Professional Documents
Culture Documents
VIOLET
Violet Print
digital plates
Version 1
European Technical Applications Group
May 2006
Table of Contents
Introduction
Chemistry
Processing
Processor Care
Baking Parameters
10
10
Press
12
Troubleshooting Plate/Platesetter/Processor
13
Troubleshooting Press
17
Introduction
This document has been issued by the European Technical Applications Group for all Kodak customers using
Kodak Violet Print digital plates. The document is designed to enable the Violet Print plate customer to obtain
optimum performance through recommended guidelines and best practice operational procedures.
This Customer Information Manual for Violet Print plates is functional for all markets supplied by the European
region of Kodak. This includes Europe, Africa and the Middle East Region (EAMER) and the Greater Asia Region
(GCR and INSEAN).
Compared to conventional workow, Computer-To-Plate (CTP) workow requires a higher level of control,
maintenance and cleanliness to maintain a consistent and reliable prepress and print process.
Kodak does not accept any liability for the misuse of their products.
Page 1
Bulk boxes:
Max. 2 pallets,
same size
Container:
Max. 4 pallets,
same size
Handling
When plates are being carried in either their outer casings or paper packaging, the plates must be carried
vertically to avoid bending or kinking. The outer packaging can look undamaged, but the plates inside can become
kinked if proper handling procedures are not carried out.
Picking up and carrying plates with the strapping will also bend
and kink the plates. The strapping may also incur edge damage on
the plates.
Page 2
When loading plates of sizes 1030 mm and larger, two people should carry the
plates from the packaging to the platesetter cassette, (Fig 1).
Fig. 1
Correct loading of the cassette
It is not possible for one person to load a full packet of plates and keep the
plates at due to the weight, (Fig. 2).
Fig. 2
Incorrect loading of the cassette
If only one person is available, split the pack and load a few plates at a time to maintain atness and prevent
kinking.
Page 3
Chemistry
Recommended storage conditions for un-opened developer and replenisher containers are 5C to 27C. Store in
a dry area away from bright sunlight.
The shelf life of un-opened developer and replenisher is 24 months.
When in use, an opened container of replenisher will start to absorb carbon dioxide from the atmosphere and the
pH will fall. Replace with a fresh container after 2 weeks in use.
When lling the developer tank of the processor, it is likely that a part-used container of developer will be left. If
the part-used container is less than 1/3rd full, discard as waste. If the part-used container is more than 1/3rd full,
re-seal the container for later use.
Finisher
Deletions
Additions
Plate cleaner
Page 4
Processing
Quick Set-Up Checklist
Before the installation, ensure that all chemistry and equipment is accredited for use with the Kodak Violet Print
digital plate.
a) Ensure that the brush and roller pressures are correct and are appropriate for the plate gauges being used.
It is important to set the brushes in the developer section correctly to give even development and smooth
transport. The same brush pressure settings should be used for all gauges of plate being used.
See Additional Notes.
b) Set transport speed to give the correct developer dip-to-nip time of 19 to 21 seconds. Check the dip-to-nip
time to be certain of the correct developer time.
c) Set the correct preheat temperature to give the target Thermax strip reading of 110C - 116C.
(Thermax strip readings of 104C - 116C are allowed on processors where the preheat
uniformity is not good, but this may give a little more variability in high screen ruling at tints).
Check the preheat for each gauge of plate used. Processors with hot-air preheat should be
able to give correct plate temperatures for each gauge at the same panel setting. For those
processors with IR ceramic tiles, dierent settings will be required for each gauge. With IR
ceramic tiles allow 10 to 15 minutes when changing gauges for the preheat to re-equilibrate.
See Additional Notes.
d) Make sure that the chiller system is functioning properly.
e) Set the developer temperature to 23C.
Illustration of Thermax
strip reading 110C
f) Set the developer system replenishment regime which is appropriate for the processor
being used. Check the replenisher pump calibration. The recommended procedure to
set the calibration is to measure the volume of replenisher that is delivered into a graduated vessel.
g) It is important that the pH of the developer is maintained to 0.3 pH units relative to
fresh developer. See Additional Notes.
h) Ensure the drains and plumbing are congured correctly. Any discharges to drain must comply with local
regulations.
i) If necessary, correctly position all spray bars.
j) Ensure that all other processing parameters have been set correctly.
