FUJIFILM GRAPHIC SYSTEMS USA, INC.

SOLUTIONS DEVELOPMENT & SUPPORT

850 CENTRAL AVENUE
HANOVER PARK, IL 60133
800-877-0555

Reference Manual
for Brillia

Ecomaxx-T
Confidential
Revised 1/2/09
 Contents

1. Ecomaxx-T Overview
1.1 Product Concept ...................................................................................................................................4
1.2 Competitive Advantages ......................................................................................................................4
1.3 Limitations & Considerations ..............................................................................................................5
1.4 Plate Specifications ..............................................................................................................................7
1.5 Plate Gamma Curve ..............................................................................................................................7
1.6 Plate Construction.................................................................................................................................8
1.7 Technology............................................................................................................................................8
1.8 Image Fornation Principle ....................................................................................................................8
1.9 On-Press Development Principle..........................................................................................................9
1.10 Visible Image Fade ...........................................................................................................................10
1.11 Platesetter Qualification Status .........................................................................................................10
1.12 Presses...............................................................................................................................................11
1.13 Ink & Fountain Solutions..................................................................................................................11
1.14 On-Press Development Factors ........................................................................................................12

2. Platesetter Set Up
2.1 Javelin or Screen PT-R 8000 ..............................................................................................................13
2.2 Javelin II, E or Screen PT-R 8002, 8100 ............................................................................................14
2.3 Javelin HS or Screen PT-R 8600........................................................................................................15
2.4 Dart, Dart II, III E or Screen PT-R 4000, 4002, 4300, 4100 & PT-R News 2000 .............................16
2.5 Kodak (Creo) Trendsetter & Quantum Lotem....................................................................................17

3. Calibration
3.1 Initial Calibration Tables ....................................................................................................................18
3.2 Halftone Calibration Procedure ..........................................................................................................19
3.3 GRACoL Standard Ink Densities........................................................................................................19

4. Pressroom
4.1 Educating the Pressroom ....................................................................................................................20
4.2 Segregated and Integrated Dampening...............................................................................................21
4.3 Analysis of Segregated vs. Integrated Dampening .............................................................................22
4.4 Analysis of Pre-Dampening................................................................................................................23
4.5 Basic Start-Up Method .......................................................................................................................24
4.6 Optimizing Start-Up Sequence ...........................................................................................................25
4.7 Effects of Over or Under Pre-Dampening ..........................................................................................26
4.8 Roller Pressure ...................................................................................................................................26

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 4.9 Checking Roller Condition .................................................................................................................28
4.10 Printing Pressure Check....................................................................................................................28
4.11 Using Plate Cleaner ..........................................................................................................................31
4.12 Plate Storage after Printing……………………………….…………..……………………………31

5. Troubleshooting…………………………………………………………………………………..32
O-

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1. Ecomaxx-T Overview

1.1 Product Concept

Ecomaxx-T is negative working thermal digital plate designed for high quality offset printing in a
processless CTP work flow.
Cost reduction
• Cost of processor
• Cost of developer, gum & effluent disposal
Reduced burden
• No processor maintenance
• No developer control
• Footprint reduction with no processor and no storage of chemistry
Environmental benefits
• No waste solution and reduced power needs
• Improved corporate image for those concerned about the environment
Stabilization of platemaking performance
• Since strict control of chemistry & the mechanics of a processor are not necessary, you can expect
stabilization of the plate making process.

1.2 Competitive Advantages

1. Productivity
High sensitivity (like LH-PJ) allows the same productivity as with current 830nm IR laser
thermo-platesetters and conventional thermal plates.
2. Ablation free technology
Technology that represses dust during imaging and on-press development provides smooth transition to
processless with no special equipment.
3. NEW Multigrain
Employs the same NEW multigrain as LH-PJ for wide ink/water balance and reduced piling, especially
for high definition printing.
4. Superb tone and fine line reproduction
Tone fluctuations are minimal, enabling consistent high quality printing results. FM screens (Taffeta20,
Co-Res 300lpi and Staccato 25) are supported.

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1.3 Limitations & Considerations
1. Run length
Ecomaxx-T is targeting the commercial sheet fed market with run lengths around 100,000 impressions.
Note that run length varies according to printing conditions.
2. Not suitable for UV ink
Run length is severely compromised with UV ink.
3. Less contrast for plate checking compared to processed plates.
Items such as color patches, job ID and basic image position can be checked. Dot percent measurement,
fine line check, and other critical checks are currently not possible.
• Image check (fine characters, resolution) must be performed upstream.
• Plate scanners cannot be used to obtain image area data for the press. Data transfer by CIP3, etc. is
required.
• Press punches (especially CCD camera types) cannot read register marks. Platesetters punches are
required. In the case of platesetters on which inner-punchers cannot be installed, thicker register marks,
etc. must be created on the image.
4. Chemical resistance
• Resistance to current plate cleaners (MC, etc.) is weak. Repeated use of plate cleaner can cause image
walk-off. Use recommended plate cleaners & desensitizers.
5. Storage
• The ideal storage condition is ≤ 25◦C (≤ 77◦F) ≤ 60% humidity
6. Press considerations
• Press start up sequence may need to be changed. More pre-dampening & pre-inking revolutions may
be needed.
• Plates should always be mounted with clean & dry blankets.
• Roller condition such as hardness, pressure (stripes), cracks & scratches not only affect printability as
with any plate, but will also effect on press development.
• Press operators should be instructed on the developing mechanism of Ecomaxx-T.
• Presses running the inking and dampening systems segregated (direct dampening) may require
additional wash-up procedures.
• Conventional dampening systems may require additional maintenance.
• Running a small sheet size relative to the plate may require additional wash-up procedures or
specialized start sequence.
• Dampening systems with high slip rate (>10%), such as the Epic Dampening System and Heidelberg
Vario may cause poor ink receptivity into the run.
• Non-VOC ink or fountain solution may also cause poor ink receptivity into the run.
• Presses incapable of pre-dampening or cannot supply a sufficient amount of pre-dampening require
manual pre-dampening before start-up for best results.
7. Plate Handling
• Scratches, scuffs and fingerprints incurred by handling before imaging can result in minus density
spots.
• During the period between imaging to printing, the plate is still subject to safelight tolerance. Plate
should be stored face down or in darkness after imaging and before printing.

