Hamilton Adhesive Labels Reduces Makeready Time By 30% With Asahi AWP

Incredibly Consistent Technology and World-Class Quality

Tokyo/Brussels, 23 September 2019 – Asahi Photoproducts, a pioneer in flexographic photopolymer plate development, today reported that Hamilton Adhesive Labels Ltd., a leading converter of printed and plain labels for the food & drink, industrial, automotive, personal and household care markets with an annual turnover in excess of £12 million, has chosen Asahi AWP™ water-washable flexographic plates with CleanPrint. Hamilton operates from a 40,000 square foot manufacturing and warehousing facility centrally located in Bardon, Leicestershire, with a dedicated team of more than 65 people focused on product and service excellence.

Upon joining the company in 2016, Operations Director Paul Larkin, an industry veteran with more than 44 years of experience, was tasked with helping to make the business more sustainable and to identify low-cost changes that could have high productivity impact using his Measurement and Control philosophy, designed to deliver a predictive system that ensures “right first time” performance with world-class quality. He then formed a Formula One (F1) pit stop team tasked with optimizing productivity based on the new predictive system. He states, “Unless you can demonstrate a level of quality, the market is limited for any company.” Over his first year, Larkin examined every phase of the flexographic printing process, including flexographic plates, seeking ways he could improve it.

Larkin tested a wide variety of flexographic plates in his search for the perfect plate, testing them with thousands of meters of print. The ultimate choice was the Asahi AWP™ water-washable plates with Asahi CleanPrint, provided via the company’s repro house partner, Creation Reprographics.

“There is nothing out there like the Asahi AWP™ plates,” Larkin states. “They deliver a great tonal range and the dots are very stable.” He notes that ink on standard flexographic plates can be drawn to the shoulder of the dot, which can have a significant impact on running speed with frequent plate cleaning stops. “Using Asahi AWP™ plates with CleanPrint, it is completely different,” he explains. “The ink is somehow drawn to the tip of the dot, and the press is able to print continually without stopping for plate cleaning. It’s an incredibly consistent technology with world-class quality. It’s been a vital element of our quest to ‘get print right the first time!’”

Award Winning Performance

Not only has the company achieved a reduction in makeready time following its conversion to Asahi AWP™ plates with CleanPrint, but quality was also significantly improved as evidenced by awards its output has achieved. These include an EFIA Gold Award in the promotional category for a Crystal London label and the two Flexotech awards Best Print and Supreme (Best in Show) Awards. “This is the first time we have won this king of awards,” Larkin proudly reports. In presenting the award for Best Print, the judges stated, “Incredible vignettes to paper white, smallest dots ever seen in flexo, sharp text and high colour density. A superb promoter of flexo.” This praise was echoed in the judges’ statement with regard to the Supreme (Best in Show) Award: “We’ve been impressed at first glance; and the more we were checking the quality, the more we were convinced to be looking at a really ‘first in class’ piece of work.”

Benefits Of Asahi CleanPrint

Asahi CleanPrint is designed to facilitate kiss touch printing pressure. Lighter printing pressure ensures constant repeatability of printing quality during the production run as well as longer plate life. This characteristic is achieved with unique Asahi-engineered photopolymer chemistry that reduces the surface energy of the printing plate and enables better ink transfer to the substrate during printing.

CleanPrint has the beneficial effect of reducing ink filling in the mid-tone area during the printing run, leading to fewer cleaning intervals and shorter press downtime for a highly sustainable flexographic printing process. Dr. Dieter Niederstadt, Asahi’s Technical Marketing Manager, notes, “Our customers, including Hamilton Adhesive Labels, are ecstatic about the quality of print they can deliver while also benefiting from reduced makeready time and improvement in OEE.”

Bright Future Ahead

Larkin sees a bright future for Hamilton Adhesive Labels and for the industry at large. “At Hamilton,” he says, “the combination of high quality printing components, including plates, inks and more, in combination with a sustainable company culture that operates from a Measure and Control philosophy with dedicated and talented employees on our F1 team, is driving the quality and price/performance of label manufacturing beyond that of any other printing technology available in the market. We are pleased to be working with Creation Reprographics and Asahi Photoproducts as critical partners that are helping us achieve our goals, win those prestigious awards, and look ahead to even more advances in the future.”

