M-System from MacDermid: The Art of Liquid
The
Liquid Advantage
For
nearly 40 years, MacDermid Graphics Solutions has invested in the development,
application, and marketing of liquid photopolymers for flexographic printing
applications. In this time, we have
witnessed the introduction of digital platemaking and thermal processing, both
of which have successfully competed with liquid platemaking. Despite the
appearance of these new technologies, liquid technology remains alive and well,
continuing to evolve while maintaining its ecological and economic strengths. Along
with the digital revolution, an equally demanding sustainable revolution returned
focus to the unique capabilities of liquid.
Figure 1: Liquid Workflow
The liquid platemaking workflow, with the Reclaim
step, highlighted in green. The ability to reclaim uncured resin differentiates
liquid platemaking from other processes.
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While
obviously strong in liquid technology, MacDermid also has the unique vantage
point of being a technology developer in multiple plate technologies such as
analog and digital platemaking, as well as solvent and thermal processing
techniques. It is therefore much easier for MacDermid to directly study the
ecological and economic advantages of liquid photopolymers. In fact, several
years ago MacDermid went so far as to develop the Environmental Footprint
Calculator, a tool which allows for direct technology-to-technology comparisons
based on Life Cycle Analysis (LCA) data compiled from each of the platemaking
technologies of interest (from manufacturing to finished plate). The table
below highlights the advantages of a water-based processing system combined
with the ability to achieve mass yields per plate far greater than any other
process. It is this unique ability to reclaim and recycle unexposed liquid
resin that fundamentally and uniquely distinguishes liquid platemaking
technology.
Table 1: Environmental Footprint Calculator Summary
The table highlights the advantages of a liquid
processing system combined with the ability to achieve mass yields per plate
far greater than any other platemaking process.
Inputs
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Baseline
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Alternatives
|
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Product
|
Liquid Photopolymer
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Digital Solvent
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Digital Thermal
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Gauge (mils)
|
.067
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.067
|
.067
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Impact
Categories
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|||
Alternatives
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|||
Energy Consumption
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Increased by 390%
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Increased by 242%
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Water Consumption
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Reduced by 29%
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Reduced by 70%
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Acidification of Water
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Increased by 367%
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Increased by 267%
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Global Warming
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Increased by 343%
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Increased by 282%
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Savings
Comparison
|
|||
Alternatives
|
|||
Cars operating for 1
year
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Increased by 347.3
cars
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Increased by 285.9
cars
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Homes powered for 1
day
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Increased by 22.3
houses
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Increased by 13.8
houses
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Laundry washloads
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Reduced by 744.2 loads
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Reduced by 1829.1
loads
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The
aforementioned economic and ecological advantages are brought together through
in-position platemaking technology, which is uniquely suited for use with
liquid photopolymers. In-position plates are made by imaging one entire color
in register as opposed to preparing individual copy pieces and mounting them. During
plate exposure, only the areas with copy are cured. The result is a plate with
islands of copy adhered to a thin and light polyester backing sheet. When using in-position plate technology, as
much as 70 percent of the original cast polymer can be reclaimed, minimizing
waste and resulting in more environmentally responsible practices. In-position
plates’ lighter weights reduce shipping costs and storage space
requirements.
Figure 2:
In-position plate
The use of liquid in-position plates can result
in as much as 70 percent of the original cast polymer being reclaimed.
M-System: What is it?
The
evolution of liquid technology culminated in the launch of the M-System
platform. The M-System platform is based
on the three core components of focus, leverage, and innovation. All three
components are intertwined into a series of innovative technologies that are
supported and guided by dedicated service, support, and research team –
leveraging years of liquid photopolymer experience into a unified technology
and service architecture. This new platform is based on the sum total of
product chemistry, platemaking equipment, a quality production environment, our
sales, service and support personnel, and our devotion to continuous improvement
and innovation.
Liquid
Photopolymers
The
heart of the M-System process is the photopolymer technology itself. Liquid
photopolymer technology has grown from use in newspaper and master resins, to
multiple print markets. M-System products cover the corrugated, multi-wall bag,
and stamp industries in addition to more unique elements such as sand-casting,
coating plates, and even multilayer plate capabilities. The full M-System
product line is outlined below.