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Handling Example:
Area Process Result
a) before exposure Problem.
Image area
b) after exposure No problem.
Non image a) before exposure Scratch and finger print resistance is similar to
area b) after exposure LH-PJ.

Example: Before imaging

Scratch/finger prints
on unexposed plate Imaging On-press development

Example: After imaging

Imaging Scratch/fingerprints On-press development

on exposed areas

Take extra care to prevent scratches and fingerprints on unexposed plates!

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1.4 Plate Specifications

Alloy 1050 aluminum

Run length* 100,000 impressions

Resolution
(same as LH-PJ)
Energy
(same as LH-PJ)
Spectral Sensitivity
(same as LH-PJ)
• 1% - 99% @ 200 line
• 20 micron Taffeta supported
• 300 line Co-Res supported
120 mJ/cm2
800-850nm (IR)

Safe Light White light @ 800 Lux – 1hr

Latent Image
One week
(time from imaging to press)
• ≤ 25◦C (≤ 77◦F) & ≤ 60% humidity
• Keep open plates wrapped in aluminum craft
paper (ALK).
Plate storage • Unused plates in an auto-load cassette should
have dummy plate on top or go back in the ALK
wrap.
• Fujifilm CS-1
Plate cleaner Product Code = 55813040 / SAP 15646263
• Thermal Deletion Pen (medium tip)
Product Code = NKK 137-1 / SAP 900012084
Deletion pens
• Thermal Deletion Pen (bold tip)
Product Code = NKK 137-2 / SAP 900012093
* Run length can vary depending on printing conditions

1.5 Plate Gamma Curve

Image Density

Shoulder Sensitivity Exposure Sensitivity

Exposure Energy

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1.6 Plate Construction Overcoat layer: Containing
inorganic thin particles.
Imaging layer Protects surface, oxygen shield
• High sensitivity radical polymer technology
Support Thermo-sensitive layer:
Containing micro gel particles
• NEW Multigrain Polymerizable compounds

• Aluminum base
Undercoat: Controls development
Substitutes gum coating

AL base: with NEW Multigrain

1.7 Ecomaxx-T technology

Ecomaxx-T technology consists of two existing Fujifilm original technologies & newly
developed technologies.
1. High sensitivity radical polymer technology
2. NEW Multigrain technology. Currently used with LH-PJ.
3. On-press development technology
4. Minute dispersion technology for on press development
5. High-functioning base interface technology.
6. Imaged visibility technology

1.8 Image Formation Principle

Imaging On-press development

⇒ ⇒ ⇒

Imaged areas are Non-image areas are

polymerized by heat developed on press

Ecomaxx-T on-press development process

Step 1: Penetration by fountain solution Inking roller
Step 2: Reduction of adhesive strength
Step 3: Release of thermo sensitive layer
Emulsified water/ink

Step 1 Step 2
Step 3
It is the moisture from the pre-dampening of the fountain solution that reduces the adhesion
strength of the emulsion to the Al base. The non-image area emulsion is then released by the ink
forms and expelled through the make-ready sheets.

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1.9 On-Press Development Principle: Where does it go?
The current methods of on-press development are to either direct the non-image area emulsion to the
fountain solution or to the ink.
To achieve development via the fountain solution, the emulsion must dissolve and disperse easily in water.
Essentially, the fountain solution acts as a developer solution. This creates a situation in which
“developer” is supplied throughout the entire the press run. Under such circumstances, high sensitivity
and long run length are virtually impossible.
For Ecomaxx-T, a design was selected that directs the emulsion to the ink.

“To Water” design “To Ink” design

・AGFA Thermolite plus ・Ecomaxx-T

・KODAK Thermal Direct

Micro-dispersion technology insures that the development residue released from the plate to the form
rollers is reduced to a harmless fine powder, which is then expelled to the printing stock at the beginning
of the press run.

Residue fragments on ink roller

immediately after on-press
development. After several impressions

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1.10 Visible Image Fade
After batch imaging, the visible image will begin to fade quickly, but plates can be used on press up to
one week (7 days) after imaging, if stored in a cool dark place.

4.5 PRO-T Fading after Imaging

25°C/50%
4.0 25°C/70%
40°C Dry
3.5

3.0

ΔL 2.5
2.0

1.5

1.0

0.5

0.0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
No. of Days after Imaging
Figure 1 PRO-T Imaging ⊿ L Change per Time

1.11 Platesetter Qualification Status

The following platesetters equipped with 800–850nm lasers are qualified. As testing continues, this list
will expand.
Screen/Fuji 4000/6000 Series: OK
8000/9000 Series: OK
8800/9800 Series: NOT OK
PT-R8800E/S/Z (Luxel T-9800E/S/HS) OK with factory upgrade only
8800II/9800II: OK for up to 200 line AM only
6600: OK
Kodak (Creo) Qualified with these imagers:
• Semi-automatic Trendsetters, VLF Trendsetters, all Magnus devices
and Lotem 400 Quantum devices (No auto-loading)
• Limited to 2400 dpi imaging on TH 1.7 and TH2 heads.
• Released with Staccato 25, 300lpi maximum screening on Quantum
(SQUAREspot® equipped) and Staccato 25, 200 lpi on non-Quantum
systems.
• Lotem fiber heads (old Scitex Lotem): NOT OK
Heidelberg Topsetter: same as Screen qualification, OK
Suprasetter: OK
Luscher OK, (FM under investigation)
Presstek Dimension 930nm: NOT OK
Dimension 830nm: NOT OK
Agfa Acento, as Screen device: OK
Avalon (Xcalibur): NOT OK

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1.12 Presses
Although there are no specific press models “unqualified” to run with Excomaxx-T, There are design
aspects of some presses to be aware of.

• Presses incapable of pre-dampening, such as the Ryobi 3200 CD, require manual
pre-dampening before start-up.
• Dampening systems which can supply insufficient amount of pre-dampening, such as Kompac
or Crestline may require manual pre-dampening before start-up.
• Dampening systems with high slip rate (>10%), such as the Epic Dampening System and
Heidelberg Vario system may have poor ink receptivity.
• It is not recommended to install Ecomaxx-T with a new press installation unless provisions can
be made for sets of back-up processed plates. The reason is that it would be too difficult to
distinguish an on-press development problem from a press installation/set-up problem.
• Although presses with full auto-start functions can be reprogrammed for more
pre-dampening/pre inking, a new program could slow production and change ink/water balance
for each pull.
• Presses running the inking and dampening systems segregated (direct dampening) may require
additional wash-up procedures. (ex. Komori Sprint or old style Lithrone)
- Emulsion residue may build on dampening rider roller. Wiping with solvent press-wash will
easily remove the residue. It may be necessary to clean the roller up to once per shift.

