minute.

RIPit Computer's SpeedSetters are internal-drum (virtual) imagers that deliver .0005˝ repeatability over four plates, with a maximum resolution of 4,000 dpi and up to 175 lpi screen on a plate (225 lpi with film). Portrait, landscape and new large (six-up) formats are available. The SpeedSetters are driven by OpenRIP series.

Xanté offers the PlateMaker 4, a low-cost platesetter that prints straight to clean polyester (Myriad 2) or paper (Myriad 4) plates, eliminating the need for chemicals.