Even though flexographic printing accounts for the lion’s share of printed labels, suppliers are not resting on their laurels. Innovation is taking place on a daily basis, as evidenced by the newest product developments at Xitron.

Xitron has developed SmartFlexo Screening, which is a new screening technology that puts all the variables of hybrid screening in the hands of prepress operators. This combination of AM and FM screening allows prepress staff to dial in the best possible performance for every plate, tape, substrate, anilox, and press combination in a print shop.

SmartFlexo screening is a customizable solution that can be adjusted to almost any flexographic printing condition, providing the tools to enhance overall print quality while bringing a new level of sophistication across the entire flexographic spectrum.

“Unlike other hybrid screening solutions on the market, SmartFlexo does not require users to choose a group of pre-determined settings that may ‘get them close’ in terms of optimal print quality,” explains Bret Farrah, executive vice president, Xitron. “Instead, SmartFlexo lets the operator determine all facets of screening creation, including the point at which AM dots change to FM in both the highlights and shadows – separately.”

This product optimization allows for the applied settings to take into account the minimum dot held by the plate, the pressure response based on the mounting tape and press, substrate absorption, anilox performance, frequency, angle, and job type. At the same time, SmartFlexo can be instructed to produce supporting, non-printing dots to help bolster the structure of the highlight dots that do print.

Additionally, SmartFlexo allows operators to evaluate the solid ink coverage of individual jobs and automatically remove pixels (SmartCells) from shadow and solid areas, resulting in better ink coverage with reduced pooling or mottling. SmartCells can be adjusted in ranges anywhere from 50% to 100%, and the SmartCell sizes are selectable from 1 pixel by 1 pixel to 6 x 6.     

According to Farrah, built-in edge protection (SmartCell Boundary Width) prevents pixels from being removed from the edges of halftone dots, which helps maintain dot shape and integrity.

“The results achievable with SmartFlexo include a marked increase in print quality and the ability to more accurately reproduce design elements that were previously unprintable when using one-size-fits-all screening technologies,” comments Farrah. “Specific enhancements include remarkable highlight and shadow reproduction, which are the typical problem areas in flexography.

“Flexographers who use SmartFlexo Screening provide a higher standard of quality across a range of jobs, which results in a higher level of satisfaction among print buyers,” he adds. “Designers – especially those who specialize in packaging – can push the envelope in package creation, knowing that the elements will reproduce properly in the package’s final form, which ultimately results in better product and brand recognition.”

This technology allows flexo printers to tailor the screening process to their unique needs. This advancement on the aforementioned one-size-fits-all screening gives converters complete control of their flexo runs. By adding this versatility, flexographers have the ability to deliver eye-catching artwork and design elements that can be faithfully reproduced across numerous prepress and pressroom conditions.

“Prior to SmartFlexo, users were forced to choose from vendor-provided preset configurations that would work well for some jobs in some environments but not work well in others or with different presses, plates, tapes or anilox rollers,” says Farrah. “SmartFlexo adapts to all conditions to provide the highest quality screening possible.”

Xitron’s SmartFlexo Screening has been developed with the future of flexo in mind. An increasing number of flexo printers have brought platesetting in-house, mainly due to the availability of lower-cost CTP engines, and that trend is expected to continue. Plus, those with existing systems are searching for ways to improve their print quality, and SmartFlexo has been designed to provide that precise control over the process.

“SmartFlexo is an agnostic technology that can be used with any manufacturer’s CTP engine, plate, anilox, or substrate, which means it can easily integrate with existing prepress environments,” remarks Farrah. “The net result to users will be excellent zero-to-N transition, superior density in solids, the ability to run presses faster without dot mitigation, and overall improved print quality. Brand owners are able to incorporate next-level designs that will reproduce as intended, creating recognition and, ultimately, higher product demand.”