1.13 Inks & Fountain Solutions

In general, there are no limitations to inks and fountain solutions used with Ecomaxx-T, however:
• Non VOC inks & fountain solutions may result in poor ink receptivity or blinding especially
with FM screening.
• Emerald JRAB, # 20413 was specially developed for Ecomaxx-T with an anti-blinding agent as
a countermeasure to poorer ink receptivity.

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1.14 On-Press Development Variation Factors
The figure below shows factors in on-press development variation.

Materials

Rollers 1. Ink
2. Fountain solution
1. No. of rollers
2. Surface roughness
3. Hardness
4. Pressure (most Water Supply System
critical points are)
1. Direct/Indirect
Plate 2. Slippage on plate surface
cylinder 3. Roller configuration
Other 4. Water pan roller speed up function.
2. Press temperature
Blanket
cylinder
Paper Printing Start Sequence
1. No. of revs of water application
Pressure 2. No. of revs of ink application.
cylinder 3. Press speed at start of printing.

• Condition for BEST on-press development:

- Direct dampening
- Low surface tension of fountain solution (wetting agent) allows easy penetration of the
emulsion
- High pre-dampening rate (speed of water pan roller)
- Many pre-dampening & pre-inking revolutions
- Soft rollers in good condition increase amount of water that pass to the plate
- Number of rollers (most presses have 4 ink forms, duplicators have 2)
- Proper form roller to plate pressure (ink stripe), most critical being dampener form to plate as
well as dampener form to chrome roller as shown above.
- Existence of slipping roller (hicky picker)
- High tack ink
- High viscosity ink
- A warm press

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2. Platesetter Set Up
2.1 The Javelin or Screen PT-R 8000
• Platesetter technician will adjust parameters in platesetter such as focus and zoom.
- Focus can be determined in pre-press using the latent image on the plate. The darkest center
point of the focus series, in increments of 20 units, will be the correct focus setting. See
platesetter setup manual attach to this document.
- Zoom can be determined in pre-press by running a zoom series, in increments of 200 units,
and wiping the grid pattern with straight Fuji FN-6 finisher. The grid line with the smoothest
and most uniform appearance is the correct zoom setting. See platesetter setup manual.
- Zoom photos:

In zoom @ value 6550 Out of zoom @ value 7350

• The technician should set the exposure energy to the exposures determined by Fuji and Screen.
• Exposures are as follows:
DPI (AM or FM) Drum Rotation Laser power (%)
1200 1000 rpm 90%
2000 1000 rpm 95%
2400 1000 rpm 90%
2438 1000 rpm 90%
2540 1000 rpm 90%
4000 640 rpm 75%

NOTE: Exposure can be verified by imaging and printing the light intensity test.
- At the resolution (dpi) and drum rpm in use, image & print the light test
- Initial value at 10%,
- Increments of 10%
- Count 10
- Either visually or with a densitometer, find the first solid present in the 100% patch on the
press sheet. This is the solid sensitivity and should be around 30% to 40%

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2.2 The Javelin II, E or Screen PT-R 8002, 8100
• Platesetter technician will adjust parameters in platesetter such as focus and zoom.
- Focus can be determined in pre-press using the latent image on the plate. The darkest center
point of the focus series, in increments of 20 units, will be the correct focus setting. See
platesetter setup manual attach to this document.
- Zoom can be determined in pre-press by running a zoom series, in increments of 200 units,
and wiping the grid pattern with straight Fuji FN-6 finisher. The grid line with the smoothest
and most uniform appearance is the correct zoom setting. See platesetter setup manual.
• The technician should set the exposure energy to the exposures determined by Fuji and Screen.
• Final exposure for plates sizes smaller than 21 5/8 x 25 5/8 (650mm x 550mm) for all DPI resolutions
is 70% @ 600 RPM.
• Final exposures for sizes 21 5/8 x 25 5/8 (650mm x 550mm) and larger are as follows:
DPI (AM or FM) Drum Rotation Laser power (%)
1200 900 rpm 85%
2000 900 rpm 85%
2400 900 rpm 85%
2438 900 rpm 85%
2540 900 rpm 85%
4000 600 rpm 75%

NOTE: Exposure can be verified by imaging and printing the light intensity test.
- At the resolution (dpi) and drum rpm in use, image & print the light test
- Initial value at 10%,
- Increments of 10%
- Count 10
- Either visually or with a densitometer, find the first solid present in the 100% patch on the
press sheet. This is the solid sensitivity and should be around 30% to 40%

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2.3 The Javelin HS or Screen PT-R 8600
• Platesetter technician will adjust parameters in platesetter such as focus and zoom.
- Focus can be determined in pre-press using the latent image on the plate. The darkest center
point of the focus series, in increments of 20 units, will be the correct focus setting. See
platesetter setup manual.
- Zoom can be determined in pre-press by running a zoom series, in increments of 200 units,
and wiping the grid pattern with straight Fuji FN-6 finisher. The grid line with the smoothest
and most uniform appearance is the correct zoom setting. See platesetter setup manual.
• The technician should set the exposure energy to the exposures determined by Fuji and Screen.
• Final exposure for plates sizes smaller than 21 5/8 x 25 5/8 (650mm x 550mm) are as follows:
DPI (AM or FM) Drum Rotation Laser power (%)
1200 600 rpm 57%
2000 600 rpm 70%
2400 600 rpm 57%
2438 600 rpm 57%
2540 600 rpm 57%
4000 600 rpm 70%

• Final exposures for plates sizes 21 5/8 x 25 5/8 (650mm x 550mm) and larger are as follows:
DPI (AM or FM) Drum Rotation Laser power (%)
1200 900 rpm 75%
2000 600 rpm 70%
2400 900 rpm 75%
2438 900 rpm 75%
2540 900 rpm 75%
4000 600 rpm 70%

NOTE: Exposure can be verified by imaging and printing the light intensity test.
- At the resolution (dpi) and drum rpm in use, image & print the light test
- Initial value at 10%,
- Increments of 10%
- Count 10
- Either visually or with a densitometer, find the first solid present in the 100% patch on the
press sheet. This is the solid sensitivity and should be around 30% to 40%

