AFP TRAINING MANUAL

Asahi Photoproducts (Europe) - AFP Training manual 1

 Table of contents

Introduction

General information 4.
Different types of AFP plates 5.
Plate structure 6.
AFP packaging & labelling 8.
AFP process 9.

Section I

Tests 12.
Backflash test 13.
Wash out test 14.
Face exposure test 15.
Post exposure test 17.
AFP Platemaking test chart 18.
Production process 19.
Preparation step 19.
Exposure process 20.
Wash out process 23.
Drying and stabilisation 25.
Post exposure / light finishing 26.
Plate quality control 27.
Platemaking control strip 28.
Defects relating to platemaking process 29.
Storage of AFP finished plates 30.
Daily production check list 31.
Platemaking check list 32.

Section II

Negatives 34.
Technical specifications 35.
Other specifications
Print elongation 36.
Artwork 37.
Linework .
Screens (conventional)
Dot gain principles 39.

Section III
Trouble shooting 41.
Prepress troubles 42.
Press room troubles 44.

Appendix

Asahi Photoproducts (Europe) - AFP Training manual 2

Introduction
 I. General information
The purpose of this manual is to give all suitable information
about AFP photopolymer solid plate systems. It will introduce
you to the different Asahi products, to the application for each
of them, to the way to process plates, optimize the platemaking,
and finally the way to check them, and find out reasons for
potential troubles.

AFP (Asahi Flexo Plates) flexographic plates can be used for

several types of applications, like Plastic sack, Paper sack,
Flexible packaging (plastic films), Aluminum foil, Tissue, Milk
cartons, Labels, Preprint, Stamps, Corrugated board. The AFP
plate processing is quite similar to other solid photopolymer
plates, and the AFP plates can be easily processed on most of the
current solid platemaking systems on the market.

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 II. Different types of
AFP plates
Asahi is currently manufacturing several types of photopolymer
solid plates.

Thin plates technology (from 1.14 to 3.18 mm) is mostly used for
flexible packaging, plastic bags, pre-print, paper sacks, and
labels. Those plates usually feature fine repro for high quality
graphics printing, showing in some cases results very close to
litho. Generally speaking thin plates are also rather hard in
order to prevent excessive fattening (dot gain) during the
printing process.
Thick plates technology (ranging from 2.84 to 6.35 mm) is used
for corrugated post print and heavy-duty carrier paper bags.
They cannot achieve the same repro quality as thin plates as they
have been designed to print on rough substrate. Those plates are
also softer than thin plate so that they provide a far better
contact with the uneven printing substrate like corrugated board.
The AFP plates are all compatible with usual flexo inks, like
water based, solvent based, and UV inks (a table of solvent
compatibilities is enclosed in appendix).

Shore hardness
The shore hardness value is actually dependant on several
parameters. The value traditionally given by the suppliers is
made under laboratory conditions, and so does not necessarily
correspond to the value of the production plates.
The given values must be understood taking into account the
following.
The theoretical shore hardness is checked and recorded under
very strict and well-defined parameters by any supplier. The
first comment is that the check rules may slightly change from
one supplier to another. This means that the same product
checked by two different suppliers may appear with quite
different values.
The second point is that the announced shore value is not for
all plate thickness, but for only one plate thickness into a
family of plates (for instance HF 10 type).
This value is given as a comparative indication.
The real values of the plate will be actually affected by the
check method, by the thickness of photopolymer, and by the
base film thickness. Thin plates will always be harder than
thicker plate even when made from the same photopolymer.

Asahi Photoproducts (Europe) - AFP Training manual 5

 III. Plate structure
Whatever the plate type, the AFP structure is always the same.
Cover sheet
Protective layer
An AFP solid plate is composed, before platemaking, of four
elements.

1. Base film

The base film is a polyester sheet. The sheet has a thickness that
can vary from one plate to another but that is usually between
100 & 200µ. It guarantees the dimensional stability of the plate
and prevents it from being distorted when it is put on the printing
cylinders. The base film also improves the plate resistance to
Photopolymer demounting. The photopolymer is strongly bound to this film by
UV light during the back exposure.
Anti Halation Base Film

Base Film
2. Raw photopolymer
Fig 1. Structure of the plate After the exposure and the wash out the layer of "raw" or
unexposed photopolymer forms the printing relief. This is the
basic material of any photopolymer plate.
The protective layer is an invisible micro layer that binds the
cover sheet and photopolymer. After the cover sheet removal it
allows a perfect contact and vacuum between the film and the
plate during the relief exposure.
The protective layer is dissolved during the first moments of the
wash out process.
This protective layer is extremely sensitive, especially to
bending. So great care should be taken when handling the plate.

3. Protective layer

The protective layer is an invisible micro layer that binds the

cover sheet and photopolymer. After the cover sheet removal it
allows a perfect contact and vacuum between the film and the
plate during the relief exposure.
The protective layer is dissolved during the first moments of the
wash out process.
This protective layer is extremely sensitive, especially to
bending. So great care should be taken when handling the plate.

4. Cover sheet

The cover sheet protects the raw plate from time of manufacture
until platemaker has given the reverse side exposure. It also
makes the plate more resistant and less flexible during the
handling at the first stages of platemaking.

Asahi Photoproducts (Europe) - AFP Training manual 6

 5. Anti halation Base Film (AHBF)*

The anti halation Base Film is a unique feature of the AFP plates.
The AHBF is an anti reflection film coated between the base film
and the photopolymer. It shows major benefits during the
exposure of the plate by a tremendous increase of the latitude
during the backflash. The result is a perfect control of the depth
of relief and a very smooth and consistent anchor layer.
The AHBF also improves sharpness of screen dots and reduces
filling in, since it prevents any light reflection during the face
exposure.

Standard plate Plate with AHBF *All AFP 1.14 - 1.70 mm, all SH, DSH plates, and SQ / DSQ
2.84 are featuring the AHBF.
Fig 1. Effect of the AHBF on dot
reproduction

Fig 2. Extended Back exposure latitude with the AHBF

Asahi Photoproducts (Europe) - AFP Training manual 7

 IV. AFP Packaging &
labeling
The standard AFP packaging is a reinforced carton box specially
designed to prevent any accident or damage to the plates.
Inside the box, the photosensitive plates are wrapped in a plastic
foil that protects them from light. A foam sheet is laid in between
each plate, as shock protection.
Leaving the plates in the box is the best guarantee of safety.
Some basic storage conditions must be respected in order to
prevent when using the plate.
Fig 1. AFP packaging
Storage of AFP cartons

*Shelf life of raw plates

6 months at least (provided they are kept in the original packing).

*Storage temperature
5 to 25° C
In case the storage temperature is lower than 10°C the plates
must be stored for a certain time at the platemaking room
temperature to avoid thermal shock on the exposure unit.

*Carton storage
Flat, never more than 10 cartons on top of each other.

Labeling

Two labels are stuck on each AFP box with all suitable
information about the product. Every label mentions
1. Plate type
2. Plate thickness
3. Plate size (code)
4. Contents (number of plates in the box)
5. Lot number
6. General information about the plates
(i.e. plate storage conditions, safety information and warranty)

Note: In case of claim the plate type, thickness, size, and lot
number must be recorded and communicated to Asahi.

