Asahi Photoproducts, a pioneer in flexographic photopolymer plate development, recently reported that Tennessee-based Gateway Packaging Company has chosen to partner with Asahi Photoproducts and its North American Distributor CTGA after an exhaustive benchmarking process in its search for an improved platemaking process.
Gateway operates three manufacturing locations serving the United States and Canada and produces packaging for consumer packaged goods manufacturers and industrial packaging for the food, agricultural, chemical and charcoal industries.
As one of the leading high-end printer and packaging converters, and the largest pet food packaging provider in North America, Gateway Packaging is continually seeking ways to improve products and solve problems for its customers. Gateway also installed an Asahi Photoproducts AWP 1116 PD Processor as part of the revamping of its platemaking process.
“With the variety of flexographic plates and platemaking solutions available in the market, we wanted to do a thorough evaluation to ensure our investment decision was the best possible choice,” said Tharrin Akers, prepress manager. “With that in mind, we benchmarked solutions from the leading players, ultimately bringing our selection to the top two, including Asahi Photoproducts. As a final test, we ran a number of production jobs using plates generated by CTGA to compare efficiency with our current process, and we were very pleased with the results achieved using the Asahi solutions.”
The production test was run on an F&K 20six flexographic press using 40-pound coated white paper and solvent inks, with a run length of 675,000 feet (205,200 meters). The press ran at 1,400 feet per minute (427 m/min.). The run using competitive plates experienced a total production time of 483 minutes or 11 hours with a total plate cleaning time of 177 minutes and a requirement to clean plates every 2.5 rolls of media at 32 minutes per time.
“When running the Asahi plates,” Akers explained, “we were able to run the press at a 17 per cent higher speed — 1,640 feet per minute (500 m/min.) — only having to stop for plate cleaning once. The result was a total production time of 432 minutes or 7.2 hours and a 53 per cent improvement in Overall Equipment Efficiency (OEE).”
As a result of these tests, Gateway decided to make a significant investment in a new platemaking department, implementing Asahi Photoproducts AWP water-washable plates and adding a Kongsberg cutting table, a Glunz & Jensen Concept 401 ECLF Exposure Unit, and the Asahi Photoproducts AWP 1116 PD Processor. Gateway estimated a payback period of 10 months for this significant investment based on the productivity and quality gains it would deliver.
Asahi AWP plates feature Clean Transfer Technology, which allows a kiss-touch printing pressure setting. It makes use of low plate surface tension, made possible by a specially engineered Asahi polymer chemistry, to inhibit liquid flow. The ink forms a globule, with a large contact angle and high pinning point. This results in a cleaner and more homogeneous ink transfer from plate to substrate, helping flexographic printers meet the ever-increasing quality demands of their customers. It also ensures precise register and fewer press stops for cleaning or plate changes, increasing Overall Equipment Effectiveness (OEE).