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2.4 The Dart, Dart II, III, E or Screen PT-R 4000, 4002, 4300, 4100 & PT-R News 2000
• Platesetter technician will adjust parameters in platesetter such as focus and zoom.
- Focus can be determined in pre-press using the latent image on the plate. The darkest center
point of the focus series, in increments of 20 units, will be the correct focus setting. See
platesetter setup manual attach to this document.
- Zoom can be determined in pre-press by running a zoom series, in increments of 200 units,
and wiping the grid pattern with straight Fuji FN-6 finisher. The grid lines with the smoothest
and most uniform appearance represent the correct zoom setting. See platesetter setup
manual.
• The technician should set the exposure energy to the setting determined by Fuji and Screen.
• Final exposures determined by Fuji and Screen are as follows:
DPI (AM or FM) Drum Rotation Laser power (%)
1200 1000 rpm 85%
2000 1000 rpm 90%
2400 1000 rpm 85%
2438 1000 rpm 85%
2540 1000 rpm 85%
4000 1000 rpm 90%

NOTE: Exposure can be verified by imaging and printing the light intensity test.
- At the resolution (dpi) and drum rpm in use, image & print the light test
- Initial value at 10%,
- Increments of 10%
- Count 10
- Either visually or with a densitometer, find the first solid present in the 100% patch on the
press sheet. This is the solid sensitivity and should be around 30% to 40%

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2.5 Kodak (Creo) Trendsetter & Lotem Quantum
• Technician will set the exposure energy value to 100mJ/cm2 at the lens.
• Technician will adjust the following parameters:
- sr value (surface reflectivity) relates to the reflectivity of the plate. This varies according to
plate type.
- sd value (surface depth) adjusts focus. A plot 115 (multiple pixel checkerboard pattern) should
be imaged at about 60% power and run on press. The darkest band should be chosen as a set
point.
- A bm slope (beam slope) series is imaged at nominal exposure using plot 115 (multiple pixel
checkerboard pattern). This series is run on press and checked for banding to find the optimal
setting.
- Example of bm slope:

- A bm curve (beam curve) series is imaged at nominal exposure using plot 115 (multiple pixel
checkerboard pattern). This series is also run on press and checked for banding to find the
optimal setting.
- Example of bm curve:

- Tint Printing: It is recommended to image and print a large 50% tint, covering the entire plate
surface, as a final check to insure there is no banding or other problems.

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3. Calibration
Ecomaxx-T is a negative working plate that requires calibration. Raw data from the platesetter with no
media linearization is likely to be too full for the end user; therefore some type of tone compensation
curve will be needed.
3.1 Initial Calibration Tables
If matching color reproduction on the current plate system is not critical, some default plate
linearization data has been provide by Fuji R&D. Choose the most appropriate calibration table form
the selections below to obtain a near linear plate.
AM 175lpi/200lpi CoRes 300lpi TAFFETA20 Sta
20
PTR PTR PTR PTR Kodak PTR PTR PTR PTR PTR PTR PTR PTR Kodak
4300 8000 8600 8800II TS 4300 8000 8600 8800II 4300 8000 8600 8800II TS
T-6000 T-9000 T-9000HS T-9800II 800Q T-6000 T-9000 T-9000HS T-9800II T-6000 T-9000 T-9000HS T-9800II 800Q

1 2.1 2.1 1.3 1.0 1.1 0.0 0.0 1.4 1.1 2.0 2.0 1.7 0.9 1.1

2 3.5 3.5 2.3 2.5 1.5 1.5 1.6 2.3 2.7 3.3 3.3 2.8 2.4 2.3

3 5.6 5.6 3.8 3.5 3.3 3.6 2.2 4.1 3.9 5.5 5.5 4.4 3.3 3.4

4 7.0 7.0 4.9 5.1 4.3 4.0 4.0 5.2 5.3 6.5 6.5 5.3 4.8 4.2

5 8.8 8.8 6.7 6.1 5.5 5.9 4.0 6.8 6.1 8.6 8.6 7.1 5.9 5.4

10 15.7 15.7 13.0 12.3 11.5 11.5 9.3 13.0 11.4 16.7 16.7 13.3 11.2 10.2

20 27.9 27.9 24.9 24.7 23.1 22.3 19.5 25.7 23.5 34.0 34.0 27.5 24.2 21.7

30 38.8 38.8 35.3 34.5 33.9 34.5 30.9 36.8 34.1 46.4 46.4 40.2 36.9 34.6

40 50.7 50.7 46.2 45.8 44.1 48.7 42.5 49.7 45.6 58.6 58.6 52.4 47.9 44.8

50 60.0 60.0 56.7 55.6 53.1 63.6 58.5 61.0 58.2 69.2 69.2 63.8 59.3 55.2

60 68.2 68.2 64.5 63.8 63.1 72.9 68.6 69.8 66.7 77.3 77.3 73.8 69.0 67.0

70 76.1 76.1 73.5 72.7 72.0 80.2 76.5 78.1 75.5 83.9 83.9 81.3 77.6 76.4

80 84.2 84.2 82.3 82.1 81.9 88.3 85.3 86.6 84.2 89.4 89.4 88.0 86.0 84.8

90 93.3 93.3 91.7 91.7 91.1 96.5 95.9 93.5 92.6 94.1 94.1 92.5 92.1 92.4

95 96.4 96.4 96.0 95.8 95.8 100.0 99.4 98.2 97.8 97.0 97.0 98.3 95.8 95.7

96 97.2 97.2 96.7 96.4 96.4 100.0 99.6 98.5 97.9 98.0 98.0 98.6 96.3 96.7

97 98.6 98.6 97.3 97.0 97.2 100.0 100.0 99.0 98.5 99.0 99.0 98.8 98.0 97.3

98 99.0 99.0 99.0 98.8 98.9 100.0 100.0 99.2 99.2 99.5 99.5 99.2 99.0 99.0

99 99.5 99.5 99.5 99.5 98.8 100.0 99.7 99.5 99.5 100 100 99.5 99.4 99.2

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3.2 Halftone calibration procedure to accurately match current tone production.
• Obtain tone reproduction that matches the current plates in use.
1. Output the current plate with an appropriate test target (ex: Fuji ISS) using the customers
standard conditions for calibration and imaging. Make a set of Ecomaxx-T plates with the
same target using NO media linearization.

