UK pre-press house expands with Kodak’s Flexcel NX

Reproflex 3, a Newcastle, UK-based packaging pre-media specialist, is planning a move to larger premises as a result of the significant boost in production capacity thanks to its Kodak Flexcel NX digital flexographic system. Installed in April 2010, the integrated system comprises the Flexcel NX thermal imaging layer, imager and laminator. The technology has brought about a significant increase in business and the company is now preparing to expand in 2011 to a new-build production plant of 16,000sq ft on two floors on an adjacent site.

Partners Andrew Hewitson and Trevor Lowes set the company up in 1996 with a ten year strategy. Fifteen years on and still growing, they attribute their success to continuous investment in new technologies. ‘We started off with a small studio and a dream to invest and optimize the latest technologies in packaging pre-press,’ said Hewitson. ‘Using our long experience in flexography we have enhanced these tools and maximized their potential to deliver the highest quality products. Our service is built around a Kodak Prinergy Powerpack workflow delivering specialized packaging pre-press tools which are scaled to grow as we grow. This system allows for full automation including rules based automated production. It is integrated with the Kodak Insite pre-press portal system alongside a Kodak Matchprint inkjet proofing system for accurate color management. We also use the Kodak Approval NX digital color imaging system. This supports the specification requirements of leading design agencies and brand owners. With these tools there are huge benefits in quality, consistency, accuracy and time efficiency. 

‘Our investment in Kodak’s Flexcel NX plate processing system is allowing us to be a genuine competitor to the gravure and litho process. We are recognizing significant efficiencies with this process and the print quality from the Kodak Flexcel NX digital flexographic plate is outstanding. On a global scale once a concept has been produced the technology allows for consistency across all media. Our mission is to drive the advantages and offer cost savings and transparency to our clients and their printers worldwide.’ 

A key aspect of the Kodak Flexcel NX digital flexographic system occurs during the lamination, which ensures close contact between the layer and the plate, eliminating any oxygen. This results in a stable flat-topped dot, which is much sharper and cleaner on the plate. Trevor Lowes continued: ‘In 25 years of working with flexo we both believe that this is a true revolution in flexo technology which will soon become a recognized standard competing with litho and gravure. 

‘We are achieving an astonishing 240 screen ruling. Along with smooth vignettes, extended color gamut and sharper images, the Kodak Flexcel NX plate is producing photographic quality on flexible and rigid substrates. This offers our customers a brand that stands out from the crowd and a unique opportunity to introduce higher quality work into their portfolios. It gives us the ability to explore new business opportunities.’   

Reproflex3 is planning to expand in 2011 to new premises on an adjacent site. The company believes the timing is right for growth within the packaging market and that it the platform to take advantage of the opportunities. Andrew Hewitson concluded: ‘We truly believe with Kodak’s Flexcel NX system we can offer our clients a world class solution. This technology is the future and we will be developing it further to give our customer base unique products and the differential to build their businesses. After 15 years we have reached a milestone and our vision is becoming a reality. With Kodak behind us we are ready to move onto the next phase.’ 

Norprint has recently signed a three year ‘in-plant’ reprographics contract with Reproflex 3. Paul Johnson, divisional director for Norprint, said: ‘We selected Reproflex 3 Ltd as they have their finger on the pulse when it comes to pre-press technology. Their internal processes coupled with leading-edge software from suppliers such as Kodak means that there are many benefits for our customers. We run a 24/7 operation and sending jobs to print as quickly as possible with maximum accuracy is paramount. With the Reproflex 3 pre-press solution from Kodak, technical information relating to the job is held on the system, delivering Rules Based Automation. This means files are verified and delivered immediately to the platemaking function in a CTP environment. Repeat ordering is faster and a completely painless process. Regarding the Kodak Flexcel NX digital flexographic system, we are using this in high quality labeling applications and we are very impressed with the sharpness and detail that the NX technology brings – it is a truly comparable printing process.’ 

Norprint, part of Magnadata Group, has headquarters in Boston, Lincolnshire, UK. It has revenues of over GBP £20 million per year and employs over 125 people throughout the UK. The company produces over seven billion labels per year, from blank labels to high quality primary packaging labels. 

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