More than just innovative technology, the PremiumSetter series marks a pivotal shift towards greener, faster and superior printing processes. Area sales manager Jan Leonhardt is passionate about the potential these machines offer. ‘With elastomer plates, we’re addressing the demands of modern printing – higher quality, faster turnaround and a more eco-friendly approach.’

We all know that direct laser engraving is nothing new. However, over the past 60 years, direct laser engraving has transformed from a niche technology into a cornerstone of precision printing. Initially used primarily in high-end applications, early systems were limited by their rudimentary capabilities and high costs. As laser technology advanced, so did its applications, with modern systems offering unprecedented accuracy, speed and versatility. The development of sophisticated lasers, improved optics and advanced software has revolutionised direct laser engraving, enabling intricate designs and fine details with unmatched consistency and efficiency. This evolution has made laser engraving indispensable in industries requiring high-quality, high-volume print production.

Evolution of elastomer plates

According to Jan, the advantages of elastomer plates over conventional photopolymer plates are numerous and significant. Elastomer plates, made from synthetic rubber, offer unparalleled durability and resilience. They are particularly well suited to withstand the rigours of long print runs and demanding printing conditions. He says that unlike photopolymer plates, which can degrade and lose quality over time, elastomer plates maintain their integrity, ensuring consistent, high-quality output.

‘The longevity of elastomer plates means fewer plate changes, less downtime and, ultimately, lower costs,’ he points out. ‘This is crucial in a highly competitive market where efficiency and cost-effectiveness are paramount.’

But, the benefits don’t stop there. Elastomer plates are also more resistant to solvents and inks, which is a critical factor in maintaining print quality, especially in high-volume production environments. Jan believes this resistance reduces the risk of swelling and distortion, common issues with photopolymer plates that can lead to print defects and costly reworks.

Precision meets efficiency

HELL Gravure’s PremiumSetter machines are designed to leverage these advantages to their fullest potential. The direct laser engraving process used by the PremiumSetter range ensures that every detail of the design is transferred to the plate with absolute precision. This technology allows for the creation of high-resolution images and intricate designs that would be challenging, if not impossible, with traditional plate making methods.

Jan maintains that the HELL Gravure PremiumSetter has undergone significant technical advancements that position it at the forefront of direct laser engraving technology. Key improvements include enhanced laser precision, allowing for ultra-fine detailing on elastomer plates and sleeves, which is critical for high-resolution printing. The integration of advanced optics and control systems has improved the accuracy and consistency of engraving, ensuring that even the most intricate designs are reproduced with exactitude.

The PremiumSetter introduces a true digital workflow, allowing for 3D modulation tailored to specific applications or customer requirements. ‘This capability includes the possibility to apply an undercut – varying printing heights that eliminate dot gain down to zero without needing a bump-up curve,’ he adds. ‘This level of precision ensures that even the most complex designs are rendered with exceptional clarity and accuracy.’

At the core of the PremiumSetter are one or two high-performance fibre lasers, each delivering 600W of power. These lasers efficiently remove the three-dimensional relief in a single pass, achieving depths up to 800μm, while depths of up to 3mm are attainable through a multi-pass method. Jan claims the fibre laser’s advanced capabilities allow for a standard writing resolution of 5 080dpi enabling HD-quality engravings. ‘Additionally, the screen ruling is infinitely adjustable without affecting the PremiumSetter’s performance, ensuring precise and high-quality results for every engraving project,’ he enthuses.

‘The direct engraving process is a significant leap forward. It eliminates the need for intermediate films and exposure units, reducing the number of steps in the workflow. This speeds up production and minimises the potential for errors.’

A sustainable future

In a world increasingly focused on environmental responsibility, embracing sustainable practices has surpassed trends. It has become an essential commitment. HELL Gravure Systems recognises this and has made sustainability a core principle of its product development. Elastomer plates are durable and recyclable, making them an eco-friendlier option compared to photopolymer plates, which often end up in landfills.

‘The environmental impact of our products is something we take very seriously,’ Jan emphasises. ‘By using elastomer plates and sleeves, our customers can reduce waste and their overall carbon footprint. It’s a win-win situation – better for the environment and better for their bottom line.’ Elastomer plates offer a significant sustainability advantage and ease of maintenance by eliminating the need for harsh solvents. Instead, they can be cleaned effortlessly using just water. This not only reduces the environmental impact associated with chemical waste, but also simplifies the cleaning process, making elastomer plates a more eco-friendly and user-friendly option for modern printing operations.

The PremiumSetter operates through a streamlined two-step production process: engraving followed by washing with water. This efficient workflow simplifies maintenance and enhances the machine’s versatility. According to Jan, the PremiumSetter excels as a multifunctional tool, adept at handling a range of printing applications including flexographic printing, dry offset and offset varnishing. ‘Its adaptability across different processes makes it an invaluable asset for various printing needs, delivering high-quality results and boosting productivity across multiple applications.’

Jan continues: ‘Ultimately, our goal is to empower our customers to achieve the best possible results,’ Jan concludes. ‘With the PremiumSetter, we’re giving them the tools to do just that – efficiently, sustainably and with an uncompromising commitment to quality.’

For more info, contact Jan Leonhardt, jan.leonhardt@hell-gravure.de.

Ed’s note: HELL Gravure’s PremiumSetter range of direct laser engraving machines is represented and distributed in South Africa by MDC Max Daetwyler.