Corrugated
The
top of the line product in the M-System line is LTL, which has proven to
be the gold standard for liquid platemaking in the corrugated market,
especially when used at 6.35-7 mm (.250-.280”) thickness in combination with
in-position platemaking techniques. Its patented composition provides
outstanding UV stability, low tack, and clean printing. For
those requiring a softer product for use with recycled board or board with
thinner liners, LTS is available at 25 durometer. For those with less stringent
print demands, MRC is the newest
corrugated product development from MacDermid available in 32 Shore A. This
material is widely suited for multiple board types and plate thicknesses, with excellent
UV stability and an extremely wide exposure latitude to cover the most
demanding combination of process and line work.
Capping
Technology
Capping
technology allows for the use of a second layer of photopolymer on top of a soft
or hard base photopolymer. In corrugated printing, capping not only increases
the tonal range of the finished plate but also reduces fluting to an extent
that rivals or surpasses that of the leading “flat-top dot” technologies in the
industry. MacDermid offers two cap products, M Cap 45 and FC 55HR-R,
which differ in their hardness values, offering highly tunable print
performance benefits.
Multiwall
Bag
Several
high durometer, thin plate photopolymers round out the selection of products
commonly used in the multiwall bag or paper sack printing segment. These
photopolymers are built from the same patented technology used with LTL and
LTT. MWH
is a high resolution, 50 durometer product capable of 175 ls imaging, highly
competitive against the premium analog sheet plates on the market today. For
less demanding resolution, a UV stable formulation is available in 50
durometer. MWB 50
has proven to be highly durable even on the most demanding paper stock, while
still capable of 120 lpi imaging (especially when capped).
Stamp
Photopolymers
Rounding
out the major segments of the M-System product line are the stamp and molding
photopolymers. The workhorse products are M Stamp 40 and M Stamp 50. While used predominantly as hand stamps,
these formulations are also used in more unique applications such as
bronze/sandcasting, coating plates, and for printing on paper or envelope
stock. Where clarity and colorfastness are required, such as hobby and craft
applications, M Systems offers M Clear. M Clear produces an extremely
colorfast stamp that is renowned for its high strength as well
Table
2: Photopolymer Selection Guide
Product
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Market
Segment
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Thickness
(mils)
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Durometer
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Tone
Range Capability
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LTL
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Corrugated
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.112- .280
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32 Shore A
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2-95%, 100 lpi
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LTS
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Corrugated
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.112-.280
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25 Shore A
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3-95%, 85 lpi
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MRC
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Corrugated
|
.112-.280
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32 Shore A
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2-95%, 100 lpi
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M Cap 45
|
Capping Resin
|
.004-.007
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45 Shore A
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2-95%, 120 lpi
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FC-55HR-R
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Capping Resin
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.004-.007
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55 Shore A
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1-95%, 175 lpi
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MWH
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Wide Web
|
.045-.125
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50 Shore A
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1-95%, 175 lpi
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MWB 50
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Wide Web
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.045-.125
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50 shore A
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3-95%, 120 lpi
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M Stamp 40
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Hand Stamp,Wide web, Bronze/ sandcasting
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.067-.125
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40 shore A
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2-90%, 100 lpi
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M Stamp 50
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Hand Stamp, Wide web, Coating, bronze/ sandcasting
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.067-.125
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50 Shore A
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2-90%, 85 lpi
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M Clear
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Hand Stamp
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.067-.140
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40 Shore A
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n/a
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Washouts
M-System offers a complete set of washout chemistry to process the photopolymers
listed above. This chemistry is fully
optimized for all M-System products and provides crisp, clean images in
combination with improved bath life and cleanliness. A three-component system
is used; M Clean Detergent, M Clean Developer, and M Clean
Defoamer. Formulation guidelines are available through the M-System
Technical Tip series. However, since washout quality and effectiveness is
directly linked with incoming water quality at each customer location, M-System Technical Service experts work directly with each customer to maximize
system performance.
To
complete the plate processing optimization, M Clean PX is added to the
post-exposure bath to ensure thorough polymerization during this critical
exposure step. M Clean PX enables better surface cure during the underwater
post-exposure step, which greatly enhances the results of the final light
finishing step, where required.
Ancillary
Materials
M-System also offers a complete set of platemaking consumables used in the
creation of your printing plate.