2. Print both sets of plates on the same press at customers standard printing conditions (solid
ink density, dot gain etc). See reference 3.3 below if customer does not have a known standard

3. Measure the dot% for both sets of plates on the printed sheets using a reflection
densitometer.

4. Create a new calibration curve for Ecomaxx-T based on the dot % differences between the
two press runs if the sheets do not match.

5. Make a new calibrated set of Ecomaxx-T plates and print with it to confirm the new curve
matches the current plate.

3.3 For Reference: GRACoL 6 Standard Ink Densities (gloss sheet, sheet-fed)
Standard Black Cyan Magenta Yellow
density
GRACoL 6 1.70 1.40 1.50 1.05

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4. Pressroom
4.1 Educating the Pressroom
The following items MUST be carefully explained to press operators:
• Press operators should be instructed on the developing mechanism of Ecomaxx-T.
- It is the moisture from the pre-dampening of the fountain solution that reduces the adhesion
strength of the emulsion to the AL base. The non-image area emulsion is then released by the
ink forms and expelled through the make-ready sheets.
• Chemical resistance may be weaker than current plate. Use recommend plate cleaners.
• Press start up sequence may need to be changed.
- We are currently recommending about 10-20 revolutions of pre-dampening and then about
5-10 revolutions of pre-inking as a starting point.
- On-press development of spot colors is slower compared to process colors. Metallic inks
(gold, silver) are particularly slow and may require a change to the on-press development
conditions.
• Plates should always be mounted with clean & dry blankets.
- Ink or solvent on the blanket contacting the plate during plate mounting may prevent proper
pre-dampening from taking place.
• During the period between imaging & printing, the plate is still subject to safelight tolerance. Plates
should be stored face down or in darkness after imaging and before printing.
• Roller condition such as hardness, pressure (ink stripe), cracks & scratches not only affect printability
as with any plate, but will also effect on press development.
• Presses running the inking and dampening systems segregated (direct dampening) may require
additional wash-up procedures. (ex. Komori Sprint or old style Lithrone)
- Emulsion residue may build on dampening rider roller. Wiping with solvent press-wash will
easily remove the residue. It may be necessary to clean the roller up to once per shift.
• Conventional dampening systems may require additional maintenance (more frequent changing of
molleton cover).
• Running a small sheet size relative to the plate may require additional wash-up procedures (additional
blanket & impression cylinder washing).
• Dampening systems with high slip rate (>10%), such as the Epic Dampening System and Heidelberg
Vario may cause poor ink receptivity into the run.
• Non-VOC ink or fountain solution may also cause poor ink receptivity into the run.
• Presses incapable of pre-dampening or cannot supply a sufficient amount of pre-dampening require
manual pre-dampening before start-up for best results.

- 20 -
4.2 Differences between segregated & integrated dampening systems (Direct vs. Indirect)
Dampening Type Characteristics Roller Configuration
• Dampening and ink systems
are independent of each other.
• Faster on-press development
Segregated • Emulsion residue may build
Plate
(Direct) on dampening rider roller if
cylinder
oscillation is ≤ ±4mm.
• Komori is most common
example
Continuous
• Dampening contacts Inking
via bridge roller. Connected by
• Slower on press development bridge roller
compared to segregated
Integrated
• Emulsion easily dispersed to Plate
(Indirect)
the inking system. cylinder
• Most presses have a bridge
roller or selection capability
(on/off).

• Also segregated or direct.

• Molleton is wrapped around
the dampening roller. IPA not
Conventional Molleton
required. Plate
• More frequent change of cylinder
molleton may be needed.

- 21 -
4.3 Analysis of Segregated vs. Integrated Dampening Systems (Direct vs. Indirect)
Using a DMS (Dampening Measurement System), measurements were made of the amount of water on
the plate surface up until printing.

8
Direct
7

Indirect
5

DMS
4
Output
Value
3

1
Press sheet OK
0

Dampening Print run

Press Revolutions
Inking

• Results show that the amount of water supplied to the plate differs between direct and indirect
dampening.
• Startup with direct water supply is fastest.
• Presses running the inking and dampening systems segregated (direct dampening) may require
additional wash-up procedures. (ex. Komori Sprint or old style Lithrone)

- 22 -
4.4 Analysis of Pre-Dampening
Sufficient pre-dampening (amount of water on plate surface) before inking is essential to successful
on-press development.
Black sheets Developed
Insufficient
water rate Printing NG
Sufficient # of Inking
pre-dampening

Black sheets Developed

Sufficient water
rate
Printing NG
Insufficient # of Inking
pre-dampening

Sufficient water Developed

rate
Printing OK
Sufficient # of Inking
pre-dampening

Pre-dampening 10
16
Pre-dampening 20

14

Pre-dampening 5
12

OK point
10

Water
Amount 8

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 1
Water ON Printing
No. of times is changed

Pre-dampening Print run

Inking

Press Revolutions

- 23 -
4.5 Basic Press Start-Up Method
On-press development properties vary according to the settings and condition of the individual printing
units. The properties may also vary according to the type of ink and fountain solution used. It is necessary
therefore, to set a start-up method suitable to each individual press.

Definitions:
Pre-dampening: The number of revolutions the dampening roller is applied to the plate before impression
or printing.

Pre-inking: The number of revolutions the ink forms are applied to the plate before impression or
printing.

Start-Up Guidelines:
Step 1: Ask press operator for 20 revs of pre-dampening
Step 2: Ask press operator for 10 revs of pre-inking
Step 3: Run paper on impression continuously until sheets look clean

Basic Troubleshooting:
Image area is washed-out: If the non-image area is immediately clear of ink, but has low ink density or
shows other signs of too much water, reduce the number of pre-damp revolutions on subsequent plates, if
available.

Non-image area is scumming:

Stop the press and wipe the scumming areas with an approved plate cleaner such as Fuji CS-1 or other
non-alkaline, mild plate cleaner, then re-start.

