Virtual (digital) Proofing in Plate Mounting Improves Productivity and Quality
Submitted by Tim Reece, APR Technical Solutions Group

The advancements made in the mounting process of photopolymer plates over the last decade are undisputable. Using a multiple camera system with high magnification to accurately align targets or micro-dots has not only increased accuracy of registration, but has also greatly improved throughput. However, while it is hard to argue the accuracy of modern video mounting systems, there certainly has been room for further development regarding productivity. There are multiple steps to the plate mounting process, but the three main steps that consume the most time include wrapping the print cylinder with mounting tape (stickyback), physically positioning the plate on the print cylinder, and pulling a proof to insure proper registration.

Wrapping the cylinder and aligning the plates on the print cylinder have proved to be necessary evils of the plate mounting process. However due to the time needed to ink up the printing plates and pull a proof, some equipment manufactures and convertors have decided to eliminate the feature from the mounter or simply not utilize this feature. There is no doubt that video mounting systems are very accurate or at least as accurate as the operator, but waiting for a job to be pulled up in the press can prove to be a costly decision when a registration problem arises.

It is for this reason that the most technologically advanced mounters have incorporated a technology known as the virtual proofing or virtual imaging. These innovative systems allow for the mounting of plates with or without out crosses or references while allowing for virtual proofing without inks or substrate. This virtual image effect may be used to both align the printing plates during the mounting process, and/or capture an image of each mounted plate and superimpose each plate on top of one another in a semi-transparent image allowing for a virtual proof that ensures proper registration without the added time of inking plates and pulling a proof proofing. The virtual proof also minimizes previously needed proofing supplies and waste generated by these supplies.

When using the system to mount plates, the operator mounts the first plate and save that image. The image is viewed by the operator as a transparency and the following plates can be overlaid with the image in the background. So you can align plates with or without targets or micro-dots using this fast and easy system. Equally as important, plates that have targets or microdots damaged or removed are no longer deemed as unusable. The very latest in virtual image technology adds further functions to the mounters with automatic smart control of camera parameters for both overlay simulation and virtual proofing with different magnification levels for a more advanced level of inspection of the mounted job. It is even possible to save the jobs with the self learning systems and the software drives the operator in the automatic mounting of a plate sequence.

Truly today's most advanced virtual proofing systems have a reached a level of both accuracy and throughput that we have never seen before, while reducing consumables and waste in the mounting department. A common question regarding these systems is, "How much time can I expect to save during the mounting process when using a virtual image system?" The answer to that question varies often according to the width of the cylinders. The technology does not add additional time to the process; therefore by eliminating time spent to hang the substrate on the impression drum, ink plates, pull the proof, clean the plates, multiplied by the number of colors, will be the time one can expect to save. Those who have already elected not to produce a proof will not necessarily see a difference in throughput, until you factor in the insurance you have given yourself by having an electronic proof. You no longer will rely on the printing press to pull the first "proof". Therefore a reduction in re-mounts could be expected which ultimately affects the throughput of the department.

Sys Tec's Virtual Image System introduced the first system in the market that provides an easy, reliable and accurate Virtual Proof-Print Plate mounting machine for mounting corrugated plates.

Main technical features:

• The rotation of the drums is provided by torque motors with electronic servo-drivers that allow the possibility to have a proof with 1:1 ratio.
• The user-friendly software interface allows the possibility to draw the box shape on the proof drum through an easy "wizard" interface or to manage directly the graphic file used for the project. Microsoft Windows (no CNC to be programmed).
• The machine is equipped with 2 autofocus color cameras
• 270x zoom (up to 8 cameras in option) and all our best electronics solutions:
• STAR HT camera movement with motors, that permits the reading method for the camera position without connection of mechanical parts.
• VIRTUAL IMAGE system available for the managing of the graphic files and for the simulation of the 3D PLATE EFFECT.
• Software PHOTO-SPLIT with multi-language interface
• Monitor sliding on rail with electric movement Jobs creation and save

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