Esko launches XPS Spark 4835 LED system

Esko has announced the worldwide commercial availability of the XPS Spark 4835, a digital LED flexo plate exposure system designed to replace aging UV tube bank exposure frames in label converting, tradeshop and flexible packaging environments.

The XPS Spark 4835 uses patented kaleidoscopic optics technology to deliver homogeneous UVA light distribution across the full plate surface, eliminating the hotspots and uneven exposure associated with tube-based systems. Full-surface UVA LED exposure removes warm-up time and delivers exposure times comparable to or faster than conventional bank systems. Energy consumption is reduced by up to 80 percent compared with conventional UV tube bank systems, enabled by patented air-cooling technology that removes the need for energy-intensive chillers and a patented insulated plate drawer that minimizes heat loss.

The launch addresses growing obsolescence of UV tube bank systems as replacement mercury-containing UVA lamps become harder to source under EU Directive 2011/65/EU, with degrading tubes causing inconsistent exposure and variable print quality. The XPS Spark is positioned between conventional bank exposure systems and the Esko XPS Crystal platform as a more accessible LED exposure option.

The system features a compact footprint, optional integrated UVA/UVC finishing drawer combining back exposure, main exposure and finishing in a single unit, and an open exposure parameter system supporting all flexo plate vendors. Esko is also developing Spark Screens, a dedicated screening technology for the platform designed to enhance UV ink print quality and reduce press make-ready times.

Early users include Nagels Druck in Germany and MackayMitchell Envelope Company in the US. 'LED exposure eliminates bulb warm-up time, resulting in measurable time savings and a more streamlined platemaking process,' said Dawn White, prepress manager at MackayMitchell.

'Thousands of flexo operations worldwide still rely on aging UV tube exposure systems that are increasingly difficult and expensive to maintain,' said Eddy Fadel, Esko GM Flexo. 'The XPS Spark provides a future-ready alternative that delivers premium exposure quality while lowering energy use and reducing waste.'