Written by Alexandra Blanck
Content Manager, Esko
What if your flexo plates could anticipate issues before they happened?
What if solids optimized ink laydown on their own?
What if imaging quality was perfected through thousands of AI-calculated variations before a plate ever reached the press?
That future is closer than many realize.
The Esko research team has already leveraged AI to calculate imaging variations that contribute directly to the exceptional imaging quality achieved with Quartz technology.
And as AI becomes more deeply embedded across the Esko ecosystem, CDI Quartz is emerging not only as a breakthrough hardware platform, but as the foundation for the next intelligent era of flexographic print.
Quartz today: A New Benchmark in Flexo Platemaking
Before exploring AI’s impact, it’s worth grounding ourselves in what CDI Quartz already delivers:
- 4,000 ppi imaging resolution — nearly double the current industry standard.
- 2,000 lpi Q-Cells microstructures — improving ink transfer, density and solid-area smoothness.
- Sharper details and smoother gradients through advanced optics and surface structuring.
- Gravure-level print quality, achievable through flexo.
- Sustainability gains through compatibility with water-based inks, PU inks, lower-volume anilox rollers and the emerging fully recyclable substrates like mono-foils and PCR (Post-Consumer-Recycled) materials.
- Reduced setup time and waste, leading to more consistent production and lower costs.
As Pascal Thomas, Director of Flexo Product Management at Esko, notes:
“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.”
Quartz has already set a new standard.
And now, AI is expanding what that standard can become.
Here’s how.
AI-Enhanced Research: The Hidden Engine Behind Quartz Quality
One of the most significant — and least visible — advancements behind Quartz is the role of artificial intelligence in the development of its imaging performance.
The Esko research team has successfully used AI to:
- Calculate and compare thousands of imaging variations
- Identify the optimal combinations of exposure behavior, optical parameters and structural geometry
- Refine microstructures (like Q-Cells) for better ink transfer, smoother solids and improved highlight detail
- Accelerate development cycles with data-driven experimentation rather than purely manual testing
This means that Quartz’s high imaging quality is not only the result of precision hardware — it’s the result of AI-guided optimization behind the scenes.
This is a powerful new message:
Quartz imaging is elevated by AI-assisted scientific research, supporting performance improvements that traditionally require significantly longer development cycles.
Where AI is Headed Next in the Quartz Ecosystem
While AI has already contributed to the quality Quartz delivers today, the next phase is about bringing AI closer to the operational workflow.
AI will increasingly support:
- Automated plate-quality prediction
Models trained on Quartz imaging data could identify plate inconsistencies before they reach press. - Adaptive screening recommendations
AI could dynamically select optimal Q-Cell patterns based on artwork, substrate or anilox combinations. - Smarter ink-laydown optimization
Data from previous jobs can guide operators toward the lowest-ink, highest-stability configuration - Predictive maintenance across imaging and exposure
AI will help detect optical drift, LED degradation or exposure inconsistencies early. - A closed-loop ecosystem
Press-side quality data feeding back into imaging recommendations — enabling self-optimizing print production.
What this Means for Converters and Brands
AI + Quartz strengthens the benefits converters already experience today:
- More predictable plate-to-print performance
- Improved solids, smoother gradients and stronger density
- Lower waste and reduced makeready time
- More confidence with water-based ink workflows
- Consistent brand color accuracy across runs
- Higher operator efficiency — fewer surprises on press
Quartz delivers excellence today.
AI will amplify it tomorrow.
Quartz Moves Flexo into an Intelligent Future
Quartz already raises the bar for flexographic print quality and efficiency.
And thanks to AI-supported research, its imaging quality is stronger, smarter and more optimized than ever.
As Esko continues expanding AI across the S2 platform, the Quartz ecosystem is positioned to evolve into a next-generation, intelligent flexo technology stack.
A system that learns.
Improves.
And ultimately helps converters print better from the very first pull.
Interested in learning more? Contact us today!
