Promopack reports increased productivity with Esko’s CDI Spark platesetter

Promopack in Heanor, Derbyshire, UK, has reported significant productivity gains and cost savings since installing a CDI Spark 4260 platesetter with Optics 80 from Esko. The flexo-repro house specializes in plates for the packaging industry and invested in the platesetter to support the production of 15,000 meters squared of photopolymer plates per year. Esko's CDI digital technology has proven to be an effective solution for increasing productivity while delivering a fast, cost-effective means to turnaround high quality flexo plates. ‘We will be ordering a second machine in the very near future,’ affirmed Mike Baxter, managing director. ‘Our goal is to achieve full digital production.’

Promopack has a solid reputation for its flexo platemaking and the 40-person staff has extensive experience in the packaging industry. The company has depended on Esko equipment to grow its business over the past 20 years and was one of the first UK firms to install a BackStage server to digitize its workflow and design studio. Promopack is often an alpha test house for new Esko technologies. The decision to invest in the CDI Spark 4260 platesetter with Optics 80 was made in full confidence.

‘On the press, digital flexo plates from a CDI achieve much better registration and dot reproduction. Esko's CDI platesetters are the best you can buy and we knew that plates produced on the 4260 would be of a very high standard,’ explained Baxter. ‘We chose this model for its impressive speed and consistency. We see platemaking as a manufacturing process and with Optics 80 the device quickly and consistently images perfect plates up to eight meters squared per hour. The amazing reduction in waste has surprised us and has achieved significant savings in production costs.’

Marie Gilbert, production manager, said: ‘Our repro staff have had long careers in the industry working for printers and understand packaging prepress, so they know what can and cannot happen when plates are put on the press. Esko's packaging software is the best in the industry and with the CDI 4260 we are able to produce the highest quality digital flexo plates in the marketplace.’

Promopack handles approximately 1200 different jobs per month and invested in the latest Scope workflow modules to achieve its goal of 100 per cent digitization. The digital artwork studio handles files that often require special attention to achieve perfect color rendition and dot control. Promopack prides itself on working with retailers and brand owners right up to the point of monitoring how the plates perform on the press. ‘What matters to us is whether our customers are happy or not,’ said Mike Baxter. ‘We see our job as providing plates that match the proof perfectly. Our customers may use a variety of printers, so we make sure that our plates will match different presses. We take a hands-on approach and work closely with the printers and our customers to achieve a perfect product every time.’

The investment in the CDI Spark 4260 platesetter with Optics 80 reflects a carefully planned decision to move forward into CtP and digital platemaking. For Promopack, Esko is the right technology partner to drive this growth. ‘We have carefully watched the advancements in Esko's software tools for the packaging industry and adopting Esko's CtP solution was a natural progression. With the right training, the right people and Esko equipment, our business can't go wrong,’ concluded Baxter. ‘Our experience with the platesetter has been very encouraging - there is virtually no waste and plates are perfect every time. We are ready to build on this investment and order another Esko CDI system with the goal to double our digital output, streamline our production and support our business model. Promopack is 100 per cent committed to Esko because for us, there is no other supplier in their league.’