Selecting the correct CTP screen material for plates making should not be taken lightly.
Pick the right option and your plates will produce crisper images, allowing you to turn jobs around faster and print at a cheaper cost.
Pick poorly?
You'll wind up with bad plate quality and inconsistent press output. Worst of all? You'll lose time and money.
Luckily for you,
Selecting the best CTP screen for plates making is simple once you know what sets each material apart.
In this article you'll learn:
- What CTP Screen Materials Are
- Why Material Choice Matters
- The Different Types of CTP Screen Materials Available
- Which Factors to Consider When Selecting
- How to Select Based on Print Job Requirements
- What Mistakes to Avoid
What Are CTP Screen Materials?
Computer-to-plate printing doesn't require film. Images are exposed directly onto the printing plate using CTP technology. The screen material is a coating on the plate which absorbs the image.
The plate surface will determine how the image transfers to substrate, how well the plate runs on press, and how many impressions it can make before wearing out.
You can think of it like a dry erase board. The coating on the board impacts how easily it absorbs the marker ink, how cleanly it releases it, and how many times you can rewrite on the board before the quality begins to suffer.
According to Grand View Research, the global printing plates market reached $15 billion in 2024. Plates are big business and for good reason. The better the plates, the better a print job will turn out.
When buyers compare CTP solutions, material choice should be a top consideration. Clever material choices translate to sharper dot reproduction, stronger ink adhesion, and longer run lengths.
The Different Types of CTP Screen Materials Available
CTP Screen materials fall into three categories:
Thermal coatings are currently the go-to option for most printers. Thermal CTP platforms account for almost half of all industry market share. That's because they offer incredible image resolution and press performance. The plates work by reacting to a thermal laser during exposure.
Violet sensitive plates contain a polymer coating that reacts to violet light wavelengths. During exposure, the plate is subjected to intense violet laser light. This hardens the coating and "develops" the image on the plate.
Process-less plates do not require chemical processing. After running through the CTP system, plates are sent directly to the press for printing. This plate type is growing in popularity as printers look for ways to reduce waste and increase efficiency.
Factors to Consider When Selecting
Screens materials are not created equal. Here are the four things you need to take into account.
Dot quality: Thermal plates win on this front. The smallest lasers on the market are thermal. Printers needing extremely high levels of detail should strongly consider a thermal plate.
Processing costs: Process free plates offer the lowest total cost when you account for cleanup and wastewater disposal expenses. Water chemistry also requires storage and handling procedures to keep operators safe.
Volume: How many impressions do you need to print before the job is complete? Thermal plates have the longest plate life (some offer baking options that push 100,000+ impression lifespan.) If you're printing shorter jobs, violet plates typically offer the best price/performance ratio.
Budget: Like any piece of equipment or supply, CTP Screen materials come in a range of prices. Know how much you're willing to spend per plate before starting your search.
How to Select Based on Print Job Requirements
Lets talk practical application.
If you print long-run commercial jobs, your best bet is to stick with thermal. Long run length, maximum dot control, and predictable ink-water balance make thermal plates the best choice for busy printers.
When running packaging jobs, look to either thermal or process free plates. Packaging requires plates that can withstand longer run lengths and reproduce spot on colors across thousands of impressions. Both of these material types handle these demands well, with process free plates gaining ground due to their streamlined workflow.
For short-run or digital hybrid printing tasks, violet plates will give you the best balance of cost and quality. These plates are versatile and readily available at most resellers. Just remember to calculate processing costs into your "cost per plate" when factoring affordability.
Finally, if your printing business is focused on going green, process free plates are the clear choice. There are no chemicals to clean off, and no processing steps required. The workflow is faster and kinder to the environment.
Common Mistakes to Avoid When Selecting Screen Materials
A few common pitfalls tend to trip up printers when they research CTP screen materials. Let's go over those so you can avoid them.
The most common mistake we see is getting cute with the cost per plate. Going too cheap will end up costing you more money in the long run. Scraped plates, poorly defined dots, and repeat jobs are bad for business and your bottom line.
Secondly, many printers fail to account for their laser incompatibility. Not all lasers work with all materials. If your screen material doesn't react to your lasers wavelengths/power output you'll end up with plate that are either too dark or too light.
Finally, some printers simply don't store their plates correctly. Like most things in life, CTP Plates don't like sitting in direct sunlight, next to a heater, or in extremely humid conditions. Take the time to store them properly or watch your plate life decrease dramatically.
Conclusion
Picking the right CTP screen material starts with knowing your print shop's needs inside and out. The coating you choose can impact your run length, image quality, cost per plate, and eco-friendly initiatives.
Remember:
- Understand how many impressions you'll need to run per plate
- Make sure the coating is compatible with your laser wavelength
- Calculate total cost of ownership, not just cost per plate
- Process free plates are an option if your business is seeking ways to improve their environmental footprint
- Check that the material can run on both your plate maker and press