Asahi CleanPrint – Clean and in balance with the environment

Re-post from asahi-photoproducts.com

As regulatory agencies around the world place more stringent focus on environmental sustainability, Asahi Photoproducts continues to innovate platemaking technology with a solution that aims to produce plates in an office-type environment, processing photopolymer reducing VOC’s into the atmosphere. CleanPrint plates use less ink, emitting fewer VOCs in the pressroom. There is less makeready waste and waste due to plate cleaning press stops, adding even more environmental sustainability to the process. And more efficient throughput means less energy consumption. Not only does this help with regulatory compliance, it creates a safer, cleaner work environment for employees.

In fact, CleanPrint plates can be produced in an office-type environment, processing photopolymer without introducing VOC’s into the atmosphere.

GOLDEN ERA RECOGNIZED WITH AWARD FROM FLEXOGRAPHIC TECHNICAL ASSOCIATION OF SOUTH AFRICA, USING ASAHI AFP-TOP PLATES

Re-Post from Asahi-Photoproducts.com

Tokyo, Japan & Brussels, Belgium, December 14, 2015 – Asahi Photoproducts, a pioneer in flexographic photopolymer plate development, is pleased to announce that its customer, Golden Era, is a 2015 recipient of the Flexographic Technical Association of South Africa’s (FTASA) Best of Show Print Excellence Award. The company was recognized for packaging it produced for Kellogg’s Coco Pops using Asahi AFP-TOP plates. Asahi customers walked away with a total of seven awards.

The FTASA Print Excellence Awards have been held in South Africa since 1997; first under the auspices of the Institute of Packaging and later independently. This competition focuses on printing quality and not innovation, design or origination, although the printer’s skill in implementing these is taken into consideration. A total of 23 companies entered the competition with a total of 166 entries which were spread over 10 categories, many of which were subdivided into line and tone and process working. Some categories, like paper, were further subdivided into coated and uncoated. A total of 51 awards were made. The judges set their standards very high and any blemish or mark, poor transfer, less than perfect register or non-compliance with the requirements are bases for rejection. Magnifiers are regularly used to examine dot integrity, ink lay down and -transfer.

With respect to Golden Era’s Best of Show award, the judges commented, “The multicolour registration issues created by the design for this entry are well-handled. Smooth and even gradations, fine highlight dots and good solids with solids and halftones on the same plate are all achieved with water-based inks. The Kellogg’s Coco Pops print was therefore judged ‘as close as you can get to perfect.’”

Another Asahi customer, New Era Labels, reaped two Gold awards. With regard to the Nola Tangy Mayonnaise Dressing shrink sleeve entry, the judges commented, “The entry achieves excellent ink laydown, particularly for the gold.” They also applauded the smooth, fine highlight
dots. “Smooth fine highlight dots is one of the differentiation factors making a difference between Asahi Pinning Top Dot plates and plates from other manufacturers,” said Dieter Niederstadt, Technical Marketing Manager for Asahi Photoproducts, “largely as a result of the inherent capability of Asahi plates to deliver High Definition Clean Transfer of ink.” The award of a second Gold medal to New Era Labels for its OK Soup Powder package demonstrates this point, with the judges praising the density of all of the colours and “magnificent, clean positive type.”

In addition to the above awards, the following entries printed using Asahi plates secured medal awards.

• Ellis Brown Creamer 1Kg – Silver Award – AFP TOP (Golden Era Printers)

• Spar White Onion Soup 65g – Silver Award – AFP DSH

• Lux Wake Me Up 400ml – Silver Award – AFP TOP (New Era Labels)

• Kellogg’s Fruit Loops 350g – Bronze Award – AFP TOP (Job moved from Litho to Flexo) (Golden Era Printers)

“Print quality has historically been a focus for this prestigious award,” says David Galton, Asahi European Sales Director. “It is that print quality that is helping to accelerate growth in flexographic printing, bringing flexo quality on a level with offset and gravure. We are honoured that our plates played a role in enabling Golden Era and other Asahi customers to be recognized with these awards. It is especially rewarding in light of the stringency of the judging criteria.”