Page 5
Additional Notes
Setting Brush Pressures
Several methods are available for determining optimum brush pressures in the prewash, developer and rinse
sections of the processor. Set the prewash and rinse brushes to medium pressure. Set the developer brushes to
a medium to hard brush pressure evenly across the width of the plate. Do not over-tighten the brushes as this will
damage the brushes and provide no benet. Over-tightening the brushes can result in plate bending or crashing.
It should be possible to achieve uniform development for dierent plate gauges at one setting of developer brush
pressure.
Preheat Setting
The preheat value on the processor has to be set to give the required preheat plate temperature. Adhesive
temperature step wedges are used. The recommended temperature strips are Thermax B 10-level strips having
10 values from 77C to 127C.
Thermax strips are used to set the preheat temperature on the processor. These strips comprise steps of
increasing temperature sensitivity. When the plate reaches a certain temperature, the step will change from white
to grey/black. The highest step on the strip to become grey/black is the preheat temperature. Several strips
should be applied to the back of a plate, at the leading edge, centre and trailing edge and aligned in the direction of
processing. The plate should be fresh, do not use a plate which has been processed, the coating can aect plate
temperature. After applying strips to the back of the plate, process the plate as normal. Read the temperature
from the strips. Adjust the preheat setting on the processor if necessary and re-check the plate temperature with
a new plate.
Page 6
Setting
Transport speed
Preheat
Set to give Thermax strip reading on the back of the plate of 110C
- 116C. 104C - 116C is allowed on processors where the preheat
uniformity is not good, but this may give a little more variability in
high screen ruling at tints.
Background fogging may occur at a Thermax strip temperature of
121C or higher.
Prewash
Prewash options
1 Bristle brush
Medium pressure
Developer
Developer temperature
23C 1C
A chiller unit will be required for the processor
Developer pH
12.2
Developer life
Developer top-up
Not required
Replenisher
Replenisher pH
13.0
Page 7
Parameter
Setting
For plate throughput = 80 mls/m2
For O and Standby anti-oxidation
= 40 ml/hr for 850 mm and smaller width processors
= 80 ml/hr for greater than 850 mm processors
Replenishment rates
Rinse
Rinse options
Finisher life
Typically 1 to 4 weeks
50C
Waste disposal
Contact your local Kodak technical support if you need set-up information for a specic processor.
Page 8
Processor Care
A regular maintenance and cleaning regime will produce a more consistent plate, minimising both downtime and
remakes.
During any maintenance of the processor and the handling of chemicals, suitable safety glasses and chemicalresistant gloves should be worn. Always refer to the Material Safety Data Sheets (MSDS).
Weekly
Page 9
Baking Parameters
Normal exposure
Baking solutions
Conveyor oven
Static oven
Equipment
Step Wedge
In this document, we refer to UGRA and Stouer step wedges. Specically, by UGRA we mean the UGRA Plate
Control Wedge 1982, and by Stouer we mean the Stouer 21 Step step wedge. These step wedges are in
intervals of 0.15 density units. For the UGRA step wedge, step 1 = 0.15 neutral density units, and for the Stouer
step wedge, step 2 = 0.15 neutral density units. UGRA step 1 = Stouer step 2, UGRA step 2 = Stouer step 3,
etc.
Plate Reading Device
For linearisation of the tonal range you will need to use a standard densitometer or plate reader. For
densitometers, such as the Gretag D19C, the Yule-Nielsen value is 1.07. Plate readers such as the Gretag IC Plate
II can also be used and these do not require a Yule-Nielsen factor to be applied.
Page 10
Page 11
Press
As with all CTP plate products, Violet Print plates require compatible fount solutions and press chemicals to
obtain optimum press performance.
Please contact your local Kodak technical representative to advise on compatible pressroom products.
Page 12
Processor related
Check plate speed with a step wedge. Increase the platesetter power
and re-linearise.
Check safelight integrity; ensure the plate is not left more than 15
minutes under the recommended safelight. Violet Print plates have no
tolerance to white light.
Check the age and the pH of the developer.
Check the preheat and developer brush pressures.
Processor related
Check plate speed with a step wedge. Decrease the platesetter power
and re-linearise.
Page 13
Check the pressure is set correct and that it is even from side to side.