- M Film Clear and M Film Matte are used during
the platemaking process as a barrier between the liquid resin and film
negative. M Film Matte offers a matte surface that can alter the surface
roughness of the finished printing plate. M Film Clear offers greater imaging
resolution in more demanding applications.
- M Strate is a coated polyester backing used as the
support layer for M-System printing plates. Specifically designed for use with
M-System resins, M Strate offers a combination of high photopolymer adhesion and
anti-halation properties to maximize detail-holding in the printing plate.
- M Strate AB has a pressure-sensitive adhesive
coating on the back for savings in plate mounting.
Table
3: Ancillary Material Selection Guide
Product
|
Description
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M Clean Detergent
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Surfactant
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M Clean Developer
|
Developer
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M Clean Defoamer
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Defoamer
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M Clean PX
|
Post-Exposure Salt
|
M Film Clear
|
Clear Coverfilm
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M Film Matte
|
Matte Coverfilm
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M Strate
|
Adhesive-coated substrate
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M Strate AB
|
Adhesive-backed version of MStrate
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Equipment
With
liquid photopolymer, you are the plate manufacturer, so accurate, dependable
platemaking equipment is critical to plate quality. MacDermid has pioneered
many elements of liquid platemaking, such as in-position and multilayer
platemaking, through the development of equipment. In addition, MacDermid
platemaking systems are ideally suited for the increasing quality demands
placed on platemakers today. Full production systems, complete with exposure
unit, reclaim system, washout system, post-exposure, and light finisher, are
available in sizes ranging from 30x40 all the way up to 52x80.
Figure 3: M System exposure unit
Industry-proven liquid exposure system, the M-System exposure, continues to set the mark in liquid platemaking production efficiency.
Changes
in the larger market for silver halide film have affected the availability of
film processors and film negatives, and in response, MacDermid has developed an
alternative to film processing known as M Jet. This latest generation
inkjet technology offers improved resolution capability and color-to-color
registration compared to previous options.
M Jet eliminates the need for film processing chemicals while allowing
for the continued use of film-based platemaking technologies. In addition,
MacDermid has partnered with Exile Technologies to market its Liberator thermal film product line
offering customers another option for film negatives.
Figure 4: M Jet
In response to changes in the availability of
film processors and film negatives, MacDermid has developed an alternative to
film processing known as M Jet.
Quality
MacDermid’s
M-System products are produced at two separate locations globally. A
multi-million-pound facility in the United States is being utilized to produce
high quality liquid photopolymer resins for the European, North and South
American markets. This facility is ISO 9000:14001 certified, and the close
relationship between the manufacturing staff and the M System development and
support team enables quick and consistent communication on market and customer
needs. A second production facility, also ISO 9000:14001 certified, is
strategically situated to serve the Australian and Asia markets.
Service
& Support
The
global service and support team are a core component of M-System. The team is
comprised of specialists in liquid development, sales, and support, with a
majority having more than a decade of experience developing and working on liquid
photopolymer technology. MacDermid’s Bookend Strategy places significant
emphasis on the dual elements of innovation and service. With this combined
emphasis, one can expect a consultative relationship rather than merely a
customer-supplier relationship; MacDermid strives to make our customers better
Continuous
Innovation
The
other element of the bookend strategy, innovation, is only truly successful
when innovation is done with the customer in mind. The driving force behind the
success of the M-System platform is that we understand the full span of
relevant technologies - how chemistry affects photopolymer imaging, how
photopolymer imaging affects dot shape, and how dot shape affects print
results. We develop resins that image better so that they print better. We
design and manufacture equipment that enables easier platemaking and more
consistent plate uniformity. We develop methods that optimize reclaim
efficiency to further enhance the economic and sustainability benefits of
liquid. We make consumables that enhance resin imaging capabilities, delivering
better print quality. We use product packaging that is more sustainable. These
are examples of the types of innovation you have gotten from MacDermid for
years, and you can expect more to come from the M-System team.
No
system combines more expertise and leverages more printing experience than M-System. M-System is about focusing on liquid and its core benefits to the
flexographic industry, leveraging our experience and core technologies, and
innovating even further in order to meet market needs. Simply put: if it’s not
M-System from MacDermid, it’s just Liquid.
Find
out how M-System from MacDermid can improve your workflow, contact us
today.