Fig 2. AFP labeling

Asahi Photoproducts (Europe) - AFP Training manual 8

 V. AFP process
The platemaking process of solid photopolymer plates can be
divided in four major steps. During the first one an image is
transferred or copied from a negative film to the plate. This copy
is made via the principle of exposing the plate to light through a
negative film. This step is commonly called "Exposure step".
The second consists into developing or showing the image built
during the exposure.
This engraving or wash out step is made using solvent that
dissolves the unhardened photopolymer.
According to the quantity of solvent used during the wash out,
the plate will have then to rest for some time to make sure that
the solvent absorbed by the polymer during wash out is
completely evaporated. This is the "Drying and stabilization
time". An after treatment is applied to the plate as a final step.
The treatment essentially increases the plate resistance and
treats its tacky surface. This is called the "Post exposure".
The four steps are described hereunder in detail.

1. Exposure

The exposure step builds the printing relief within the plate, by
changing the chemical structure of the material.
The UV light (365 nanometers of wavelength) has a physical
effect on the material by changing its chemical structure. The
areas of the plate affected by light are transformed and become
"harder".
Parts hardened by UV light will not be soluble anymore in wash
out solutions. Unexposed areas will be soluble to wash out
Fig 1. Backflash solvents.

1.1.Backflash
The backflash or back exposure is the very first step. This is
given through the base film, in order to create a uniform layer, or
a base that will holds the printing relief images.

1.2. Face exposure

The face exposure is the copy exposure. In fact this is the step
that builds the printing relief through a negative. The material
affected by UV light will gradually harden, until it reaches and
binds with the floor created by the back exposure.
Fig 2. Face exposure

2. Wash out

After exposure, the plate is composed of two different chemical

structures, but still looks the same (no relief). The wash out
process will dissolve and remove unhardened parts of the plate,
and thus form the plate relief. It reveals the relief by engraving.
A chemical solution in combination with mechanical action
(brushes) will dissolve and remove the raw material of the plate
(areas unaffected by UV light). The hardened parts of the plate
cannot be dissolved by this mean and will thus stay on the plate.
Fig 3. Wash out During the first seconds of the process, the solution will also
dissolve the protective layer of the plate.

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Fig 4. Drying
Fig 5. Post exposure (UVA) and light
finishing (UVC)
A = PTT (Plate total thickness)
B = BLT (back layer thickness)
C = Rd (Relief depth)
Fig 6. Structure of the finished plate
3. Drying and stabilization
Drying & stabilization time are required after the wash out
process in order to remove the excess solvent kept within the
plate.
Drying and stabilization are necessary, as after wash out process
the plate is swollen (up to 10 % of the plate thickness) by solvent
from the bath. This excess of solvent must be removed, in order
to get the original plate thickness back.
The plate will be dried with hot air (60°c) for a certain time
(from 1 to 4 hours depending on plate thickness and on solvent).
The drying process removes most of the solvent, and is usually
followed by a resting period (stabilization) to complete the
evaporation process.
4. Post exposure & light finishing
The post exposure process is the final step of the platemaking
process, preparing the plate to go to press.
The post exposure is divided in two steps
1. CL Post exposure (UVA)
A last short exposure to UV lamps (same type of lamps as used
for the exposure)
This will fix the plate in its final chemical structure, giving it
more strength, more resistance and the final plate hardness to go
to the pressroom.
At this time the plate is technically able to print, but is still
affected by tackiness on its surface.
2. Anti tack GL Light finishing (UVC)
An anti tack treatment must be applied to the plate to remove this
stickiness that could be a problem during the printing.
The most usual process to remove the tackiness is the light
finishing. This is normally processed in the same unit as the post
exposure, but with different UV wavelength (around 255-260
nanometers).
The latitude of exposure is narrow with this treatment, so care
must be taken to ensure it is correct.
A lack of GL exposure will still leave some tackiness on the
plate.
An overexposure to GL lamps will provoke a “cracking” defect,
affecting the mechanical properties of the plate.
Note: Other anti tack treatment can be applied as chemical
bath (Bromination, Chlorination), or powder treatment.
Asahi Photoproducts (Europe) - AFP Training manual 10
Section I
 I. Tests
Good and stable platemaking results require, at the installation
of new units, tests to confirm platemaking conditions. This
should be done from time to time to see that no major changes
have happened.
The AFP photopolymer plates are very constant in sensitivity to
U.V. light, but despite this some platemaking data might change
after a long period or after technical amendments on units. This
is usually not due to the plate itself, but to external influences as
the type of unit, the power and the life of U.V. lamps or some
specific technical improvement on machines.

The purpose of that test is to define the best conditions to get a

perfect plate, with optimal repro characteristics.

Test procedures are in fact basic stepping that will allow the
operator to find out or to approach the required result. It is
important to keep in mind that tests are not giving the final
platemaking times, but only results that will be close to those
times. The reason is that when making a test, one step of the
whole platemaking process is isolated and checked. When all
those steps are then set together, it can lead to light differences
in the behaviour of the plate.

Caution
1. When making a test, please pay attention to change one
parameter only!!!
2. The test must always be confirmed by a plate made,
according to test results, in production conditions.

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 1. Backflash test

• Purpose

Define the amount of UV light required to harden the back layer

of the plate.

Fig 1. Exposure steps with mask

• Principle

The basic principle is to give several back exposure steps to one

Fig 2. Exposure steps before wash out
plate sample. Those steps will then indicate the reactivity to UV
of the plate, and the building of its floor layer. The target of the
test is to determine for the plate under test the best relief depth
for the different applications (see table of recommended relief
depth).

• Process

1. Cut a raw plate sample. (± 15 x 50 cm)

Fig 3. Exposure steps after wash out 2. Give different back exposure steps, keeping always the same timing
if possible. Ensure to give enough steps to cover the whole range of
possible relief depths for the type of plate you are testing.

3. Expose a stripe of ± 2cm on one edge (back and relief exposure)

This solid will be the reference value (as the plate will be swollen by the
solvent).

4. Wash deeply the plate to remove all unhardened polymer.

Fig 4. Measuring the different steps (an incomplete wash out would leave some unhardened photopolymer on
the plate and thus a faulty result as shown on fig. 5.)

5. After drying time record -the solid stripe thickness

-the different steps thickness

6. Remove the different Backlayer thickness (B) from (A) (reference

value) to obtain relief depth (C)

Fig 5. A too short wash out leaves 7. Report the results on the back exposure curve graph.
unhardened polymer on some of the
steps, and gives faulty results
Plate Line work 3% / 85 lpi 3% / 120 lpi 1% / 150 lpi
1.14 0.7 0.6 0.6 0.5
1.70 0.8 0.7 0.7 0.6
2.28 0.9 0.7 0.7 0.6
2.54 1.0 0.9 / 1.0 0.8 0.6 / 0.7
2.84 1.0 0.9 / 1.0 0.8 0.6 / 0.7
3.18 1.0 0.9 / 1.0 0.8 0.6 / 0.7
3.94 1.8 1.0 / 1.2 - -
4.32 1.8 1.0 / 1.2 - -
4.70 1.8 1.0 / 1.2 - -
5.00 1.8 1.0 / 1.2 - -
5.50 2.0 1.0 / 1.2 - -
6.00 2.0 1.0 / 1.2 - -
6.35 2.0 1.0 / 1.2 - -

