Kirk Group invests in Xsys and Hybrid Software technologies

Australian reprographics expert Kirk Group has partnered with Xsys and Hybrid Software to deliver flexo plate innovation to RollsPack by leveraging a powerful combination of technologies, utilizing nyloflex plates, ThermoFlexX imaging, Velvet Screening, Woodpecker surface patterns and Catena+ automated processing.

Established in 1972, Kirk Group is a reprographics company headquartered in Sydney. It supplies graphic services and image carrier technologies for packaging production and works with global brands and major printing companies across the ANZ region and Asia.

Ben Prout, group technical manager at Kirk Group, said: ‘Kirk Group has worked with RollsPack for over 20 years, so we appreciate and understand their ambitions, requirements and workflow. For this project, we also drew on the technical expertise and experience of Xsys and Hybrid Software, as well as RollsPack collaborating closely to create a customized solution that not only meets or exceeds the quality of competitors but also offers a more competitive price point.’

To meet RollsPack´s specific criteria, the team considered the combination of plate and specialized screening technologies necessary to achieve the desired outcome. They were able to leverage the versatility of the ThermoFlexX imaging system and Catena+ automated processing line to implement nyloflex NEF D, Velvet Screening and ThermoFlexX Woodpecker Nano.

The nyloflex plates with Velvet Screening and Woodpecker micro surface patterns provided by Kirk Group ticked all the boxes for RollsPack Group, meeting its demands for quality, sustainability and costs.

‘This solution offers a lot of potential. Set-up times have been reduced significantly due to precise color profiles, and longevity on the press is comparable to other major players on the market,’ said Kirk Group’s print manager Thanh Huynh. ‘There’s a marked difference in the ink laydown on surface print; it’s one of the best I’ve seen in flexibles. Even when printing colors on a white ink base layer, where we typically experience a drop in density – the results with Woodpecker are impressive. In addition, Velvet Screening holds the dots really well, ensuring that there are minimum hard edges.

‘We are dedicated to elevating the market by supplying innovations that benefit our customers and meet their sustainability goals. We successfully achieved the same high-quality print with water-based inks as with solvent-based inks. This drives a constant need to explore new avenues and Kirk Group plays a fundamental role in this endeavor. Together, we are pushing the boundaries of brilliant flexo.’

In this scenario, advanced screening technology and dedicated plate surface structures simplified the challenging task of controlling the dots and the ink behavior on press. ThermoFlexX Woodpecker and Velvet Screening proved their individual strengths to deliver a successful outcome for RollsPack. Both software technologies are open without any extra steps, meaning they can be implemented into any workflow.

Brenton King, Hybrid Software’s sales manager for Australasia, commented: ‘The beauty of Velvet is that the software doesn’t require any proprietary information or special equipment; it just slots into the existing setup. Used at any resolution or ruling, it can be imaged onto the plate of your choice on any CTP device and then processed through your existing exposure frame. In this collaboration, Kirk Group simply applied Velvet Screening and then added the Woodpecker surface patterns during imaging. It’s a very clever combination.’

On the hardware side, Kirk Group relied on ThermoFlexX technology from Xsys, including a Catena+ automated plate processing line installed at the Melbourne site in 2021.

Kirk’s chief operating officer Robert Selvaggio, said: ‘The investment in Catena+ has been a great success story for us. We were among the first in the market to realize the potential of this high-performance, one-touch technology, which tripled our capacity and elevated plate quality. We’re now in the process of installing a Catena+ line in Brisbane and a third one is already planned for Sydney.’

‘Kirk Group has been reaping the exceptional benefits of Catena+ for a few years, and we have witnessed the innovative solutions it enables, such as this special project for RollsPack Group,’ said Roy Schoettle, vice president of Xsys Asia Pacific. ‘We are delighted that this partnership has been so successful and look forward to taking the next steps with the team, as they equip all their manufacturing sites with full Catena+ lines.’