The heralded advantages promised by a streamlined, all-digital operation are now drawing even printers with four-page equipment away from film and toward computer-to-plate (CTP) imaging.
State Street Consultants, a Boston-based industry research group, reports that four-page platesetter installations among printers with 20 to 49 employees grew by 10% last year, 30% among shops with 50 to 99 employees. Sales of the equipment to printers with fewer than 20 employees remain slow but are steadily increasing.
"About half of the larger printers already have CTP, so it's the smaller shops that will now answer questions about the technology's overall acceptance," says John Zarwan, a State Street Consultants principal who led the CTP study released this summer.
Similar findings come from Vantage Strategic Marketing (VSM), an industry research group based in the United Kingdom that completed its "Direct-to Technologies 2001-2006" report several months ago. The study shows that while eight-up systems accounted for a little more than half of U.S. platesetter sales last year, demand for four-up units jumped significantly.
A breakdown from Heidelberg last year showed twice as many sales of four-up systems than two-up and eight-up units combined.
"On the whole, it's word of mouth that's pushing this four-up segment. Printers hear from other printers who've invested in CTP and found it very much worth their while," says Barry Happ , a VSM principal. "With filmless platesetting becoming more affordable, printers will find less reason not to take the plunge."
In Happ 's view, the CTP market is certain to undergo change over the next few years as true commercial processless plates and platesetters become available, faster systems using true conventional plates debut, and inexpensive, higher quality ink-jet devices undercut present imaging technologies.
Violet's blooming
Meanwhile, sheer economics and practicality are driving more violet diode visible-light systems into the market. The imagers are a lot less expensive than thermal systems, plus violet-sensitive photopolymer plates represent the elimination of silver from the process.
At this month's Graph Expo show, Fujifilm, Itasca, Ill., will introduce the Brillia LP-NV violet-sensitive photopolymer plate using a 30mW diode.
Western Lithotech, a Lastra Group company, is finishing field-testing of its DiamondPlate LV-1 photopolymer violet-light plate using a 30mW diode.
Printer weighs costs
After researching four-up thermal devices and deciding that the costs involved in plates and maintenance--on top of the higher platesetter purchase price--were too high, Lawrence Printing of Atlanta opted to make its entre into CTP with violet, picking Heidelberg's Prosetter 74.
The four-page device uses Heidelberg's Signastation imposition to a Delta workflow and Heidelberg's Saphira violet plate with a Pro 85 processor. Lawrence is one of the first customers to install an HP 5000 color-managed proofing solution to work in conjunction with the Prosetter.
George Lawrence, president of Lawrence Printing，estimates that it took one month to work out the kinks associated with his firm's new digital workflow.
He adds, "It's much, much cleaner printing than we've ever had before. Productivity has gone through the roof in our prepress department and the workflow is extremely efficient. We can make a plate in 90 seconds."
Smooth transition
In Holyoke, Mass., one of the first printers to install Agfa's new automated Palladio flatbed violet laser platesetter reports a surprisingly smooth transition among customers when it eliminated film and switched to digital proofing. When it purchased the platesetter in March, Marcus Printing had upgraded from an Iris proofer to an Agfa Sherpa proofing system.
"Where our customers are concerned, CTP is really a trust-building process more than it is a learning process," reports Susan Goldsmith, president of Marcus Printing, a family-owned commercial printing company. "At first, the only thing customers wanted to talk about was proofing, but now it's not an issue."
Goldsmith explains, "They'd say, 'I have to see a proof with a dot,' and I'd tell them we can't do that anymore. Then I would invite them to come in and press check their job the first time, to let me prove that the digital process works. Now, clients who went from two-color to four-color work with us serve as testimonials for new customers giving us four-color jobs."
Constant action
Of all the violet-laser device's automation advantages, Goldsmith says she was excited most by the Palladio's ability to produce a constant stream of press-ready plates that keep Marcus Printing's pressroom productive. "We specialize in short- to medium-length runs, which is why the Agfa system works so well for us. We can make plates and we can make changes. I like to put eight or 10 jobs on press in an 18-hour day."
At Graph Expo, Fuji will introduce its Violet Saber Luxel Vx-6000 system, a four-up version of the violet Saber in a manual and semi-automatic configuration. The device, using Fujifilm's multilaser imaging technology alongside a 30-mW, 405-nm violet laser diode in a one- or two-laser configuration, features automatic plate loading.