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Solid Photopolymer (the reference value)
Unhardened Photopolymer
Fig 1. Plate sample before wash out
Sample 1 result from first test (short wash
out time)
Sample 2 result from second test
Sample 3 result from third test (long wash
out time)
Fig 2. Plate samples after wash out
Fig 3. Records of the test results
2. Wash out test
• Purpose
Define the right time required to remove the unhardened parts of
the plate.
• Principle
The principle of the wash out test will be to wash different plate
samples in different conditions, to determine the effect of the
wash out. The two parameters that may have influence in the
wash out are the pressure of the brushes, and the time or speed of
the wash out. The brush setting is usually defined according to
the highest targeted relief depth, and remains standard; this
means that the only variable will be the time or the speed.
The test must of course be processed with an unhardened plate
sample otherwise it would be impossible to control the wash out
efficiency.
The results of this test must always be linked to the results of the
back exposure test, as they are dependant upon one another.
• Process
1. Cut 3 raw plate sample (± 10 x 15 cm).
2. Expose a strip of ± 2 cm on one edge of each sample (back and
relief exposure). This solid will be the reference value (as the plate will be
swollen by the solvent).
3. Determine the brush pressure setting (the brush pressure setting will
be deduced from the targeted relief depth)
4. Wash the sample at 3 different times (or speeds).
5. After drying time record -the solid strip thickness A
-the back layer thickness B
6. Remove the Back layer thickness (B) from (A) (reference value) to
obtain the relief depth (C)
7. Report the results on the back exposure curve graph.
Asahi Photoproducts (Europe) - AFP Training manual 14
3. Face exposure test

• Purpose

Define the required amount of light (time) to copy accurately the

negative, taking into account the relief depth of the plate.

• Principle

The test will be processed using a dedicated test negative

including the points that may present some difficulties to be
copied onto the plate. This negative is presenting four times the
same patterns, which enables making four steps.
Knowing the type of plate to be tested, the first point is to
determine what will be the targeted repro - will it be linework,
coarse or fine screen, up to which screen %... The relief depth
will then be defined taking into ac count the different parameters
(Plate thickness, repro to be held).
Different exposure steps will then be given to the plate, and after
platemaking the plate will be analyzed to check which step will
produce the best result. The best result being of course the step
that holds the fine details, and that does not show filling in
problems.

• Process

1. Define the back exposure time corresponding to the requested

relief depth. (see on the back exposure curve)

2. Give the back exposure time.

3. Using an Asahi test negative, process the face exposure test,

giving different exposure times.
Note: Asahi can supply different types of negatives film dedicated to
the different type of plates.

4. Wash the plate according to the wash out curve.

5. Let the plate dry for 1 hour.

6. Define the optimal relief exposure time. (No losses / No filling in)

• How to read the result of Face exposure test

How to read the result of Face exposure test

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Details of the test result on plate

Underexposed Correctly exposed

Wavy fine lines / fine isolated Straight lines / copy of the finest
dots loss dots

Highlight dots loss Copy of the finest highlights

Correctly exposed Overexposed

Open reverses Filled in reverses

Open reverses straight shoulder Filled in reverses / larger

shoulders

Asahi Photoproducts (Europe) - AFP Training manual 16


Fig 1. This test shows up to 9
combinations of UVA / UVC, helping to
define the most appropriate one
Fig 2. Feeling with fingers is the only
way to check tackiness level on plate
surface, in production
Fig. 3. Bending the plate shows a
white matt aspect meaning that the plate
is cracked
4. Post exposure test
Purpose
The first step of post exposure (strengthening of the plate) is
usually easy to define, a small amount of light (CL or UVA)
being enough to post expose the plate (time equivalent to a short
main exposure time).
The second test will define the optimal time of anti tack
treatment or light finishing. (GL or UVC lamps)
Process
1. Take a sample of plate processed in normal conditions (Exposures
/ Wash out / Drying & stabilization time)
2. Give first CL (UVA) exposure times that correspond to an average
main exposure time.
3. Give then different steps of GL (UVC) exposure
4. Check the plate and define the optimal GL (UVC) time
(no cracking / no tackiness)
A lack of Finishing time (UVC), leaves a tacky aspect on the
plate surface. This can only be controlled, in production by
touching or feeling the plate (fig. 2.).
The cracking (over finishing) can be observed by bending the
plate. The centre of the bent area will show a white matt aspect
(fig.3.).
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Asahi Photoproducts (Europe) - AFP Training manual 18

Safety rules for platemaking
1. Conform to official health and
safety regulations, concerning
handling, use and disposal of
solvents and chemicals.
2. Do not smoke in platemaking
room.
3. Wear safety glasses and
protective gloves when handling or
using solvent or chemicals.
4. During platemaking ventilation
system must always be switched
on.
II. Production process
Please follow accurately this production process chart to
optimize your production quality. A single error in one of the
steps can affect your result.
1. Preparation stage
1.1. The unexposed plate
*In case stored below 10°C, AFP should be kept at room
temperature for a few hours before use.
*Keep the unexposed plates in the carton, wrapped in the
original black plastic film.
*Only peel off the cover sheet immediately before giving the
relief exposure.
*When the cover sheet is still on the plate, avoid bending the
plate or laying it on an uneven surface; this will prevent any
accidents such as the cover sheet splitting.
*After cover sheet removal, excessive plate bending will wrinkle
the protective layer! Such wrinkles will diffuse the ultra-violet
rays during the relief exposure consequently leaving marks on
the printing plate relief.
1.2. Cutting the unexposed plate
*As AFP plates are sensitive to cover sheet splitting, and
protective layer wrinkling, it is important adopt the correct plate
cutting technique to avoid accidental plate bending, torsion or
stress resulting in raw material waste.
*The ideal cutting tool is a flat-bed operated guillotine, with a
large table and a sharp blade.
*The plate will be laid flat on the table with the cover sheet side
facing down. The blade must first penetrate the base film, then
the polymer, and finally the cover sheet.
Note : the blade must be regularly cleaned and lubricated.
* The AFP plate can also be cut by hand using a sharp knife, in
the same way.
1.3. Preparation
*Check the negative (quality & graphics)
*Check unit cleanliness (cleanliness of the vacuum foil & copy
board)
*Set processing times (exposure, wash out, post exposure time)
Note: A regular (daily) check of the units must be done, before
starting production. (Lamps of exposure & post exposure units;
wash out bath quality;...)
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Removing the cover sheet
1. Flick gently on one edge of the plate.
2. The cover sheet will partially be
removed from the plate.
3. Peel and remove the cover sheet in
one continuous flowing movement.
2. Exposure process
2.1. Backflash
The back exposure fixes the relief depth. At the same time it
builds a floor layer required for holding fine details.
The back exposure is given through the base film, the plate
laying on the copyboard.
• The relief depth
The relief depth of the plate is one of the most important
parameters for the quality of the copy. Copying fine details and
screen will always require a narrow relief depth (thus a thick
backlayer). The quality of the repro is also better with shallow
relief depth, as it reduces the main exposure time, and problems
linked with the latitude of exposure. The only case where deep
relief depth may be used is for extremely simple artwork, but
high quality jobs never be made with deep relief depths.
• The influence of external factors on relief depth
In theory, the right exposure time is deduced from the graph
plotted on the occasion of preliminary tests. In practice the
results of "back exposure test" must only be seen as an attempt to
the find the correct exposure time. The real relief depth on the
plate will indeed be influenced by external parameters, during
the production. Those parameters are the temperature (heat
during production), that affects the photosensitivity of the plate;
and the reflection of the light on the frame (especially in case of
double exposure units). The direct consequence is usually a relief
depth shallower than the result obtained by tests, with the same
values.
2.2. Removing the cover sheet *
1. Flick gently on one edge of the plate.
2. The cover sheet will partially be removed from the plate.
3. Peel and remove the cover sheet in one continuous flowing
movement.
Note : If the cover sheet is not entirely removed in one go, this
can leave visible marks on the protective layer.
*in case of double side exposure unit this is done prior back
exposure
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 2.3. Face exposure

The negative film must be free of any surface defect, kink or fold
A
mark, thick opaque,... The negative should be cleaned to remove
any dust particles adhering to it.
The negative will be placed on the plate, emulsion side in contact
with the plate.
Vacuum strips should be placed surrounding negative and plate
Unroll carefully the vacuum film over the plate. The vacuum foil
must be kept clean, free of any dust particles, dirt, or any defect.
B Note: Vacuum foil must be regularly renewed (once a month), as
the UV light affects its transparency.