Asahi’s solvent-washable AFP-TOP flexo plates embody a unique design that ensures the highest possible quality print with the least amount of press downtime. Its Pinning Top Dot Technology ensures exceptional print performance and enhanced press profitability, as demonstrated by the quality of Golden Era’s submission.

DS SMITH RECEIVES PRESTIGIOUS EUROPEAN AWARDS FOR EXCEPTIONAL QUALITY IN FLEXOGRAPHY

Re-post from Asahi-Photoproducts.com

Tokyo, Japan, & Brussels, Belgium, June 29, 2016 – Asahi Photoproducts, a pioneer in flexographic photopolymer plate development, today congratulates its customer, the DS Smith plant in Fulda. DS Smith, a leading display & packaging supplier, is the recipient of two prestigious awards from the FTA Europe Diamond Awards. The company was recognized with a diamond first in the Super Wide Web Flexo Print on Paper category and also Best in Show due to the outstanding printing quality for its pre-printed liners produced for Henkell & Co. Sektkellerei KG. The inaugural FTA Europe Diamond Awards ceremony was held at the Hyatt Hotel in Düsselsdorf, 2nd June 2016, during the drupa 2016 exhibition.

The FTA Diamond Awards recognizes companies that have been Gold Award winners in their respective countries. DS Smith had achieved gold in a category of the EFIA UK awards in March and was then put forward to participate in the FTA Awards.

“We submitted printing samples for pre-printed liner we created for Henkell & Co. Sektkellerei KG. These images were printed in very high quality that compares favorably with conventional offset-printed packaging,” said Steffen Blankenburg, print production manager at the DS Smith plant in Fulda.

In producing the packaging, DS Smith strove to achieve a close match to the brilliance normally achieved with offset printing, but using fixed color palette 4-color flexography. “The challenge was to reach high brilliance comparable to offset printing. We were able to do this through a combination of the prepress expertise of our well qualified employees and the quality enabled by using Asahi’s AFP-TOPTM plates with Pinning Technology for Clean Transfer.” added Jan Brandtner, plant manager at DS Smith Pre-Press Services GmbH.

“This terrific achievement was the result of a very fruitful collaboration between Asahi and DS Smith over the last six months,” said David Galton, Sales Director for Asahi Photoproducts. “We are proud to have been part of this process and extend our hearty congratulations to DS Smith for this prestigious recognition.”

More than 200 like-minded individuals from across the European flexographic community came together to celebrate the best of flexography during the event. In addition to well-deserved recognition of exceptional performance, it was an ideal opportunity to celebrate the vibrancy and competitiveness of flexography whilst providing a perfect forum for colleagues to network.

UNIFLEX ADOPTS ASAHI PHOTOPRODUCTS FLEXOGRAPHIC PLATES FOR HIGHER QUALITY, IMPROVED EFFICIENCY

Re-post from Asahi-Photoproducts.com

Tokyo, Japan & Brussels, Belgium, 24 January 2017 – About eight years ago, Belarus-based Uniflex began its journey to enhance quality and competitive advantage through the use of fixed colour palette printing (also called Extended Colour Gamut printing), using a fixed set of inks to replace most, if not all, requirements for spot colour inks. Uniflex is one of the largest flexographic printing companies in the Commonwealth of Independent States (CIS) and Eastern Europe. The company offers a wide range of high quality flexible packaging such as vacuum bags, pouches, sachets, roll packaging, and self-adhesive labels in up to 10 colours and using a variety of materials.

“We saw fixed colour palette printing as the next milestone in quality and efficiency for flexographic printing,” said Eugen Lungin, Production Manager of Uniflex. “We worked to assemble a suite of industry-leading solutions to position us at the forefront of modern printing techniques to better serve our existing customer base and to expand our global footprint. Our partnership with Asahi Photoproducts was essential to our success in achieving these goals.”

Uniflex chose to use Asahi’s AFPTM-TOP and AWPTM flexographic plates with Pinning Technology for Clean Transfer, finding them to be the ideal plate choices for Full HD Flexo production. “Our customers have strict requirements relative to the quality of their printing,” added Eugen Lungin. “We are always striving to take advantage of the latest innovations in flexography in order to meet and exceed customer expectations, and fixed colour palette printing is definitely one of those innovations. High quality, eye-catching, yet functional packaging is what our brand owners are looking for, and plates from Asahi Photoproducts are a vital enabler for us to achieve that and more.”

