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As printers seek ways to produce quality output while minimizing downtime, waste and cost, they are faced with a bit of a quandary.

When two different printing technologies can produce comparable quality output, but cost and press life is significantly less for one than it is for the other, which is best? Using both may be the ideal answer. It’s often a hybrid solution worth exploring.

A typical ITR sleeve
All photos courtesy of Rol-Tec

Every flexographic print operation is different. There’s no one best application that’s perfect for all. When considering photopolymer (PP) plates vs. in-the-round (ITR) laser-engraved print technology, there are pros and cons to each. In some cases, however, those differences present a cost-efficient use of both.

A hybrid solution—where both PP and ITR are employed—depends on the fit each application offers each specific flexographic operation.

The Photopolymer Fit

Photopolymer plate technology has been around for a long time. Most flexographic printers purchase photopolymer plates from third-party providers, while larger printers may produce their plates in house—requiring a significant investment in equipment. In either case, the initial acquisition cost is a factor of the many steps in producing a PP plate—including liquid castings, multiple exposures, washes and drying.

Dot shaping allows manipulation of the angles of the side walls to strengthen a particular set of dots, adjust the height of each dot, and flatten or round the dot tops to help sharpen impressions.

Still, photopolymer plates are significantly less expensive than laser-engraved sleeves and rollers—making then highly cost effective for short runs. The actual cost of PP plate ownership, however, comes from a set of different factors, including lifecycle. For example:

Other PP plate factors include:

ITR Fit

Laser-engraving ITR technology has continued to make huge advances with machine performance as well as operating software. The process still uses lasers to “carve” dots and patterns on an elastomer (rubber) surface, but with greater precision than ever. Elastomer compounds have also evolved to provide better response to laser engraving while also being formulated for specific inks, required hardness and durability.

There are many considerations when looking at ITR laser-engraved technology, such as:

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