As soon as a perfect vacuuming is ensured, give the main

exposure time, according to:
1. the plate type (there can be difference in photosensitivity)
2. the pattern on negative (finer details require longer exposure
times)
C 3. the relief depth (deeper relief requires longer exposure times)

Under and overexposure

It is of great importance to perfectly calibrate the face exposure

Fig 1. The same face exposure time with
different relief depths (A-B-C) will give
different results
time. Insufficient exposure will always leave problems of copy,
especially on fine details. The most visible effect of a main
underexposure is the loss of fine dots (isolated and in screens),
and a wavy aspect of the fine positive lines.
On the other hand excessive face exposure (overexposure), will
produce another typical fault called "filling in" problem. This
fault which is not always easy to detect means that all the
reverses or negative parts of the image are filled in with
hardened photopolymer and consequently not deep enough to
provide good contrast on the impression.

Latitude of exposure
under exposed plate
The latitude of exposure is the amount of time between
underexposure and overexposure. The latitude of exposure
depends on several factors. The first one is of course the
sensitivity and the reactivity of the photopolymer. A second one
is the design or the repro to be copied on the plate. It is obvious
good plate
that in case of fine repro, as the required main exposure time is
longer, the latitude is narrower. The depth of relief can also be
of some influence, as deep relief require long exposures.

over exposed plate

Fig 2. Different face exposure times

Fig 3. Latitude of exposure

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Lamps
The standard exposure lamps for photopolymer plate exposure
must be UVC TL lamps in the range of 360 - 370 nm wave
length, usually equipped with a reflector that concentrates the
light rays, and increases the intensity. The average life of such a
lamp - depending on type and supplier - is about 600 to 1000
hours. After that period those should be replaced, because of the
loss of power and output (it can be more than 20%), and this will
create exposure troubles.
However lamps must be daily checked in order to ensure that
there is no lamp out of use.
In case of lamp out of use, all the lamp set must be replaced, to
avoid any discrepancy between the UV output of the different
lamps, it could affect the exposure result.

Copyboard (single exposure units)

It is very important to prevent any UV reflection (halation)

during the exposure (back and face). This is the reason why the
copy board should be of non reflective colour. Actually, most of
the current types of exposure unit are equipped with such a
board, except the very old ones, or the double side exposure
units.

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Fig 1. An inappropriate wash out time
(too short), can leave raw photopolymer
on the base and affect the relief depth.
3. Wash out process
The correct wash out time must be defined according to the
targeted relief depth (to the amount of polymer to be removed).
The shortest adequate time will guarantee the best final result. To
make sure that wash out is complete it is advisable to increase
slightly the wash out time. For instance a plate with a targeted
relief depth of 1.00 mm will be washed out with the time (or
speed) corresponding to 1.20 mm relief depth on the Wash out
graph. This will guarantee a deep and complete wash out
process.
Too short wash out time will leave raw material on the floor
layer, and affect the relief depth. This fault is virtually
impossible to detect, as the raw material will later (during post
exposure) be hardened. It will also reduce the relief depth of the
plate. It may give the impression that relief depth is correct,
when it is actually far too deep (but invisible), and lead to major
copy problems during the main exposure (see fig. 1.)
Too long wash out time will swell the plate, and can provoke
chipping off defects on fine details. It will also leave brush marks
on the floor layer.
The Wash out solution must be carefully checked, and must fit
the manufacturer’s recommendations (Temperature / Solvent
ratio /...).
If this is not respected, a poor or faulty result will be produced.
*Do not touch the polymer while it is swollen by the wash out
solvent! Not conforming to this recommendation can result in
damaged printing image and/or ugly marks on the plate floor
layer.
*When handling the wet plate, do ensure you are not breathing
solvent vapours.
Wash out solvents
AFP plates are compatible with the majority of solvents on the
market. The choice of a solvent can be extremely important as
they may have influence on production ratio (wash out and
drying times). All the solvents are mixtures, composed of a
minimum of two different products. It must be understood that
each of the products has specific characteristics. One of the
products (usually alcohol family) will have a chemical action on
the protective layer of the plate and dissolve it. Once this layer is
dissolved, the other solvent(s) of the solution will dissolve the
unhardened parts of the plates. The balance percentage of the
different solvents of the wash out solution is thus of great
importance, as improper ratio will affect the wash out efficiency.
In this respect a very accurate control must be applied to the
solvents used in production, especially when a distiller is used on
site.
More complete information about solvent compositions,
conditions of use and distillation, are available from the different
solvent suppliers.
Asahi Photoproducts (Europe) - AFP Training manual 23
 Solvent consumption & Regeneration

The average solvent consumption is about 10 to 15 litres per

square meter / per mm relief depth (this must only be considered
as an indication, as it can vary depending on solvent type,
temperature of solvent in use, wash out unit type...)
It is also a must to make sure that the solution is not containing a
too high percentage of dissolved polymer - this percentage
depends on solvents but usually never exceeds 3 to 5% -
otherwise poor wash out may result. Fresh solvent must be
regularly added to maintain the saturation at an acceptable level.

Orange peel

This eventual defect (appearing mainly with Perchlo & butanol)

can be very easily solved by a short surface treatment as follows:

1- Predry the plate for 10 to 15 minutes

2- Remove the plate from the dryer
3- Let the plate cool down for a few moments
4- Wipe gently the plate surface with a clean soft cloth
dampened with pure Perchloroethylene
5- Place your plate back in the dryer and leave it for the required
drying time (Drying time defined according to the plate type and
to the solvent used during the wash out process)

Note: Orange peel can also be observed in some rare case with
Fig 1. Orange peel
other solvents. It is then the sign of a too short face exposure of a
lack of surface cleaning with fresh solvent in the wash out unit.

Asahi Photoproducts (Europe) - AFP Training manual 24

4. Drying and stabilisation

4.1. Drying time

The drying and stabilization times are actually the evaporation

steps. The solvent content in the plate after the wash out process
must be assured to evaporate. The drying time is actually
proportional to the wash out time. Practically the longer the plate
is in contact with the solvent, the longer will be the drying time.
The conventional drying process is done with heated pulsed air.
The drying temperature must be 60° C to optimize the drying
process.
The drying time is usually standard according to the solvent and
the plate thickness.
The average drying time for thin plates is between 1 and 2 hours,
and between 3 and 4 hours for thick plates. The drying times
depends on photopolymer type and on the solvent used during
the wash out process

4.2. Stabilization time

The drying process in itself is insufficient to complete total

solvent evaporation. (A too long stay in the dryer at 60° c would
harm the polymer). A second evaporation step is thus
additionally required. This step is the resting or stabilization
time.
The plate will be laid flat at room temperature (± 20°C) for some
time (alternative solvent only requires relatively short
stabilization, but Perchlo requires up to 8 hours).
A too short resting time can cause thickness tolerances and
ageing problems.
A too long resting would not present any problems.