Pinning Technology for Clean Transfer is a unique plate technology specifically engineered to transfer all remaining ink to the print substrate due to the photopolymer plates having a lower surface energy than other plates on the market. It is an ideal technology for fixed colour palette printing. Not only does this deliver stunning graphical quality, but it also

improves overall production efficiencies due to reduced make-ready waste and fewer press wash-ups. In fact, independent testing reflects that Asahi plates with Pinning Technology for Clean Transfer deliver at least a 26% improvement in Operational Equipment Effectiveness (OEE).

“We began our fixed colour palette printing journey with Asahi’s AFPTM-TOP plates after a thorough market review, and found they had the best and most consistent ink transfer from start to finish during production runs. We subsequently added AWPTMwater-washable plates to take advantage of their precise plate-to-plate register, fast platemaking time and environmental benefits to round out our plate portfolio, for the best of all worlds in fixed colour palette flexographic printing.”

“Uniflex is a delight to work with,” said Martin Wohlschlegel, Sales Manager Key Accounts and Emerging Markets at Asahi Photoproducts Europe. “Their dedication to quality and environmental sustainability, and their heritage of innovation in the flexographic printing process, sets them apart and bodes well for their future success. We look forward to an ongoing relationship that is mutually beneficial.”

“With the implementation of fixed colour palette printing and our use of Asahi AWPTM and AFPTM-TOP plates,” Eugen Lungin concluded, “we not only have the cost and productivity benefits of fixed colour palette printing, but we also are able to achieve higher line screens and extremely brilliant colours without any compromise in colour stability. Homogenous ink transfer makes it nearly impossible to distinguish our fixed colour palette flexo printing from the highest quality gravure. We are now technically able to provide high-end printing quality that meets the expectations of even the most demanding customers while benefiting from improved OEE!”

Robinette has the answers to the Great Plate Debate!

“The Asahi AWP™ plates have proven very successful for us. The support from Asahi and its dealer CTGA has been outstanding. Asahi has a full-time representative in CTGA’s Nashville technology center, and their experts also help us with the entire platemaking process. We really appreciate all that they have done for us.”

— Gene Martin, Plant Manager at The Robinette Company

A Solvent-Free Approach to Platemaking

With a focus on sustainability, The Robinette Company was interested in reducing its environmental footprint. “In 2010, I attended the Great Plate Debate in Louisville, Kentucky, sponsored by the Flexographic Technical Association (FTA),” explains Gene Martin, Plant Manager at The Robinette Company’s Bristol TN plant. “All the vendors were there discussing the usual topics and latest technology. Then Asahi Photoproducts came forward with a plate that could be washed out with water and that didn’t require press stops for cleaning as frequently. That immediately got my attention.”

Subsequently, Martin and his team tried the Asahi AWP™-DEF water washable plates featuring Asahi’s CleanPrint Technology. “We ran some test jobs successfully, and our press operators liked the plate,” Martin states. “We were using solvent plates at the time, and it took three hours for the whole platemaking process. With the Asahi AWP™-DEF plates, the first time out in the platemaking process was one hour, with each additional plate in 20 minutes, increasing our platemaking capacity by 33%.” Since Robinette only works with AWP™ plates, this is a substantial time savings in the plate room.

Improved Quality, Faster Job Change Overtime

Robinette’s tests delivered better highlight dots and overall contrast. “The plate itself is very consistent,” Martin says, “when compared to other plate technologies. When you wash out with solvent, the plate swells, and you have to dry it and remove all the solvent to get to the correct caliper. We didn’t have that issue with the AWP™-DEF plates.”

With the AWP™-DEF plates, operators were also able to set impressions more consistently. “The plates have a more consistent surface tension,” he adds. “They release ink consistently with much better color matching between jobs that share the same colors without the need to retone the colors.”

