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Flexo Platemaking

Advancing Flexo Printing: How to Enhance Quality and Efficiency

CDI Quartz 4835

As flexographic printing continues to evolve, so too does the need for a higher quality, more efficient, and more consistent process.

Do you want to achieve gravure-like precision while maintaining the cost and flexibility advantages of flexo? To do so, you must leverage advancements in imaging and plate-making technology.

One recent development addressing these challenges is the CDI Quartz, a new imaging technology designed to improve resolution, ink laydown, and workflow integration.

The technology brings together imaging, screening, UV exposure, and plate processing in a coordinated system. This helps printers achieve finer details, stronger solids, and smoother transitions all while optimizing production efficiency.

Key Innovations of CDI Quartz

CDI Quartz works by introducing several enhancements to flexo imaging, including:

  • Higher-resolution imaging (4,000 ppi) for sharper details and smoother gradients.
  • Improved surface structure technology (2,000 lpi) to minimize pinholes and enhance ink laydown.
  • Dual Optics System that supports both legacy and forward-looking flexo platemaking.
  • Integrated platemaking workflow that aligns screening, imaging, UV exposure, and processing for consistency.

These advancements address common flexo challenges such as fine detail reproduction, ink coverage, and repeatability, providing a pathway for more precise and stable print results.

Quartz Highest Ink Transfer example

How Does CDI Quartz Compare to Gravure?

Traditionally, while gravure printing has been favored for its fine details and smooth tonal transitions, it is often costly with long production cycles.

Flexo, on the other hand, offers greater efficiency and adaptability. Historically, however, it has struggled to match gravure’s precision.

The imaging resolution of CDI Quartz closes this gap. Whereas most gravure cylinders are engraved at 2,540 ppi, CDI Quartz images at 4,000 ppi, allowing for:

  • More defined fine lines and small text without distortion.
  • Higher ink densities, reducing the need for excessive ink pigmentation.
  • Consistent ink laydown, minimizing defects like pinholes.

The system also supports low volume anilox rollers, enabling better ink control and improved highlight reproduction.

This results in smoother transitions and increased print detail sharpness.

Quartz Text rendering example

Gravure compared to Quartz

The Role of Q-Cells in Imaging and Ink Transfer

A key component of the Quartz system is Q-Cells, which refine how ink is transferred onto the substrate.

These microcell structures enhance both solid areas and screening dots, resulting in:

  • Stronger solids with more uniform ink coverage.
  • Smoother gradients with reduced graininess.
  • Better print repeatability across production runs.

By improving how the plate interacts with ink, Q-Cells contribute to greater stability in press performance, allowing for more predictable and controlled printing.

Q-Cells for Labels

Q-Cells also work very nicely when printing with UV inks in Labels, both for adhesive label stock as well as for shrink sleeve applications.

The benefits are:

  • Smoother ink laydown, with higher ink densities especially for shrink sleeve applications
  • More stable highlights improving the capability for printing transitions to zero consistently
  • Smoother vignettes and improved detail sharpness in images.
Quartz Excellence in Labels

Optimizing Press Setup with Print Control Wizard

Consistency in flexo printing often depends on accurate press fingerprinting and profiling, which can be time-consuming and complex.

Print Control Wizard (PCW) simplifies this process by:

  • Guiding users through fingerprinting and calibration steps.
  • Providing pre-configured screening options, including Quartz Screening.
  • Standardizing print conditions for more repeatable results.

For printers working with multiple substrates and applications, this level of automation reduces setup time and improves consistency across jobs.

Ensuring Precision with XPS Crystal Exposure

Imaging quality depends not only on laser resolution but also how the plate is exposed to UV light. The XPS Crystal system provides:

  • Uniform UV LED back and front exposure, preventing inconsistencies.
  • Better reproduction of fine details and Q-Cells, maintaining their structure on the plate.
  • A more predictable imaging-to-print process, reducing variability.

By integrating plate imaging and exposure, the system ensures the intended image is accurately transferred to the final print.

Workflow Efficiencies and Practical Benefits

Beyond quality improvements, printers adopting a fully aligned imaging and exposure system can expect operational efficiencies such as:

  • Reduced press downtime due to fewer adjustments.
  • Less ink consumption from more efficient ink transfer.
  • Shorter setup times with more consistent plates.
  • Improved print durability, leading to longer-lasting results.

For many, these factors contribute to lower production costs and a more streamlined workflow, making high-quality flexo production more attainable.

Better Flexo Printing is Here to Stay

Advancements in imaging, screening, and exposure technology are helping flexo push past its previous limitations. The CDI Quartz ecosystem demonstrates how an integrated approach to imaging and platemaking can lead to more consistent and cost-effective print production.

By aligning high-resolution optics, refined screening, and precise exposure, flexo printing is becoming an even more viable alternative to gravure and digital printing.

Want to meet the growing expectations of your brands and consumers? Get in touch with us today!

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