3,09
3,05 Drying curve
3,04

2,99

2,94

2,88
2,89

2,84 2,85
2,84
2,84
after 1 our
Thickness

Thickness

Thickness

Thickness
thickness

complete
recovery
Original

wash out

drying

drying
after 2
hours
plate

after

after

Fig1. Plate thickness recovery versus drying and stabilization time

Asahi Photoproducts (Europe) - AFP Training manual 25

5. Post exposure / light finishing

The two steps are in most of the cases carried out separately
UVA before UVC, but in one shot*, in the same unit.

5.1. Post exposure (UVA)

The UVA post exposure (conventional U.V.) is given first.

A too short post exposure time can be the reason for poor plate
resistance to solvents and ozone, limiting the printing run length.
A too long post exposure can lead to loss of plate flexibility.

5.2. Light finishing (UVC)

The UVC (anti tack treatment or light finishing) exposure is

given after the Post exposure.
The UVC exposure time must be accurately set, to eliminate
tackiness but without losing the mechanical properties (elasticity,
flexibility)., and without provoking the “cracking defect” on plate
surface.

The split process giving first CL and then GL increases the plate
resistance to printing solvents, and confers more latitude with
regards to the GL exposure. Nevertheless, if the unit is not
equipped to split the two exposures, CL and GL can be given
together.

Lamps

The post exposure process is made with conventional UVA lamps

- the same as used during the exposure process- but those have
usually a lower wattage (40 - 60 w). For more information about
those plates please refer to the former explanation.
Light finishing lamps or germicidal lamps, are UVC lamps
featuring a wavelength in the range of 255 nm. Those lamps
produce a very low amount of visible light, but on the other hand
this light is extremely dangerous for human beings, as it can
provoke immediate burns on eyes and skin. Any direct contact
without protection (gloves, glasses, masks...) must be absolutely
avoided.
It is anyway easy to recognize UVC lamps as tubes are
transparent, when UVA tubes are white

Asahi Photoproducts (Europe) - AFP Training manual 26

6. Plate quality control
To ensure an optimal printing result it is always important to
control the plate accuracy and plate repro, after platemaking

6.1. Plate accuracy check

Check of plate total thickness and plate accuracy

Plate accuracy specifications

Thin plates (1.14 to 2.84 mm): max. 0.04 mm (+/- 0.02 mm)
Thick plates (over 2.84 mm): max. 0.05 mm (+/- 0.02 mm)

Thickness device specifications

pressure 100 gr
pad surface 1cm²

6.2. Relief depth check

Check if the relief depth is not too shallow or excessive.
Generally speaking thin plate will never exceed 0.9 mm, and
thick plate 50 % maximum of the plate total thickness

Plate Line work 3% / 85 lpi 3% / 120 lpi 1% / 150 lpi

1.14 0.7 0.6 0.6 0.5
1.70 0.8 0.7 0.7 0.6
2.28 0.9 0.7 0.7 0.6
2.54 1.0 0.9 / 1.0 0.8 0.6 / 0.7
2.84 1.0 0.9 / 1.0 0.8 0.6 / 0.7
3.18 1.0 0.9 / 1.0 0.8 0.6 / 0.7
3.94 1.8 1.0 / 1.2 - -
4.32 1.8 1.0 / 1.2 - -
4.70 1.8 1.0 / 1.2 - -
5.00 1.8 1.0 / 1.2 - -
5.50 2.0 1.0 / 1.2 - -
6.00 2.0 1.0 / 1.2 - -
6.35 2.0 1.0 / 1.2 - -

6.3. Repro check

*Copy of fine details

Check if the fine work (screen and line) is well formed and is
held on plate.
*Filling in
Check if the fine reverses are not filled in.

6.4. Plate state surface

Check if the surface of the plate is not too tacky, and not
cracked.
Check if there is no dust or any other damage

Asahi Photoproducts (Europe) - AFP Training manual 27

Platemaking control strip

The principle of a platemaking control strip is to ease the check

of the reproduction on plate.

It is advised to use a control strip for every relief exposure when

making plates. The control strip contains all the details that could
cause problems during Repro, and must be used as a reference to
check plate after processing.
During plate making the strip should be placed alongside the
negative to be copied and processed in the same conditions. The
target is to hold the same range of details as the production
negative.
After plate making the strip is visually checked and the result is
compared to the values of the production negative. This check
will confirm if the plate is correctly exposed.
The plate making control strip is designed to show all of the
possible difficulties that could occur during the Repro process. It
should be used as a guide to show that the plate Repro is correct.

Asahi Photoproducts (Europe) - AFP Training manual 28

Defects relating to platemaking process
Too short time Too long time

Backflas Too deep relief depth Shallow relief depth

h
Loss of dots during the
face exposure

Face Loss of fine details Filling In

exposure (higlight dots)

Wash Incomplete wash out Chipping off

out

Excessive swelling

Drying Too thick plate Poor accuracy

Poor accuracy

Stabilizin Poor accuracy -

g

UVA - -
post
exposure

UVC Tackyness Cracking

light
finishing

Asahi Photoproducts (Europe) - AFP Training manual 29

 III. Storage of AFP
finish plates
Even after finishing treatment photopolymer plate can still be
sensitive to external factors. Those factors can be of great
influence on the plate quality.
Therefore, three conditions will have to be respected to
guarantee an optimal conservation and a longer lifetime for the
plate. Those conditions must be applied directly after
platemaking / before impression, and of course for storage after
impression.

Before storing the plate, it is important to make sure that the

plates have been perfectly cleaned from ink, and that those are
dry.

1. No light
The light has a dangerous effect, as it produces a fast ageing of
the plate, provoking a strong cracking, a loss of flexibility of the
plate, and loss of mechanical properties. The colour of the plate
also turns yellowish. This fault can be provoked by any type of
light (lamps or sunray) emitting UV's. The plate will thus have to
be totally protected from any UV emission.

2. Ventilation
To ensure the best conservation the ventilation of the plate is also
of prime importance. The first point is the air quality, which
must be free of any aggressive vapours like ozone or solvent
vapours as they will have an aggressive effect on the plate
material. Also pay attention that the air is clean of dust and
particles. The second point is to make sure that the plates are
properly ventilated, and that air can circulate freely between the
stored plates. It means that plates should not be stored in contact
with each other.

3. Temperature conditions: 5 to 35°

Excessive temperature (maximum 35°c) should also be avoided
to prevent any plate damage.

Asahi Photoproducts (Europe) - AFP Training manual 30

 IV. Daily production
check list
These instructions are basic rules to be followed by the
operator in his daily work. Respecting them will be helpful in
preventing any trouble before starting the platemaking process.
These actions should be done every day before starting the
production.

Check list
Item Remark

1 Switch ventilation ON -

2 Switch all units ON -

3 Give preheating 10 minutes of preheating to

-Exposure unit
-Post exposure

4 Check Exposure lamps Visual check

5 Check Post Exposure Pilots lamps Pilots lamps only ! GL

lamps are extremely
dangerous for eyes and
skin (risk of heavy burns)

6 Check Wash Out bath quality & Run Wash Out process for
Solvent saturation 10 minutes.

7 Check Wash Out bath temperature Conform to values given by

the supplier

8 Check Dryer temperature 60°c

9 Clean Exposure frame -

10 Clean Vacuum foil -

Asahi Photoproducts (Europe) - AFP Training manual 31

 V. Platemaking check
list
These instructions are a guideline to help the operator in his
platemaking job. Respecting them will be helpful in preventing
any trouble during the platemaking process and will ensure
optimal platemaking results. This guideline can also be used,
when facing eventual troubles, to locate the origin of the
problem.

