ThermoFlexX has used an open house at its factory in Ypres, Belgium, for the worldwide launch of the completely redesigned ThermoFlexX 60 digital flexo plate imager. Based on the company’s groundbreaking developments in flexo technology over the last two years, the new ThermoFlexX 60 is the most advanced 1,067 x 1,524 mm flexo imager on the market.

“Our commitment to the flexo industry and our determination to push forward the boundaries of what can be achieved in the field of plate imaging has resulted in several major breakthroughs which have positioned ThermoFlexX as a leading manufacturer in this sector,” says Christophe Lievens, director sales and marketing for basysPrint and ThermoFlexX.

“In addition to advancements in technology, we have established a growing network of global dealers and distributors while our customer base has expanded considerably. Our recently launched ThermoFlexX 80, the largest imager in our range, has attracted significant interest. Models are now in full production at AtoutFlex, a leading service bureau in north-east France, and at a new 800 sq metre factory in Bejaia, Algeria, completed recently by the Miller Graphics Group. The third ThermoFlexX 80 has recently been installed in Egypt and we expect to announce further orders in the near future.”

All of the technology incorporated into the ThermoFlexX 80 is available on the new ThermoFlexX 60. This includes the ability to fit a dual-head imaging system, which enables output speeds of 12 sq metres an hour at 2,400 dpi, making these two models the fastest flexo imagers in the world.

The state-of-the-art imaging concept consists of three independent modules - the motor, laser and optics. The flexible design means that replacing any of these modules is straightforward, which simplifies service and hardware upgrades and provides the possibility for remote optical fine-tuning.

The newly designed optical system has improved imaging quality even further, while the maximum resolution of 5,080 dpi is the highest on the market, allowing the production of halftone screens of 250 lpi, which is suitable for intricate, high quality work. The ThermoFlexX 60 will automatically select the correct resolution depending upon the job being sent by the workflow and alter the optics accordingly.

“We listen continuously to what customers and other industry players say they want from a plate imaging device and this feedback steers much of the development work we carry out here in Ypres. This is why we have dedicated so much research effort into output quality and why we have recently developed the ability to change resolution on-the-fly on the ThermoFlexX 80 and 60 models.

“ThermoFlexX already provides the widest choice of resolutions on a flexo imager, from 2,400 dpi to 5,080 dpi, and being able to swap instantly between outputs means that customers can produce jobs with different resolutions on the same plate. This offers the potential for huge savings in time and materials. Users no longer have to wait for jobs that require output at the same resolution in order to bundle them on the same plate.”

Keeping wastage to a minimum is a key aim at every stage of the imaging process and ThermoFlexX has incorporated a high level of automation, from the automatic calibration system that guarantees jobs are always imaged under optimum conditions, to the ability for the operator to load and unload plates at the touch of a button.

To overcome the need to handle large plates manually - one of the main causes of plate damage - the company created a mobile table called the Flextray. This unit, now available for the ThermoFlexX 60 as well as the ThermoFlexX 80, can be adjusted easily to transport and feed plates into the guiding system on the imager. The advanced automatic clamping system, combined with the slow drum rotation feature, ensures that plate mounting is straightforward and accurate.

The creation of a hybrid drum that enables plates to be held by either vacuum or magnets means that customers can expose standard polymer flexo plates or steel-backed letterpress plates. ThermoFlexX has developed a vacuum slider facility that allows the operator to cut off vacuum to areas of the drum not mounted, simply by moving a slider to the edge of the plate.

This function is automated on the new ThermoFlexX 80 and 60. Eliminating the need to apply special tape, or cutting plates to fit the unused part of the drum, means that customers can easily fit and expose (at full speed) plate off-cuts that would otherwise normally be thrown away.

All ThermoFlexX imagers utilise IPG fibre lasers operating at 1,064 nm, which combine low energy consumption with high reliability. The imagers will expose any plate with a LAM layer such as flexo, letterpress and dry offset, as well as Gallus Screeny (digital screen) and ablative film.

They can handle any thickness from a 0.18 mm ablative film to a 6.35 mm flexo plate, and support all relevant technologies such as flat top dots. This means that if a printer uses plates from any leading supplier e.g. Flint, DuPont, Asahi, MacDermid, Toyobo, Toray etc., they can continue without changing their normal working practices.

ThermoFlexX imagers accept 1-bit TIFF files generated by any workflow, RIP or front-end and will handle any innovative screens such as hybrid or surface screens. The screened 1-bit TIFF file could be a single job file, which can be assembled on a template, or it could be an already assembled 1-bit TIFF plate. A philosophy of ‘openness’ means that ThermoFlexX imagers can be integrated seamlessly into existing workflows such as those from Esko Graphics, Hybrid Software, Kodak and Agfa.

“Technical innovation has to be backed up by sound, local service and support and during the last few months alone we have strengthened our distributor network in Latin America, China, Europe and Asia,” says Christophe Lievens. “In addition we have appointed sales managers for the UK and Ireland, Asia plus Germany, Switzerland and Austria.

“We completed 2014 with the installation of the first ThermoFlexX 80 models and this year has continued to be extremely successful, with imager sales coming from around the world, including the UK, Algeria, Egypt, India, Poland, Mexico and Peru. We expect interest to remain high, with a peak around Labelexpo in September when we will be showing some exciting new developments!”