If the non-image area has difficulty clearing (> 20 sheets) increase both pre-dampening & pre-inking 5
revolutions as a nominal starting point on subsequent plates, if available

- 24 -
4.6 Optimizing Start-Up Sequence
On-press development properties vary according to the settings and condition of the individual printing
units. The properties may also vary according to the type of ink and fountain solution used. It is necessary
therefore, to set a start-up method suitable to each individual press.
1. Note the number of revolutions the dampening roller is applied to the plate before impression or
printing in automatic start mode. This is pre-dampening.
2. Note any difference in the amount of pre-dampening between the 1st unit and the last if any.
3. Also note the number of revolutions the ink forms are applied to the plate before impression or
printing in automatic start mode. This is pre-inking.
4. Guidelines for the first attempts:
• 10 - 20 revs of pre-dampening
• 1 - 10 revs of pre-inking
• Count how many sheets it takes to clear the non-image area at roll-up.
NOTE: Try the normal or auto-start sequence if the pre-dampening and pre-inking seems
sufficient enough.
5. If the non-image area is immediately clear of ink, but the image area is washed-out, has low ink
density or shows other signs of too much water, reduce the number of pre-damp revolutions.
6. If the non-image area has difficulty clearing (> 20 sheets):
• Reconfirm press conditions such as form roller hardness and pressure.
• If needed, increase pre-dampening via the pre-dampening rate, pre-dampening revs or both.
• If needed, increase the pre-inking revs.
NOTE: Once a start-up is optimized it may be possible to change the auto-start sequence of the press.
Some presses have the ability to change the pre-dampening water rate OR pre-dampening revolutions OR
pre-inking revolutions by adjusting the auto-start sequence at the control panel (see press owners manual).

Example: Heidelberg SM auto-start sequence:

Press speed at 8000 iph
& 3000 iph
Pre-damp water @
99%

Running water @ 20%

Ink start Printing start

Water start (3 revs)
(10 revs)

- 25 -
4.7 Effects of Over or Under Pre-Dampening
Item Amount Possible Problem Counter Measure
Pre- Too little • Scumming/Fill-in • Higher pre-dampening rate
Dampening • Increase pre-dampening revolutions
• Wipe plate with plate cleaner &
re-start
Too much • Poor ink receptivity/ slow roll-up • lower pre-dampening rate
• Residue build-up in press rollers. • Reduce pre-dampening revolutions
Fountain solution contamination still
under investigation.

4.8 Roller Pressure

1) Improper inking roller pressure (particularly the roller pressure on the plate surface) may cause the
following printing problems:
Problem Suspected Cause
①Improper on-press If the roller pressure is insufficient, the ability to peel away the
thermo sensitive layer decreases, resulting in improper on-press
development
development. This is especially conspicuous in the shadow areas.
②Scumming Excessive roller pressure results in a tendency for scumming.

③Improper dot If the roller pressure is insufficient, dot shapes deteriorate.

reproduction If the roller pressure is excessive, the dots smear in the direction
toward the clamp edge.
④Poor run length If the roller pressure is excessive, slipping at the plate surface
becomes stronger, causing plate wear to progress more quickly,
thus reducing the run length.

2) Roller nip width by manufacturer:

Press Dampening roller Inking roller
Against Plate Against Roller Against Plate Against Roller
Ryobi 4mm (≈3/16”) 4mm (≈3/16”) 4mm (≈3/16”) 3–5mm
(≈1/8”-3/16”)
Komori 4mm (≈3/16”) 4mm (≈3/16”) 4mm (≈3/16”) 3–5mm
(≈1/8”-3/16”)
Heidelberg 5–6mm (≈1/4”) 4–5mm (≈3/16”) 3–4mm 3–4mm
(≈1/8”-3/16”) (≈1/8”-3/16”)
MAN Roland 5–6mm (≈1/4”) 4–5mm (≈3/16”) 3–4mm 3–4mm
(≈1/8”-3/16”) (≈1/8”-3/16”)
Mitsubishi 4–6mm 4–6mm 2–5mm 5–8mm
(≈3/16”-1/4”) (≈3/16”-1/4”) (≈1/16”-3/16”) (≈3/16”-5/16)
• See press operation manual for details.

- 26 -
1) Measuring the Nip Width of the Dampening Roller (Dampening
Roller/Plate Surface)
1. First, apply ink to the dampening roller. For direct systems, it is
necessary to print several sheets in order to transfer ink from the
plate surface to the dampening roller. For indirect systems, applying
ink to the inking roller will get the ink to the dampening roller. Plate
cylinder
2. Put the dampening roller in contact with the plate surface (ON).
After a few seconds, remove it (OFF). At this time, because the
plate surface is not in contact with the cylinder gap, be careful of
where you put the dampening roller in contact with the plate
surface. (Do not touch the gap.)
3. Measure the ink width (nip width) on the plate.
(1) Measurement
1. Put slide gauge in direct contact with the plate and measure. Be careful not to scratch the plate
surface with the tip of the slide gauge. See Photo 6.
2. As shown in photo 7, put a sheet of printing stock in contact with the plate. Press with your fingers
to transfer ink to the paper, then measure.

Photo 6
Photo 8
Photo 7

2) Measuring the Nip Width of the Inking Roller (Inking Roller/Plate Surface)
1. High Precision Method
This method lets you precisely measure nip width as the nip pressure during printing.
1. Mount plate on the plate cylinder.
2. Rotating the press (low speed or oscillation), put the inking roller in contact with the plate surface
to make the entire surface solid.
3. Stop the press using the emergency stop. After a few seconds, separate the inking roller from the
plate surface (OFF).
When stopped, if the inking roller is at the cylinder gap, and therefore not in contact with the plate
surface, measurement is not possible.
4. Measurement the ink width (nip width) on the plate surface. The measurement procedure is the
same as that for the dampening roller.
5. Take measurements at three spots: left, right, center. Record the measured values.
2. Simple Method
With this method, because of pounding that occurs when the inking roller is ON, the results may
differ from the nip pressure during printing.
1. Inch the cylinder to the position at which the inking roller is in contact with the plate surface.
2. Put the inking roller in contact with the plate surface (ON). After a few seconds, separate it from
the plate surface (OFF).
3. Measure the ink width (nip width) on the plate surface.

- 27 -
4.9 Checking Roller Condition
With the roller free of ink, visually observe the surface of the inking roller for cracking, scratches, etc. A
cracked or scratched inking roller may cause the following printing problems:
Problem Possible Problem
①Improper on-press Uneven development in horizontal direction especially at
development shadow area.
②Scumming Scumming happens easily at the part of crack due to less water
supplied
③Improper dot Poor dot reproduction due to less ink transfer
reproduction

Cracked and scratched roller surface Ink does not adhere well to smooth surface.

