Asahi Photoproducts has reported a productivity boost at All4Labels’ Hamburg site after installing the CrystalCleanConnect automated platemaking system, developed with Esko and Kongsberg. This system replaced a manual process that led to errors and scheduling issues, according to Mirco Wilke, head of prepress at All4Labels Hamburg.
Wilke explained that the manual process was labor-intensive and prone to errors, limiting future development. The new system automates the entire platemaking process, from imaging to plate cutting, connecting seamlessly with workflow systems and reducing operator intervention.
The CrystalCleanConnect system, developed over two years, addresses the need for minimal operator input and consistent quality. It reduces the flexo platemaking process from 12 steps to one, cutting dedicated operator time by 90%, increasing press OEE by 25%, and reducing ink usage by 20%.
Dieter Niederstadt, technical marketing manager at Asahi Photoproducts, noted that a traditional platemaking machine with two operators produces 24 plates in an eight-hour shift. In contrast, CrystalCleanConnect requires just one hour of operator time for the entire process. The system uses water-washable plates, certified carbon neutral, promoting environmentally sustainable production. Automation ensures standardization, maintaining consistent plate quality regardless of shift changes.
Pascal Thomas, director of Esko’s flexo business, highlighted the system’s suitability for large operations running multiple shifts. It can operate efficiently during night shifts with minimal training required for operators.
Wilke emphasized that CrystalCleanConnect meets All4Labels Hamburg’s customer demands for flexibility and quality. As print runs become shorter, the company needs to be flexible, fast, and sustainable. The new system connects with automation systems, reduces waste, and minimizes operator input, offering significant advantages.
The installation process was straightforward, and the site was producing plates within weeks. The system’s ability to connect prepress files directly to a fully automated process enhances productivity and sustainability.
Asahi Photoproducts’ commitment to sustainability dates back to its founding in 1973, consistently using solvent-free technology. Their plates’ low surface energy ensures complete ink transfer during printing, improving quality. Asahi plans to unveil further advancements
