XPS Spark 4835, a “next generation” digital LED flexo plate exposure system engineered to replace traditional UV tube bank exposure frames, is now available commercially worldwide from Esko, following the completion of a successful pre-release testing program with customers globally, including in Germany, the US, and the UK.
The company said the system delivers consistent, repeatable plate quality, shorter exposure times, and a dramatically reduced environmental footprint, within a compact, plug-and-play format that Esko says has been tailored specifically to label converters, tradeshops, and flexible packaging producers.
At the heart of the XPS Spark 4835 is patented kaleidoscopic optics technology that Esko says ensures homogeneous UVA light distribution across the entire plate surface. According to the company, this eliminates the hotspots and uneven, ‘wavy’ exposure artefacts commonly associated with tube-based and kaleidoscope-free LED systems, resulting in equal crosslinking and highly consistent print reproduction.
Eddy Fadel, Esko’s general manager for flexo, puts the launch in the context of helping flexo operators to modernise their plate production with simple, sustainable, efficient and high-quality solutions.
“Thousands of flexo operations worldwide still rely on aging UV tube exposure systems that are increasingly difficult and expensive to maintain. The XPS Spark provides a future-ready alternative that delivers premium exposure quality while lowering energy use and reducing waste,” he said.
Another context to the launch of the XPS Spark is that of increasing difficulty in sourcing replacement UV lamps, regulatory pressures mercury-containing UVA lamps under EU Directive 2011/65/EU, and the known performance issues around UV tubes as they degrade with use, leading to inconsistent and unpredictable exposure, and variable print quality.
The XPS Spark 4835 has been developed specifically to address this market need, Mr Fadel continued. “Positioned between conventional bank exposure systems and the Esko XPS Crystal platform, the XPS Spark is a dedicated LED exposure solution designed to make high-quality flexo plate exposure more accessible.”
Using full-surface UVA LED exposure technology, the system delivers exposure times that are comparable to, or faster than, conventional bank exposure systems, without requiring warm-up time. It also reduces environmental impact by eliminating mercury from the plate-making process and cutting energy consumption by up to 80% compared to conventional UV tube bank systems, the company said.
A patented air-cooling technology eliminates the need for energy-intensive chillers, while an insulated plate drawer – also patented – minimises heat loss. There is also an optional integrated UVA/UVC finishing drawer that combines back exposure, main exposure, and finishing within a single unit.
The open exposure parameter system supports all flexo plate vendors, enabling users to optimise and fine-tune settings according to their individual workflows and production requirements.
Esko also revealed that it is developing Spark Screens, a dedicated screening technology for the XPS Spark platform, designed to further enhance UV ink print quality, increase colour vibrancy, and reduce press make-ready times.
Among those customers to have tested the XPS Spark is Meike Bamberg, pre-press (CTP), flexo and offset at Nagels Druck, who said the system delivers “precise, uniform exposure, in stark contrast to the wavy exposure produced by the tube exposure unit; the benefits of even exposure are immediately apparent during printing”.
Meanwhile, Dawn White, prepress manager at MackayMitchell Envelope Company, USA, commented: “The new equipment has improved both efficiency and operator ergonomics. LED exposure eliminates bulb warm-up time, resulting in measurable time savings and a more streamlined platemaking process. The ergonomic drawer design reduces physical strain by minimising bending and removing the need to open and close the main exposure hood. Combined with intuitive, easy-to-use controls, the system is extremely user-friendly and supports consistent, efficient daily operation.”