4.10 Printing Pressure Check

1) Plate setup
Verify plate setup with the press operator. Obtain the printing pressure based on the following blanket
height measurement and plate setup.
2) Measuring blanket height
1. Purpose of measurement
Check if pressure between the blanket and plate is correct.
2. Measurement procedure
(1) Wash the blanket thoroughly and dry with a dry clean cloth. Measurement will be
incorrect if any ink or gum is on the plate.(2) Bring the blanket cylinder to the front (see
Photo 1).
Photo 1
(3) Wrap printing paper on the blanket cylinder as shown
in Photo 2.
(4) Place a cylinder gauge in the center of the blanket
and perform zero calibration. (See Photo 3.)
(5) Move the cylinder gauge to the bearer's position and
measure the blanket height (see Photo 4).
(6) Repeat for the opposite side.

Photo 2 Photo 3 Photo 4

- 28 -
 Photo 5
3. Printing pressure between blanket and impression cylinder
Ordinarily, when using paper of a different thickness, the operator
performs adjustment by turning the paper pressure adjustment dial
(see Photo 5). For most presses, the paper pressure adjustment dial is
set to 0 for 0.1 mm paper. (This may differ from press to press. Refer
to the operations manual.)
Thus for diagnosis:
(1) Check the type of paper in use, and measure the thickness of the
paper with a thickness gauge.
(2) Check the dial's value.
Check whether the measured thickness and the dial value match. However, for paper types that do not
form proper solids, the printing pressure may set excessively high. This is especially common for
uncoated paper with a rough surface (approximately 0.02 mm to 0.05 mm).
If the actual value and dial value differ significantly, the cause may be improper backlash of the
blanket cylinder and pressure cylinder. You may need to show this to the user.

- 29 -
 Underneath plate（paper or PET
base）

Plate
cylinder
Undercut
Plate
Blanket
height Bearer

Blanket
Day #3000 Under blanket
Blanket (paper/PET base or under blanket)
cylinder

Paper

Pressure
cylinder

Printing pressure: (Plate setup – undercut) + (blanket setup – undercut)

Reference: The following table shows standard arrangements for presses made by Ryobi, Heidelberg,
Komori and Mitsubishi. Because standard arrangement may differ according to press type and size, you
should refer to the operation manual at the site. Information may also be found on the frame of the press.
Printing pressure: Printing pressure is determined by how much both the plate and blanket protrude from
the bearer.
Ryobi Heidelberg Komori Mitsubishi
66X MOV Lithrone 26 DAIYA-1H
Plate gauge 0.24mm 0.24mm 0.24mm 0.24mm
Std setting 0.40mm 0.60mm 0.50mm 0.40mm
Undercut 0.35mm 0.50mm 0.40mm 0.27mm
+ amount 0.05mm 0.10mm 0.10mm 0.13mm
Blanket gauge 1.95mm 1.95mm 1.95mm 1.95mm
Std setting 3.05mm 3.20–3.25 2.80–2.85 2.45–2.50
Undercut 2.95mm 3.20 2.80mm 2.45mm
+ amount +0.10mm ±0–+0.05 ±0–+0.05 ±0 – +0.05
0.15mm 0.10–0.15 0.10–0.15 0.13–0.18
Pressure (.006”) (.004”-.006”) (.004”-.006”) (.005”-.007”)

• See operation manual for details.

- 30 -
4.11 Using Plate Cleaner
1) Procedure
1. Use approved plate/desensitizer cleaner for Ecomaxx-T plates.
2. Before starting cleaning, prepare two sponges and a bucket of water.
3. Use a sponge to coat the plate surface with plate cleaner by wiping the surface back and forth.
4. Immediately after coating the surface, use a sponge soaked with water to thoroughly wash the
plate surface.

Wipe plate surface back

Immediately Start
and forth with special
wash with water. Printing
plate cleaner.

4.12 Preparing Plates for Storage after Printing

For storage of plates after printing, prepare plates with GN-5 as follows:
1. Preparation
2) Use ink remover to completely remove all ink from the plate surface.
3) Use a sponge to wash the plate surface with water.
4) Use a sponge to coat the plate surface once more with GN-5 (1:1).
5) Use a clean dry cloth to lightly buff dry the plate surface.

Remove ink from Wash plate Coat with

plate surface surface GN-5 Buff dry
(Sponge) (Sponge) (Sponge)

