There are numerous polymer technologies available to narrow web printers looking to bolster their flexographic capabilities. Quality, processing times, and sustainability are among the variables to consider when investing in new polymers.

To learn more about the latest in polymer technology, L&NW sat down with Bryan Thrasher, Polymer Business Development Manager, Anderson & Vreeland.

L&NW: What should label converters know about polymers in flexo printing?
BT: There is a large variety of polymers on the market now and less of the one-size-fits-all. With this variety of polymers, there are many new benefits for cost savings and sustainability. Flat-top technology is gaining traction as it has more 1-to-1 print curve on-press, meaning less dot gain and more precise screen laydowns with ink. There are also three different types of polymers available to the label market, depending on the needs and requirements for the process, as well as time savings.

L&NW: What are the different technologies available?
BT: For the narrow web market, we have three types of polymers available: solvent wash, water wash, and thermal plate solutions. Each of these fit a specific need. The trend in narrow web is moving away from solvent wash to water wash plates.

L&NW:  How does a company decide which polymers are best to use?
BT: Solvent wash polymers have been around for a long time and have been very reliable. There are a wide variety of durometers, and flat-top versus round-top technologies. You are also able to use recycling services for the solvents. Solvent plates are the most cost-effective, but drying times are significantly higher. 

The trend in moving to water wash comes from a desire to eliminate solvent from the process and reduce total plate processing times significantly – from 2-3 hours down to one hour. You also only work with water and detergents for flexo plates, and straight water for letterpress plates that are designed for emboss/deboss and specialty applications. Also, it is important to note that water wash plates are inherently flat-top.

Thermal plates are the newest polymer technologies that require no solutions for processing, thus eliminating a drying step and creating a slightly faster total processing time over water wash. The thermal process is most cost-effective with high yearly plate volumes. You can get thermal plates with flat-top and round-top technologies.

L&NW: What equipment is needed in this space?
BT: The equipment for processing is dependent on the polymer type and the size of the plate that fits your process. If you are thinking about analog versus digital, you need a film source for analog, and a digital plate imager for digital – with very different price points. Digital is becoming the norm as traditional film processors are dying and not being made anymore.

All polymers need the same steps for processing, so you need exposure, polymer processing, drying and detac/post exposure. Thermal polymer removes the need to dry. You can get all-in-one processors for 20×22 plates up to 35×47, which saves space and allows for continuous workflow. For 42×60 and 50×80 plates, all equipment is separate depending on the steps mentioned before.

As for the polymer type (solvent wash, water wash, and thermal), each one has its own unique processing equipment designed for that polymer. With a solvent system, you need a distilling process for the solvent as an extra part of the process.

L&NW: What makes Anderson & Vreeland ideally suited to assist converters here?
BT: First, A&V supports all photopolymer types, including Avantage liquid resins outside of the narrow web space. We are the only company that can do this. 

Second, with our consultative approach, we educate customers on each aspect of each type of polymer, so they know what is involved in the decision-making process. Then we work with their budgets and specific company needs for the right solution for them. Some company goals are geared toward a sustainable process, some may be bringing plates in-house for the first time. We ask the right questions and listen to the customer’s needs to help them succeed in their business.

A&V also provides affordable bundles and financing options, meaning we can deliver all of the pieces in the process in creative financing packages that fit the customer’s budget. A&V has formed a new polymer business development team as of 2023, and this team is dedicated to the polymer business decisions for our clients. Furthermore, A&V also supports prepress software and proofing solutions for the front end, and everything going into the flexo process in the pressroom. Call your local A&V account manager for more information on our polymer technologies.