With solvent plates, presses at Robinette delivered a 49.58% Overall Equipment Effectiveness (OEE). Now with Asahi AWP™ plates, that has jumped to 64.92%, a 31% increase in OEE for the press room, with reduced makeready times and fewer press stops for plate cleaning. More specifically, the average time it took press operators to change over a job with solvent plates was 297 minutes while AWP™ plates took an average of 151 minutes. “That’s a 50% reduction in makeready time.  This is largely driven by the reduction in changeover time for jobs that share like colors, which represents about 65% of our jobs and has been reduced by two hours. Add all of that to our 33% gain in capacity in the plate room, and it is fair to say that with Asahi AWP™ plates, our plate and press rooms have been revolutionized!”

Moving to the Next Generation

Martin is delighted with the improvements achieved by using the AWP™-DEF water-washable flexo plates. “But nothing in this world stands still,” he comments, “and we are always looking for ways to improve our quality and productivity. We are pleased with the work Asahi Photoproducts is doing to continue to improve their products as well.”

In that spirit, The Robinette company beta-tested the brand-new Asahi AWP™-DEW plate. “We are getting the same great quality and taking advantage of Asahi’s CleanPrint™,” Martin states. “But now our first time out for a plate is reduced from an hour to around 25 minutes, with subsequent plates produced about every 15 minutes.

Solvent-Free

Due to its success with the Asahi water-washable plates, The Robinette Company’s platemaking department is now completely solvent-free. “This is a huge benefit for us,” Martin says. “We no longer have to recycle solvent or handle any hazardous waste.” “The partnership with Asahi is very valuable to us,” Martin concludes. “The support from Asahi and its dealer has been outstanding. Asahi experts also help us with the entire platemaking process, including the Esko plate imager, and HD Flexo and microcell patterning. We really appreciate all that they have done for us.”

CLEAN PRINT: THE HISTORICAL DEVELOPMENT OF THE NAMING CONVENTION

Since Asahi first brought to market its innovative flexographic plate technology that enabled complete release of ink onto the substrate for a cleaner image and fewer press stops for plate cleaning, our thoughts about the value of the technology have evolved. Our customers remember that we initially called this technology Pinning Top Dot technology, since we were thinking about it from a technological perspective. Over time, we began to realize, based on customer experience, that the value went well beyond the ink transfer to the increased quality and productivity it enabled when looking at the entire process from the plate room to the press room. We also wanted a naming convention that was more descriptive; thus, the naming changed to Clean Transfer Technology.

Now, after several years of field experience with this technology, and as we migrate it to other plates within our portfolio to address a wider array of applications, we have come to understand that the value of the technology goes way beyond the quality and productivity benefits it enables. There are significant environmental benefits as well, especially with our water-washable family of

plates. Not only does it eliminate the need for volatile washout solvents in the platemaking process, speed up the process to consume less energy and deliver the same high quality and press productivity (OEE) our customers have come to expect, but the technology reduces makeready times and waste as well as the amount of time the press needs to run. All of these benefits add up to a much cleaner platemaking and flexographic printing process than can be achieved with any other plates on the market. CleanPrint embodies all of these things and aims to make flexographic printing “CLEANER”.

That means that using Asahi’s AWPTM family of water washable flexo plates delivers significant benefit, from both a quality and sustainability perspective. Water washable plates are now well-positioned to completely replace solvent-based platemaking workflows for most applications. This results in faster platemaking, improved OEE on press, higher quality and longer lasting plates, reduced or eliminated VOCs, and no need to manage or dispose of toxic chemicals.

CleanPrint plates from Asahi, then, not only produce cleaner printed images, but they do so in a much cleaner, more environmentally balanced way. Some of the benefits include:

  • Significantly reduced platemaking and on-press time results in a reduction in power consumption.
  • Plates last longer and don’t require press stops for cleaning, further improving press OEE.
  • Faster run up to color and more consistency throughout the run means less waste of expensive packaging substrates.
  • Full transfer of the ink from CleanPrint plates to the substrate creates significantly higher printing quality at less cost.
  • Elimination of VOC solvents in the plate processor also making the workplace safer in better balance with the environment.

Get the details www.asahi-photoproducts.com/en/resource/46

Asahi Photoproducts to Unveil CleanPrint™ at Labelexpo Europe 2019

The absolute best way to make flexographic printing a CLEANER technology (and more profitable!)

