Esko has launched its latest innovation, the Esko Quartz flexo ecosystem, marking a significant advancement in flexographic print quality standards. The new system is now available for ordering worldwide.

“When we first introduced the Quartz ecosystem at drupa last year, we hailed the technology as the pinnacle of flexo platemaking,” said Pascal Thomas, director of flexo product management with Esko. “Following further development work and testing with our customer community, we are absolutely thrilled to be now making this innovation available to all those printers and converters across the globe looking to achieve incredible new standards in flexographic print quality. The first shipments should be expected by September 2025.”

The Esko Quartz ecosystem complements the leading Crystal ecosystem as a top-of-the-line addition to the Esko digital flexo solutions portfolio, offering a dual optics system that supports both legacy and forward-looking flexo platemaking with optimized Quartz Screening.

“New Quartz optical technology enables users to image higher frequency surface structures at 2000 lpi (Q-Cells) with an imaging resolution of 4000 ppi, providing another major leap forward in flexo plate imaging speed and print quality,” said Pascal. “Imaging at 4000 ppi is nearly double the current industry standard, and microcells engraved in the solid ink areas at a 2000 lpi resolution is proven to significantly boost ink transfer, delivering a way for print converters to match gravure print quality in flexography.”

Eddy Fadel, GM/VP Esko Digital Flexo Solutions at Esko, said that with the new Esko CDI Quartz ecosystem, the company continues to deliver solutions that accelerate go-to-market while meeting the needs of its customers. “This brand-new, top-of-the-line complete flexo platemaking solution raises the bar on quality to the very highest level,” he said. “The Esko Quartz ecosystem truly enables flexo printers to achieve the optimum results for their customers.”

Screening accuracy, quality print

Jan De Roeck, CMO at Esko, explained that the screening technology is an evolution from the award-winning Esko Print Control Wizard software, which uses all critical print parameters and variables – imaging resolution, exposure settings, plate, substrate, anilox, press type and inks – to simplify the flexo platemaking process. “The software standardizes the generation of Crystal Screens specifically used in combination with the XPS Crystal flexo plate LED UV exposure unit,” he said. “With the CDI Quartz we have taken that to the next level, adding VQ (variable highlight Q-cells) and SQ (stochastic Q-cells) for unrivalled screening accuracy.

“This is a perfect combination of Esko flexo systems and software,” he added. “The Quartz cells form in a flexo plate when exposed with the UV LED technology of the XPS, providing highly consistent and repeatable plate quality.”

Not only does the technologically advanced Quartz produce the most accurate and best quality plates, but it also reduces ink usage, making them cleaner to use. “What’s more, it does all this while delivering the absolute best quality final print,” said Jan. “It’s a genuine game-changer in flexo platemaking.”

Taking platemaking quality standards to the next level

With 30 years of experience in flexible packaging prepress, Salerno, Italy-based Inci.Flex was one of the first to incorporate the new Esko CDI Quartz into its plate production.

“Inci.Flex is excited about Esko CDI Quartz, which has taken our platemaking quality standards to the next level,” said Inci.Flex Srl CEO Vincenzo Consalvo. “As one of the first to adopt this technology in the world, we have seen a quality improvement on par with rotogravure, offering more uniform ink coverage, better contrast and deeper shadows.

“Esko CDI Quartz also eliminates dot bridging and achieves new levels of solid ink density, making our prints cleaner and more vibrant,” he said.

“In flexible packaging, gravure is still widely considered as delivering the best in print quality,” said Jan De Roeck. “With the Esko Quartz ecosystem we are giving printers a way to match that print quality in flexography.”

The Esko Quartz ecosystem is compatible with solvent and water-based inks – delivering an increased density of up to 0.7 for water-based inks, which are becoming increasingly popular due to their sustainability benefits.