Esko Launches New LED System for Plate Exposure
O XPS Spark 4835, a “next-generation” LED-based digital flexographic plate exposure system designed to replace traditional UV-lamp exposure equipment, is now commercially available worldwide through Esko, following the completion of a successful pilot program with customers in Germany, the United States, and the United Kingdom.
The company states that the system offers consistent and repeatable plate quality, shorter exposure times, and a significant reduction in environmental impact, all in a compact, easy-to-install (“plug-and-play”) format, developed specifically for label converters, prepress shops (tradeshops), and flexible packaging manufacturers.
At the heart of the XPS Spark 4835 is a patented technology that kaleidoscopic optics, which, according to Esko, ensures a uniform distribution of UVA light across the entire plate surface. According to the company, this eliminates light concentration points (“hotspots”) and irregular or wavy exposure artifacts, which are common in systems based on conventional UV lamps and in LED systems without kaleidoscopic technology. The result is uniform polymer cross-linking and highly consistent print reproduction.
Eddy Fadel, general manager of Esko’s Flexo division, describes the launch as a way to help flexographic printers modernize their plate production with simple, sustainable, efficient, and high-quality solutions.
"Thousands of flexographic operations around the world still rely on legacy UV exposure systems, which are becoming increasingly difficult and expensive to maintain. The XPS Spark offers a future-proof alternative, delivering premium exposure quality while reducing energy consumption and waste generation."
Another important factor behind the launch of the XPS Spark is the growing difficulty in obtaining replacement UV lamps, regulatory pressures on mercury-containing UVA lamps—especially under European Directive 2011/65/EU — and the well-known issues with UV tubes, whose performance degrades with use, resulting in inconsistent and unpredictable exposures, as well as variations in print quality.
According to Fadel, the XPS Spark 4835 was developed specifically to meet this market need.
"Positioned between conventional lamp-based exposure systems and the Esko XPS Crystal platform, the XPS Spark is a dedicated LED exposure solution designed to make high-quality flexographic plate exposure more accessible."
Using full-surface UVA LED exposure technology, the system offers exposure times comparable to or even faster than those of conventional systems, without the need to preheat the lamps.
In addition, the company states that the equipment reduces environmental impact by eliminating mercury from the sheet metal manufacturing process and reducing energy consumption by up to 80% when compared to traditional UV curing systems.
A patented air-cooling technology eliminates the need for energy-intensive chillers, while an insulated tray for baking sheets—also patented—minimizes heat loss. There is also an optional integrated UVA/UVC finishing drawer that combines back exposure, main exposure, and finishing in a single unit.
The system features open exposure parameters that are compatible with plates from all manufacturers on the market, allowing users to adjust and optimize settings according to their workflows and production requirements.
Esko also revealed that it is developing the Spark Screens, a screen technology specifically designed for the XPS Spark platform, intended to further improve print quality with UV inks, enhance color vibrancy, and reduce press setup time.
Among the customers who participated in the tests is Meike Bamberg, responsible for prepress (CTP), flexography, and offset at the company Nagels Druck, who stated:
"The system provides precise and uniform exposure, in stark contrast to the uneven exposure produced by UV lamp exposure units. The benefits of uniform exposure are immediately apparent during printing."
Already Dawn White, prepress manager at MackayMitchell Envelope Company, in the United States, commented:
"The new equipment has improved both efficiency and ergonomics for operators. The LED display eliminates the warm-up time for lamps, resulting in measurable time savings and a more efficient sheet metal manufacturing process. The drawer’s ergonomic design reduces physical strain by minimizing the need to bend over and eliminates the need to open and close the main exposure cover. Combined with intuitive, easy-to-use controls, the system is extremely operator-friendly and promotes consistent and efficient daily operation."