Tokyo/Brussels, 28 May 2019 – Asahi Photoproducts, a pioneer in flexographic photopolymer plate development, today reported it will be again exhibiting at Labelexpo Europe, scheduled for 24 to 27 September in Brussels. Asahi will be located on Stand 5a34 at the show and will be displaying its full array of flexographic plates. Featured at the show will be Asahi’s CleanPrint™, a technology which has evolved over time to become the industry benchmark for CLEAN flexographic printing.

“Since Asahi first brought to market its innovative flexographic plate technology, which enabled complete release of ink onto the substrate for a cleaner image and fewer press stops for plate cleaning, our thoughts about the value of the technology have evolved,” said Dr. Dieter Niederstadt, Asahi’s Technical Marketing Manager. “Not only do we continue to improve our plate quality and performance, but we have also learned from our customers that the value of the technology goes way beyond the quality and productivity benefits it enables. Not only does it eliminate the need for volatile solvents in the platemaking process, speed up the process to consume less energy and deliver the same high quality and press productivity (OEE) our customers have come to expect, but the technology reduces makeready times and waste as well as the amount of time the press needs to run. All of these benefits add up to a much cleaner platemaking and flexographic printing process than can be achieved with any other plates on the market.”

Read full release and download documents

Asahi Photoproducts at EskoWorld 2019 with enhanced plate Portfolio

Attendees will learn how Asahi CleanPrint™ significantly improves Overall Equipment Effectiveness (OEE) across the entire flexographic production process

Tokyo/Brussels, May 23, 2019 – Asahi Photoproducts, a pioneer in flexographic photopolymer plate development, today announced it is again attending and sponsoring EskoWorld 2019, scheduled for 24 to 26 June in Nashville, Tennessee. During the event, Asahi representatives will be speaking with attendees about the OEE advantages of Asahi AWP™ water-washable plates, as well as their effect on improved environmental sustainability.

“We began using Asahi AWPTM-DEF plates in 2010,” said Gene Martin, Plant Manager at The Robinette Company’s Bristol TN plant. “At the time, it was taking us three hours for the platemaking process with solvent plates. With the Asahi AWPTM-DEF plates, the first time out in the platemaking process was one hour, with each additional plate in 20 minutes, increasing our platemaking capacity by 33%.” Since Robinette only uses Asahi plates, this is a substantial time saving in the plate room.

Read full release and download documents

CTGA: Celebrating 20 Years Of Being Your Source For Quality Flexo Plates

It Began With A Simple Goal

For 20 years now, CTGA has been a top source for Flexo Plate Material and flexographic printing products and equipment in North America.

We started this business with a simple goal, to supply our clients with the highest quality flexo plates, and help boost flexographic printing to the top of the printing industry.  To accomplish this goal we partnered with Asahi, a company we saw having the foresight to innovate flexo plates and bring improved quality, productivity and sustainability to flexo.  It was the best decision we could’ve ever made, as Asahi plates have taken Flexo by storm since then, and achieved a new level of success for our clients who use them.

From there we built out the rest of our product catalog with products and equipment from the top brands in the world, Esko, Glunz & Jensen, Tesa, Techkon,  Beta Industries, CGS Oris and our own Green Dragon line.  Together with our complete line of Asahi flexo plates and equipment, we believe we offer the best and most comprehensive product catalog in the business.  And, our clients’ success over the years backs that up.

Asahi Flexo Plates

The outstanding performance of Asahi Flexo Plates is the result of over 30 years of technological development in the field of photopolymer plates for flexo printing. In that time, Asahi has grown to become a leading manufacturer of digital and analog printing plates for the flexo market. They’ve achieved this by setting the highest standards in product development and manufacturing, while continually breaking new ground in advancing technologies to improve print quality, cost-effectiveness and environmental sustainability.

AWP-DEF

Asahi AWP Water Wash Flexo Plate

AFP-TOP

AFP-DSF

Introducing Green Dragon Products By CTGA

We Carry The Top Brands In The World

ESKO

TESA

Techkon

GLUNZ & JENSEN

BETA INDUSTRIES

CGS ORIS

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