Platemaking check list

Item Remark

1 Check the negative *Technical specifications :

Density / Cleanliness /
Opaquing / Emulsion side
*Repro (does the negative fit the plate
repro capability)

2 Platemaking setting *Define platemaking times

(Back & main exposure time / Wash Out
time / Drying & Stabilization time / Post
exposure time)

3 Clean Exposure frame / Vacuum foil / Negative

4 Cut the plate Through the Base Film first

5 Back exposure time

6 Turn over the plate

7 Remove the cover film Avoiding dust

8 Place negative onto Avoiding dust

plate

9 Place vacuum strips Caution : Strips must be inside the

around plate vacuum lines

10 Vacuum process Use a squeezer

11 Relief exposure time

12 Wash out of the plate Be sure to regenerate adequately the

solvent

13 Dry the plate

14 Stabilize the plate

15 Post expose plate

16 Check plate quality 1. Plate thickness / Plate accuracy

2. Relief depth
3. Repro.
4. State surface

Asahi Photoproducts (Europe) - AFP Training manual 32

Section II
 I. Negatives
The negative film is the material that will be used to reproduce
an image onto a plate.This type of film is called negative because
it shows a negative of the image to be reproduced.As the plate
will exactly copy the negative, it is a must to have a film with a
perfect quality (each defect on the film can be copied on the
plate).

What is a negative film?

The negative film is a polyester film coated with an emulsion on

one side.After a photographic process some areas of the film are
left free of emulsion and transparent, the other areas becoming
black.
The negative film will act as a mask during the main exposure.
The transparent zones will let light pass through the negative and
the black area will stop it.
In comparison with other processes, the photopolymer plate
requires very accurate negatives, to ensure a perfect
reproduction.
All the negatives used for AFP flexo platemaking must be as the
following specifications.

Asahi Photoproducts (Europe) - AFP Training manual 34

 Technical specifications

1. Type of negative film

Matt film with high silver image density is the most

recommended type of films for AFP platemaking. The main
reason for using these types of film is that they allow the best
vacuuming between plate and film, which is a key point to
ensure a good copy.

2. Density

Density values The light transmission through the negative is a major condition
to produce good plates.
• Transparent areas
-If the transparent parts are too dense they will affect
D 0.04-0.05 maximum the light transmission and reduce the effect of the U.V.
light on the polymer.
• Black areas -If black parts are too transparent they will let U.V.
D 4 minimum
light pass through the film and produce an over
exposure or expose unsuitable areas on the plate.
All film beneath these specifications,
should be rejected!
If these values are not respected, the plate
can be spoiled.
3. Emulsion side

The basic principle in flexo platemaking is always to place the

emulsion side of the negative in contact with the polymer. This
will ensure the optimal repro, because there will be no light
diffraction through the polyester of the negative film.

4. Opaquing

If a film requires retouching, opaquing has to be applied on the

non- emulsion side of the negative.

Other specifications

Graphic quality

*The graphics design must be adapted to plate to be produced

(reproduction capability of plate, plate thickness, relief depth)

*Characters, lines, screens, reverses,... must be sharp enough to

be reproduced on plate.

*Films with too low resolution must be rejected.

Cleanliness

Always pay attention to cleanliness and state of films :

-no dust
-no traces of fingers
-no kinks
-no scratches

Asahi Photoproducts (Europe) - AFP Training manual 35

 II. Print elongation
When a photopolymer plate is mounted onto a press cylinder,
the relief surface tends to elongate in the direction of printing.
This elongation will provoke a disproportion between the
original and the print result. Therefore the negative has to be
scaled down in advance by the estimated amount of elongation in
the printing direction, in order to compensate this disproportion.
Fig 1. Original design

Scaling calculation

This scaling will be calculated easily with a simple formula that

takes into ac count the different factors implied in the elongation.
The elongation will be mainly affected by the plate thickness (the
thicker the plate the more distortion) and by the diameter of the
cylinder (the smaller diameter the more distortion)
Fig 2. After impression
The compensation can be calculated as follows:

Formula % reduction = K x 100 %

R

K = parameter depending on the polymer thickness (minus Base film)

R = Repeat length (in mm) = (printing circumference)

How to calculate R & K

K = 2 x 3.1416 (Plate thickness - Base film thickness)

R = 3.1416 x (cylinder diameter + (2x Total plate thickness) + (2x
Adhesive mounting tape thickness))

Asahi Photoproducts (Europe) - AFP Training manual 36


Fig. 1. Different type of screenings
Fig 2. Grey scale with percentages
from 0 to 100%
III. Artwork
In flexo, as in the other printing process, the original artwork or
layout to be printed must be adapted to the printing process
(flexo), the type of plate, and the printed material. The repro is,
of course dependant on the possibilities of the plate, but its
possibilities will also mainly depend on the printing substrate.
The final printing result is more limited by the substrate than by
the plate. It is possible in good conditions to produce very fine
screen ruling but it wouldn't help to produce such quality if it is
to be printed on corrugated (it would be virtually impossible to
print these details on this substrate)
It is obvious that corrugated board printing does not require the
same artwork as label printing.
Original artwork might be composed of linework and of screens.
Linework
Linework means by all parts of the image not composed of
screens, and thus includes solids and lines. Usually this does not
create too much problem in reproduction except in case of small
types or fines lines.
Screens (Conventional)
A screen is a way to reproduce halftones of a drawing or of a
picture. The most commonly used screens in flexography are
conventional screens (round or circular dots / AM). Alternative
screening, like stochastic (random or FM) or eccentric (lines),
may also be found.
In conventional screening, it is composed of a network of dots of
different sizes, which will simulate the gradation of colours of
the subject. Clearer areas will require fine dots, darker areas will
require larger dots. The screen values are defined by three
parameters:
1. The percentage
The percentage is the ratio of covered surfaces versus the white
areas, which creates the gradation aspects.
The values are recorded in percentage. The percentage is the part
of a surface covered by dots. Values are recorded from 0%
(which means a clear area-no dots) to 100% (which means dark
area-totally covered by dots)
example: a screen of 40%, means that 40% of the area is
covered by dots, and 60% is not.
2. The screen ruling
The screen ruling is the number of dot lines on each inch (or
centimetre).This has no influence on the gradation or on the
percentage, but is quite important when considering the image
definition. The same image may be treated with different line
ruling, but the finer the ruling, the better the final appearance.
Flexo plates allow screens up to 175 l/inches or 70 l/cm
(maximum).
Asahi Photoproducts (Europe) - AFP Training manual 37

Fig 1. Screen angle
Fig 2. Moire formation
Fig 3. Typical Flexo angles
3. The screen angle
A third parameter to define technically the screen is the screen
angle.
The dotted lines of a screen can be vertical, horizontal or follow
a specific angle. This point can have a critical influence on the
aspect of the final printed result, especially important in case of
process colour work in which different screens of different
colours are mixed.
4. Moire formation
The moire effect is the consequence of overlapping different
screens having different angles. A visual effect, provoked by the
overlapping of dotted lines, can appear and will disturb the
image. The fault occurs especially when the angles of two
screens are too close to each other. To avoid any moire troubles,
the film maker have to respect the standard screen angle value.
5. Specific screen angles for Flexographic printing
A colour image will generally be reproduced with four different
screens (Cyan - Magenta - Yellow - Black). The last ones need to
have particular angles, as the overlapping of dots can produce
moire defect.
This principle is true in all printing systems, but the flexo process
requires more attention due to the fact that an anilox roll is used
to transfer ink to the plate.
As this anilox is engraved with screen cells, usually with an
screen angle of 45° (or 60° angle). An overlapping of anilox
screen and of printing plate screen will provoke a moire effect.
The recommended solution is to adopt different screen angle,
trying to keep 30° between the critical colours (C - M - K).
Yellow being visually less sensitive to moire.
The following angles are standard in flexo :
Cyan : 7.5°
Black : 37.5°
Magenta : 67.5°
Yellow : 82.5°
Asahi Photoproducts (Europe) - AFP Training manual 38

Fig 1. Dot deformation due to printing
pressure
Fig 2. Dot size on negative
Fig .3 Dot size on print
IV. Dot gain principles
Due to the hardness (or softness) of polymer plates, the
flexographic printing process suffers a problem called "dot
gain". The dot gain phenomenon is basically an enlargement or
a fattening of the printing relief of polymer plates. This fattening
will not be obvious on big solids, big lines or types, but will be
rather important on fine details, isolated dots, screen dots, and
fine type.
Phenomenon
The pressure applied on press by the print substrate will be
absorbed by the plate, provoking a certain enlargement of the
printing reliefs, and thus of impression.
This phenomenon is unfortunately quite difficult to control. Each
parameter of impression can influence the final result : plate
quality (under or over exposed)- plate hardness - plate mounting
- ink viscosity - print substrate - press type - press setting (anilox
and substrate pressure on plate, speed, ...). Nevertheless, the dot
gain will change the final look of the final impression result
(darker images, bolder types, larger lines, ...), it is thus very
important to be able to control it.
Dot gain curves
As the printing result will be affected by gain, changing the
general aspect of the image and particularly of screen and four
colour process, can be compensated for at the negative
preparation. The screen percentages should be reduced on
negative and plate, to achieve the final required result after
gaining on impression.
The only way to know the factors of compensation is to make a
curve with a grey scale from 0% to 100%, showing on a graph
the difference between percentages on negatives, and
percentages on print (dot gain curve).
Caution : A compensation curve is applicable only to one
impression condition. Changing one of the parameters
(plate, ink screen ruling, anilox, press setting,...) can
change the gain curve, and thus affect the result.
Asahi Photoproducts (Europe) - AFP Training manual 39
Section III
 I. Trouble shooting

Whatever the problem, always take your time, analyse, check

your process chart, and try to locate and define the problem.
In most cases the problem will be easy to solve. The majority of
the troubles faced in plate production are linked to basic facts. It
might be a processing mistake, a wrong negative,...
With the following chapter you will be able to solve the most
common problems. Each possible defect is detailed with an
explanation of possible causes, and the counter measure to
prevent it.
If you still face a problem, don’t hesitate to call Asahi.

Investigation process
In case of trouble shooting, take your time and check carefully
each step of the production process.
-Look for any shift from the standard process.
-Never take anything as granted. Always cross check.
-Never draw conclusions on the basis of only one experiment,
systematically double check.
-Never hesitate to ask for help. An outsider will often notice
items not seen because of familiarity.
-Origin of troubles can be sorted in four different categories.

1. Handling problems
*Wrong machine setting
(incorrect processing times)
*Plate handling
(plate bent, wrong coversheet removal, wrong cutting
process)
*Insufficient unit control & maintenance
(dust or dirtiness / lamps out of use on exposure unit /
wrong wash out solution / dirty vacuum foil)

2. Negative problems
*Negative out of technical specifications
*Design out of graphical specifications

3. Fault on units
*Electrical problems on units
*Dryer defective

4. Faulty material
*Product quality problem

Asahi Photoproducts (Europe) - AFP Training manual 41

1. Prepress troubles
Problem Reason(s)

Base film delamination -Unsharp or tacky guillotine or scalpel

-Plate cut upside down

Cracks in finished plate -Too long finishing exposure to the light of GL

lamps

-Insufficient drying / stabilization time

Craters / “Chipping off” -”Pepper” film defect or dirty vacuum foil or dust
between film and plate

-Aggressive washout solvent

-Aggressive action from brushes

-Too short relief exposure time

-Low U.V. light intensity

-Lack of parallelism between brushes and plate

-Jump / vibrations of wash out unit

-Too low solvent level in washout tank

Excessive thickness -Drying problem

tolerance
-Too long wash out time

-Too deep relief depth

Filling in (of reverses) -Relief overexposure

-Reflective copyboard (halation)

-Poor quality of negative film

-Exposure frame vacuuming problem

-Inadequate wavelength of lamp output

Fluctuation of relief depth -Cf. Uneven relief depth (within one plate)
from plate to plate
-Also, fluctuations in lamp output

Inaccurate plate total -Excessive drying time

thickness
-Drying air is too hot
N.B.: above list for thickness tolerances are
also valid in this case

Kinks in base film -Large pieces stored on top of smaller pieces

-Rough handling

-Plate moved during the wash out process

-Plate moved while cutting

-Plate lifted when peeling off the cover film.

Asahi Photoproducts (Europe) - AFP Training manual 42

Problem Reason(s)

“Orange peel” surface -Missed “orange peel” removal process

structure
-Wash out solvent saturated with polymer

-Too long wash out time

-Wash out solvent out of specification

Tacky finished plate -Too short GL exposure time

-Low GL lamps output

-Ink compatibility

Uneven relief depth (within -Exposure frame uneven light distribution or lamps
one plate) not switching on simultaneously

-Too hot exposure unit copy board

-Plates stored in a cool room used immediately

after bringing them into the platemaking room

-Wash out brushes not parallel to plate surface, or

wash out unit out of level

-Plate fogged with U.V. light during storage /

handling

Wavy fine lines or washed -Negative film out of specification

away fine details
-Too much relief depth

-Too short relief exposure time

-Aggressive wash out solvent

-Exaggerated brushes pressure

-Brush hair dirty or too hard

-Poor distribution of exposure frame light

-Stained or dirty vacuum cover foil

-Too old exposure lamps

-Too low solvent level in the washout tank

-Excessive wash out time

Wrinkles -Plate was bent on the exposure frame

-Too hot exposure unit copy board (temperature

shock)

Wrinkled protective layer -Plate mishandling

of raw plate
-Poor storage state of plate carton

Asahi Photoproducts (Europe) - AFP Training manual 43

2. Press troubles
Problem Reason(s)

Cracked plate after -Plate was exposed to bright daylight or a U.V. light
storage source

-Bad storage conditions

-Aggressive plate cleaning or ink

Damaging fine dots -Mechanical abrasion

-Plate over finished

-Bad storage conditions

Delamination of polymer -Ink or plate wash dissolved the bonding layer

from base film between polymer and polyester film

“Moire” -Improper screen angle

-Too low anilox screen ruling

-Orange peel defect on the plate

Mottled solid printing -Poor ink distribution

-Low plate wetability

Plate swelling and wearing -Too much ethyl acetate in ink

-Aggressive cleaning process

Plate wear after short run -Excessive printing pressure (anilox to plate and/or
printed substrate to plate)