"The operator stages a plate on the loading platen and the system automatically centers and loads it," explains Peter Vanderlaan, Fuji's product development manager in charge of electronic imaging hardware. "The Saber Vx-6000 has a unique feature: it prompts the operator for the required plate size prior to loading."
The platesetter, designed for maximum press support for the mid-size printer, also offers one of the largest four-page imaging formats available, 269/16x30".
New at the show
Esko-Graphics will use Graph Expo for the U.S. debut of a semi-automatic version of its successful PlateDriver CTP machine. With the PlateDriver Semi, operators load plates manually, one or two at a time, which Esko-Graphics says provides high-end quality and productivity at a more cost-effective price point.
As soon as the first plate is loaded onto the drum, the next plate can be placed on the loading table, ready for automatic loading, avoiding the need for the constant presence of an operator.
Common features of both PlateDriver models include the ability to load, expose, and punch plates in landscape as well as portrait mode, plus a linear motor that enables metric as well as inch (imperial)-based output resolutions allows the PlateDriver to work with any CTP workflow system
At the show, Esko-Graphics also will demonstrate the three-beam optics model of its Plate-Driver, which exposes silver or photopolymer plates.
Processless plating
New from Creo in the four-up arena is the Lotem 400 Quantum, which combines Lotem's automation capabilities with SquareSpot thermal-imaging technology.
Processless plating technology on the Lotem product line, coupled with the SquareSpot imaging heads, is aimed at removing process control variables on the plate, says Joe Luckett, marketing manager for CTP devices for Creo. The processless devices will initially be qualified with Presstek's chemistry-free Anthem plate.
"We have only a few installations of the Quantum at this point but interest has been very, very high," reports Luckett. "People are just very interested in processless platemaking for shorter runs. It's more environmentally friendly and doesn't require chemicals, maintenance, or some of the floor space required for the processing lines. There's also a lot of interest in the fact that it's upgradable."
New buyers, new needs
As the need for CTP moves downmarket, Luckett says, Creo has made a concerted effort to develop more affordable solutions that aren't overly robust or complex and can be expanded as users require.
"Many buyers today have different needs than customers who adopted CTP five years ago," says Luckett. "Back then, a $50 million printer likely had a full IT staff and needed less technical pre-sales expertise to help construct an internal network or give recommendations for the correct platforms for workflow solutions.
"But in companies that are just $3 million to $10 million in size, principals have a much broader range of responsibilities so they do a lot more 'multi-tasking'. We recognize that they'll need more help in starting up and more outside expertise to get through some of the internal workflow changes."
Operator equation
Mark Tonkovich, CTP manager for Heidelberg USA, says much of a successful CTP transformation comes down to the capabilities of the individual chosen to run the shop's prepress department.
He recalls, "One four-up shop that recently adopted CTP had no prepress whatsoever that I'm aware of, but it had a really sharp person who had been the lead stripper, who was computer-savvy, and so forth. With training, someone like that, who's very knowledge, motivated, and aggressive, can become the key operator."
At Graph Expo, Heidelberg is introducing a single-cassette loader for its Prosetter 74 system that can hold 100 12-mil plates, or up to 150 six-mil plates, including slip sheets. Also being unveiled is the second-generation thermal Topsetter 74, the Topsetter T-74, with output speed increased from 16 to 20 plates per hour.
Also in the four-up CTP category, BasysPrint will introduce the f-generation UV-Setter 57-f and Screen (USA) will debut its Plate-Rite 4300 thermal device, featuring unique clamping and automatic drum-balancing, and rated at 20 plates per hour.
Attendees will be able to view new ink-jet technology from Pisces, Inc., which this year has sold more than 100 of its compact and affordable JetPlate alternative "liquid light" CTP systems. The unit utilizes an Epson 3000 ink-jet print engine to image conventional UV-sensitive aluminum plates in sizes up to 18x25".
The Issue of Affordability
Pinning down the prices of computer-to-plate systems, particularly in a buyer's market, can be a challenge. However, here are some guidelines, gleaned from vendors and consultants.
Keep in mind that purchase plans vary widely: equipment bundled with consumables contracts, presence of existing equipment such as RIPs or processors, and whether or not proofing systems are included.
Prices for entry-level platesetting units in the four-page format range from $60,000 to $100,000. Complete metal-plate systems, including a more automated imaging unit and RIP, can cost up to $150,000. Top-of-the-line systems, including proofers and in-line processors, have price tags from $175,000 up to $200,000.
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