- 31 -
5. Troubleshooting
Problem Cause
1. Fingerprints • Touched undeveloped plate
directly with fingers, either
before imaging or before setting
plate on press.
2. Scratches 1. Plate Handling Causes
• Scratching during handling.
• Scratching from rubbing by
interleaf paper.
• Scratching during removal from
box.
2. Exposure Causes
• Dirt on plate during exposure.
3. Printing Causes
• Scratches caused by ink residue. printing direction.
• Scratched when setting the plate • Clean inking rollers.
on the press.
• Scratching by hicky picker.
• Scratching by paper dust.
(Scratches are very fine.)
3. Incorrect on-press 1. Exposure Causes
development • Underexposure
• Plate not flat against drum or
cylinder.
2. Plate Causes
• Too long under white light.
• Poor storage condition
3. Start-up sequence
• Excess fountain solution
(pre-dampening).
• Insufficient fountain solution
(pre-dampening)
• Insufficient pre-inking
4. Other press variation factors
- 32 -
Action
• Use interleaf paper when handling
plates.
• Wear gloves.
Irregular shape, no particular direction:
• Use interleaf paper when handling
plates.
• Wear gloves.
• Handle gently. Remove from box
gently.
• Carefully remove interleaf paper.
• Clean the inside of the platesetter
(drum, belts, rollers, etc.).
Scratches are perpendicular to the
• Clean and remove particles from areas
on rollers that touch plate.
• Change the tip of the hicky picker blade
to a softer material.
• Clean the blanket frequently to
maintain cleanliness.
• Check laser power, energy at plate
surface. Image using proper exposure
amount.
• Replace with plate that stays flat.
- Adjust the platesetter.
- Adjust the clamp.
• Do not leave the plate under a white
light for long periods.
• Store plates ≤ 25◦C (≤ 77◦F) & ≤ 60%
humidity
• Work to optimize the start-up sequence.
See page 24.
• Optimize/check the list on-press
development variation factors on page
12.
 Problem Cause Action
4. Dot shrinkage 1. Exposure Causes
(highlights drop out) • Underexposure • Check laser power, energy at plate
• Laser out-of-focus surface. Image using proper exposure
• Incorrect halftone calibration amount.
• Plate not flat against drum or • Adjust the focus.
cylinder. • Perform proper calibration.
• Replace with plate that stays flat.
- Adjust the platesetter.
- Adjust the clamp.
3. Printing Causes
• Insufficient printing pressure. • Adjust to correct printing pressure.
• Insufficient inking roller nip • Adjust inking roller.
pressure.
• Insufficient ink density. • Adjust ink to correct density.
5. Shadow Fill-in 1. Exposure Causes
• Overexposure • Check correct exposure amount,
• Incorrect halftone calibration imaging parameters.
• Perform proper calibration.
2. Plate Causes
• Too long under white light. • Do not leave the plate under a white
• Poor storage condition light for long periods.
• Store plates ≤ 25◦C (≤ 77◦F) & ≤ 60%
humidity
3. Printing Causes
• Excess printing pressure. • Adjust to correct printing pressure.
• Excess ink density. • Adjust ink to correct density.
• Defective blanket. • Replace the blanket.
• Under development • Work to optimize the start-up sequence
& check other press variation factors.
6. Non-uniform Dot 1. Exposure Causes
Shapes • Laser out-of-focus • Adjust the focus.
• Faulty laser beam • Replace the laser unit.
2. Printing Causes
• Excess printing pressure. • Adjust to correct printing pressure.
• Gripper problem. • Adjust the gripper.
• Defective blanket. • Replace the blanket.
• Plate is not flat against cylinder. • Firmly set the plate.
7. Non-uniform tints. 2. Exposure Causes
• Incorrect imaging parameters. • Re-adjust the imaging parameters.
• Too long under white light. • Do not leave the plate under a white
• Dirty optics. light for long periods.
• Clean the optics.
2. Printing Causes
• Incorrect on-press development • Use the correct on-press development
procedure. procedure.
• Inking roller problem • Re-adjust or replace the inking rollers.
8. Blanket toning 1. Start-up sequence
outside paper edge • Insufficient pre-dampening • Optimize start-up sequence so that the
(plate is much larger and/or pre-inking. plate is fully developed before start of
than press sheet). print.

- 33 -
 Confidential (No time limit)

Fujifilm Process-less Plate

Brillia HD PRO-T
Technical Manual
- Platesetter setup -

Graphic Systems Business Div.

Fuji Photo Film Co., Ltd.

Provisional Version
Validated as of February, 2006
Setup procedure for Luxel T series/Screen PT-R series
1. Initial settings
Create new Media Type of Negative for "PRO-T". Since the setting other than Negative/Positive is same as LH-PJ/PI,
it is easier way to copy from "LH-PI" and then change to Negative type.
1.1 Setting the media type <Drop-in>
1) Select Media type no. and copy the LH-PI preset data.

2) Select Negative type.

1.2 Setting the plate
1.3 Setting the printing machine information <Drop-in>

1.4 Adjust the displacement sensor offset <Drop-in>

1) Input -9.99 to get offset. (To be confirmed by Screen)
2. Exposure adjustment
Exposure condition of "PRO-T" is same as that of "LH-PJ/PI".

2.1 Adjusting the focus value

1) Enter values and exposure the plate
ex) [Initial Value] : Current value - 200
[Inc. Value] : 20
[Count] : 21

2) Print the plate or

3) Check the pattern strips and designate the focus value.
2.2 Adjusting the zoom value

1) Enter values and exposure the plate

ex) [Initial Value] : Current value - 1000
[Inc. Value] : 200
[Count] : 11

2) Print the plate

3) Check the pattern strips and designate the zoom value.
2-3 Adjusting the light intensity <Reference>

1) Enter values and exposure the plate

ex) [Initial Value] : 10
[Inc. Value] : 10
[Count] : 10

2) Print the plate or develop the plate by FN-6

3) Check the pattern strips and confirm that around 30-40% is solid.

2 of 4
3. Calibration
"PRO-T" is a negative working plate. It therefore reproduces a bigger dot than positive working plates when there is no
calibration. In order to reproduce ideal tone curve, apply a "Linearization Curve" dedicated to "PRO-T" into RIP.

3.1 Linearization <Drop-in>

Linearization is compensation for dot gain/loss on the plate. Shown below is a "Linearization Curve" dedicated
to PRO-T.

<Default> <Linearization>

Dot % on plate

Dot % on plate
<PRO-T>

Data Data

Dot % on plate
Dot % on plate

<Thermal Pos.>

Data Data

3.2 Characterization
Characterization is compensation for desired dot size on the plate/paper.
Ex) In case the customer has a desired tone curve, enter the date into "Characterization Curve". If not, measure
dots on the conventional PS plate currently used then utilize the desired curve.

<Linearization> <Characterization> <Print>

Dot % on paper
Dot % on plate

Dot % on plate

Data Data Data

3 of 4
 Fujifilm Graphic Systems USA, Inc.
850 Central Avenue
Hanover Park, IL 60133
Phone 630.259.7200 / 800.877.0555
Fax 630.259.7898

www.fujifilmgs.com

Technical Bulletin
TB 0721 Date: 10/18/07

Subject: We continue to test new plate readers on the market for their ability to read PRO-
T plates. There are now two devices which successfully completed the testing.
- The X-Rite PlateScope (version 6.1 & higher)
- The Techkon SpectroPlate

These devices may be used to measure dot percent provided that the procedure below
is followed carefully:

Procedure before measuring PRO-T with the Techkon SpectroPlate:

- Liberally apply straight Fuji FN-6 finisher with a cloth and let dwell 30
seconds. Calibration target is surrounded by solid.
- Wipe with 10 – 20 strokes
- Using a separate clean cloth, wipe with tap water 10 – 20 strokes
- Dry with a dry cloth
- Feel for residue
- If debris is felt, wipe it away with dry cloth
- Begin plate reading
Solid Image

Calibration target to be
Wipe in a straight line measured

“We are committed to provide our customers with innovative technical solutions, responsive
support and to develop mutually profitable partnerships.”
 Fujifilm Graphic Systems USA, Inc.

Sample Photos:
Target before wiping: After wiping:

Mid-tone before wiping: After wiping: