Chespa adds fully automated plate processing with Catena+

Polish pre-press company Chespa has increased automation in its flexo platemaking operation with ThermoFlexX Catena+ from Xsys. This end-to-end, one-touch technology has boosted efficiency, improved plate quality and minimized human errors. 

Headquarters in Chorula, Poland, Chespa comprises 18 companies in seven countries, offering a wide range of products and services for the printing industry, including reprographics, photopolymer plates and packaging management, as well as graphic inks and cutting dies. The award-winning prepress expert supplies flexo plates to printers across Europe, utilized to produce high quality flexible packaging and corrugated boxes for numerous global brands.

Chespa is a close industry partner for Xsys, supporting technology development, such as the nyloflex  FTL plate, and participating in collaborative print trials. Over the past 20 years, the two companies have worked together to drive innovation in flexo and find targeted solutions that address evolving market demands. The installation of a ThermoFlexX Catena+ line at Chespa’s in Chorula/Poland site allows the company to continue leading the way in flexo platemaking and bring higher value to its customer base. 

‘We have great faith in Xsys as a technology partner, having established a close cooperation over many years. Our latest project has been the implementation of full automation with the Catena+ plate processing line which I can safely say has established a highly efficient production process for us,’ said Marek Siekiera CEO of the Chespa Group. ‘We chose this particular solution to address a variety of challenges, such as diversity of production machines and lack of process automation, knowing it has been proven in the market under real production conditions, with great success.’ 

Unifying platemaking in a connected workflow, ThermoFlexX Catena+ includes the ThermoFlexX TFxX80 Laser, the Catena-E LED exposure unit, and Catena-WDLS washer, dryer and light-finisher, with Catena-R rotating the plates between the two. As such, Catena+ is a true hands-off technology without any operator intervention required from initial loading to the collection of the final print-ready plate at the finish. Furthermore, the system is easy and intuitive to run, with the ThermoFlexX Graphic User Interface displaying all the key parameters and information on a full HD touch-screen. 

Siekiera explained: ‘Our main objective was to increase productivity and minimize the risk of human errors made by operators at various stages of the process. This has been achieved with the Catena+ solution. The operation of the new installation has translated into higher productivity and more efficient raw material management of the photopolymer plates. In addition, the upgrade from our previous traditional system to Catena-E with UV LED exposure is delivering better image reproduction and consistent high plate quality, which allows our customers to run their presses faster with less stops needed for cleaning.’ 

To ensure a smooth transition at Chespa, the installation ran concurrently with the existing systems without disruption, as technicians efficiently completed all implementations. The Xsys team was involved from the very beginning, first by offering advice during the decision-making, then with technical support throughout installation, and finally with training of the operators as the new system came online. 

Siekiera stated: ‘An important aspect of this investment is that the Catena+ solution gives us an entire system developed by a single supplier, not a combination of different modules from various sources. The installation proceeded smoothly, and we are highly satisfied that we have made the right decision by installing fully automated plate processing with this stable and low-maintenance system. We’re already contemplating the possibility of purchasing our next Catena+ line from Xsys.’ 

Ralph Johannpeter, sales manager DACH, commented: ‘We treasure the great working partnership with Chespa because they bring a huge amount of experience to the table, and we’re honored that they have reaffirmed their trust in Xsys’ technology. As a leader in the market, they understand the high value Catena+ offers and we can already see the huge impact this innovative technology is having on the business.’