-Ink causing abrasion

-Inaccurate mounting

-Printing press vibration

-Abrasion by substrate

-Kink in the base film

Asahi Photoproducts (Europe) - AFP Training manual 44

Appendix
 Solvent compatibility table
Compatibility table between AFP plates and solvents (inks and cleaning
agents)
Solvent Solvent
Alcohols Combinations
Methanol Ethanol/ethylacetate 90%-10%
Ethanol Ethanol/ethylacetate 80%-20%
N-propanol Ethanol/i-propylacetate 90%-10%
I-propanol Ethanol/i-propylacetate 50%-50%
N-butanol Ethanol/ethylene glycol
Benzil alcohol Ethanol/toluene 90%-10%
Esters Ethanol/toluene/ethylacetate 80%-10%-10%
Ethylacetate Ethanol/benzene 90%-10%
Methylacetate Ethanol/methylketone 70%-30%
I-propylacetate Ethanol/acetone 70%-30%
Ketones N-propanol/ethylacetate 80%-20%
Acetone N-propanol/ethylacetate 90%-10%
Methyl ethyl ketone N-propanol/methylethylketone 90%-10%
Aliphatic hydrocarbons N-propanol/benzene 95%-5%
N-hexane N-propanol/toluene/ethylacetate 80%-10%-10%
Cylo hexane N-propanol/toluene 95%-5%
Gasoline N-propanol/toluene 50%-50%
Kerosene I-propanol/Methylethylketone 90%-10%
Light oil I-propanol/ethylacetate 90%-10%
White spirit I-propanol/toluene 98%-2%
Aromatic hydrocarbons I-propanol/toluene 70%-30%
Benzene Methanol/i-propylacetate 80%-20%
Toluene Methanol/i-propylacetate 50%-50%
Xylene N-hexane/I-propanol/n-buthanol
Chlorinated hydrocarbons Water/isopropylalcohol 90%-10%
1-1-1-Trichloroethane Water/ethanol 95%-5%
1-1-2-2 Tetrachloro ethylene
Perchlorethylene Note
Trichlorethylene
Others
= Suitable
Water
Linseed oil = Limited use

Tung oil = Unsuitable

Soja bean oil
Ligroin
N-nitro propane
2-nitro propane
Ethylene glycol
Propylene glycol
Glycerol
Ethyleneglycol-monoethylether
Ethyleneglycol-monomethylether
Ethyleneglycol-monobuthylether

Asahi Photoproducts (Europe) - AFP Training manual 46

 AFP Plates - product characteristics (March 2004)

1. Thin plate technology - analogue

Plate name HF SG HD SH

Thickness 1.14* - 1.14* 1.14*

1.70* 1.70* 1.70* 1.70*
2.28 - - -
2.54 2.54 2.54 2.54*
2.72 - - -
2.84 2.84 2.84 2.84*
3.18 - - -

Application - Paper & plastic bags - Paper & plastic bags - Paper & plastic bags - Paper & plastic bags
- Flexible packaging - Flexible packaging - Flexible packaging - Flexible packaging
- Preprint - Preprint - Preprint - Preprint
- Labels - Labels - Labels - Labels
- Aluminum foil - Aluminum foil - Aluminum foil - Aluminum foil
- Flat carton - Flat carton - Flat carton - Flat carton

Characteristics - Universal plate - Universal plate - High quality - High quality

- High solvent graphics (process graphics (process
resistance colour) colour)
- High mechanical
resistance

Repro 1 - 95% 1 - 95% 1 - 95 % 1 - 95 %

150 lpi (60 lpc) 150 lpi (60 lpc) 175 lpi (70 lpc) 175 lpi (70 lpc)

Suitable Relief up to 0.9 mm up to 0.9 mm up to 0.7 mm up to 0.7 mm

Aspect Light Green Green Green Green

Latitude of Very Wide Wide Very Wide Very Wide

exposure

Ink - Water based inks - Water based inks - Water based inks - Water based inks
compatibility - Solvent based inks - Aggressive solvent - Solvent based inks - Solvent based inks
- UV inks based inks - UV inks - UV inks
- UV inks

Shore A 73° (1.14 mm) - 78° (1.14 mm) 77° (1.14 mm)
61° (1.70 mm) 62° (1.70 mm) 70° (1.70 mm) 69° (1.70 mm)
53° (2.54 mm) 56° (2.54 mm) 65° (2.54 mm) 63° (2.54 mm)
50° (2.84 mm) 53° (2.84 mm) 63° (2.84 mm) 63° (2.84 mm)
50° (3.18 mm) 52° (3.18 mm) - -

Base film 188 µ (1.14 mm) - 188 µ (1.14 mm) 188 µ (1.14 mm)
thickness 125 µ (1.70 –3.18 ) 125 µ (1.70 –2.84) 125 µ (1.70 –2.84) 125 µ (1.70 –2.84)

Surface tension 34 dynes 37 dynes 43 dynes 39 dynes

*Anti Halation Base film

Asahi Photoproducts (Europe) - AFP Training manual 47

2. Thin plate technology - digital
Plate name DHD DSH

Thickness 1.14* 1.14*

1.70* 1.70*
- -
2.54 2.54*
- -
2.84 2.84*
- -

Application - Paper & plastic bags - Paper & plastic bags

- Flexible packaging - Flexible packaging
- Preprint - Preprint
- Labels - Labels
- Aluminum foil - Aluminum foil
- Flat carton - Flat carton

Characteristics - High quality - High quality

graphics (process graphics (process
colour) colour)
- High mechanical
resistance

Repro 1 - 95 % 1 - 95 %
175 lpi (70 lpc) 175 lpi (70 lpc)

Suitable Relief up to 0.6 mm up to 0.6 mm

Aspect Green Green

Latitude of 4000 - 6000 mj 3000 - 4000 mj

exposure

Ink - Water based inks - Water based inks

compatibility - Solvent based inks - Solvent based inks
- UV inks - UV inks

Shore A 76° (1.14 mm) 77° (1.14 mm)

67° (1.70 mm) 69° (1.70 mm)
59° (2.54 mm) 63° (2.54 mm)
57° (2.84 mm) 63° (2.84 mm)
- -

Base film 188 µ (1.14 mm) 188 µ (1.14 mm)

thickness 125 µ (1.70 –2.84) 125 µ (1.70 –2.84)

Surface tension 35-36 dynes 34 dynes

*Anti Halation Base film

Asahi Photoproducts (Europe) - AFP Training manual 48

3. Thick plate technology – analogue & digital
Plate name ER SQ DSQ

Thickness - 2.84* 2.84*

- 3.18 3.18
3.94 3.94 3.94
4.32 4.32
4.70 4.70
5.00 5.00
5.50 5.50
6.00 6.00
6.35 6.35

Application - Heavy duty bags - Corrugated board - High quality

- Corrugated board - Heavy duty bags graphics on
Corrugated board

Characteristics - Hard photopolymer - Soft photopolymer - Soft photopolymer

Repro 3 - 95% 3 - 95% 1 - 95 %

85 lpi (35 lpc) 85 lpi (35 lpc) 120 lpi (48 lpc)

Suitable Relief Max 50 % of plate Max 50 % of plate up to 0.9 mm

thickness thickness

Aspect Yellowish transparent Orange Orange

Latitude of Wide Wide 6000 - 8000 mj

exposure

Ink - Water based inks - Water based inks - Water based inks
compatibility - Solvent based inks - Solvent based inks - Solvent based inks

Shore A - 41° (2.84 mm) 41° (2.84 mm)

- 39° (3.18 mm) 39° (3.18 mm)
45° (3.94 mm) 36° (3.94 mm) 36° (3.94 mm)
44° (4.32 mm) 35° (4.32 mm)
43° (4.70 mm) 35° (4.70 mm)
43° (5.00 mm) 34° (5.00 mm)
42° (5.50 mm) 34° (5.50 mm)
42° (6.00 mm) 34° (6.00 mm)
42° (6.35 mm) 34° (6.35 mm)

Base film 125 µ 125 µ 125 µ

thickness

Surface tension - 36 dynes 33 dynes

*Anti Halation Base film

Asahi Photoproducts (Europe) - AFP Training manual 49