Platesetter related
Out-of-focus condition on
platesetter - plate not suciently
in contact with the platesetter
drum or on the platesetter
atbed
Check contact between plate and platesetter bed. Check that the
platesetter bed is clean. Look for plate edge burr, coil set.
Exhausted developer
Over-exposure
Platesetter related
Platesetter related
Page 14
Humidity too high, leading to slow plate speed and weak image.
Platesetter related
Plate fogged
Ensure that the plate has not been exposed to white light, or left out in
safelight for too long.
Developer exhausted
Change developer.
Page 15
Thinner gauge plates are not fully developing, but thicker gauge plates are correct
Developer brush pressure not
set correctly
The developer brush pressure should be set to the thinnest gauge plate
to give a slight resistance as a piece of plate is passed between the
brush and the developer bed.
Platesetter related
Equipment fault
Room conditions
Platesetter related
Page 16
Troubleshooting Press
Scumming at start up or early into the press run
Scum is visible on the plate and cannot be removed with water. (Coating still present in non-image areas of plate). To
test for background scum, use a negative deletion pen on the area. If the plates no longer take ink, it is a scumming
condition. If the deleted area continues to take ink, then it is a tinting problem.
Over-exposed plate
Insucient processor
brush action
Insucient desensitisation by
plate nisher
Dampening system
contaminated with ink and/or
wash up chemicals
Insucient dampening
Page 17
Scumming after a clean start up and several thousand impressions into a run
Scum is visible on the plate and cannot be wiped o with water. (Coating still present in non-image areas of plate).
To test for background scum, use a negative deletion pen on the area. If the plates no longer take ink, it is a scumming
condition. If the deleted area continues to take ink, then it is a tinting problem.
Fountain solution is too weak
Tinting
Emulsied ink suspended in the fountain solution appears on the printed sheet, but is easily wiped o the plate with
water. To test for tinting, use a negative deletion pen on the area. If the plate continues to take ink, then it is a tinting
problem. If the deleted area no longer takes ink, it is a scumming condition.
Ink pigments bleed into the
fountain solution
Check and adjust roller pressures and plate to blanket pressures to the
minimum needed for good ink transfer.
Substrate attack
Page 18
Reduce water feed. If that results in sensitivity well into the press run,
the fountain solution may be too weak. Increase the concentration of
fountain solution.
Dampening rollers
improperly set
Wash the plate with water. Check nisher section of processor for
correct roller and settings and appropriate ow.
Thoroughly rinse the plate and never allow plate cleaners to dry on the
image areas. Sometimes wiping over the plate with the same cleaner
used initially and following immediately with a water rinse can revive
a plate. Image can be lost at the start of a re-run if an unsuitable plate
cleaner has been used to wash the plate at the end of the previous run.
Weak image
Chemicals from inks and paper can react with the fountain solution
and the plate surface to form insoluble, water receptive compounds on
plate image and non-image areas. Consult consumable manufacturers.
After excess amounts of alcohol replacements are used, the ink will
lose tack and will also loose its ability to be transferred in the ink train.
Consult with the fountain solution manufacturer.
Page 19
Use a less abrasive ink. Some white inks, or opaque inks mixed with
white, can be very abrasive. Kodak Violet Print plates should be baked
when printing with UV inks. Plates can also be baked for additional run
length for abrasive press conditions.
The thinner ink lm causes plate wear in the ghost areas before the
rest of the image area. Run more ink if possible or use ink with less
pigment loading. An oscillating ink roller may reduce ghosting, but if
pigment content of the ink is too high, the entire plate may wear early.
Page 20
Check that the plate is fully baked with the deletion gel test. Place a
deletion cross on a solid area of baked plate for 5 minutes. Wash o
with water and check for any attack to the coating. If no attack, the
plate is fully baked.
Check that the baking parameters are correct and the oven is
maintaining the correct temperature across the whole plate.
Non-image wear
Reduce water feed if possible. Change to a blanket with less tack
Paper bres, llers or coating
pile in non-image areas of the
blanket
Plate cracking
Plate not tight on the press
cylinder
Check the packing for proper length. Make sure the packing cannot
move during the run. Carefully align the packing sheets during initial
mounting.
Page 21
Plate scratching
Improper plate handling
Handle plates with care. Most CTP plates are more sensitive to
improper handling than conventional plates.
Gouges in plate
Blanket is contaminated with
hard particles
Page 22
W.PC.O28.0506.en.01