Carminati S.r.l. has reaffirmed its strong confidence in XSYS’ plate processing technology with the installation of a second ThermoFlexX Catena Washer, Dryer, Light-Finisher, and Stacker (WDLS) in less than two years. The Italian prepress expert has worked closely with XSYS to maximize the potential of this innovative technology and deliver the highest quality flexo plates to its customers.

Operating mainly in the corrugated sector, Carminati is a leader in its field. Located in Antegnate, east of Milan in northern Italy, the progressive company makes flexographic printing plates for customers across Italy, into France and beyond. The plates are produced on two state-of-the-art lines at its 5000 sqm modern plant, where 35 staff work tirelessly to maintain the company’s well-established reputation for high quality and excellent customer support.

Doubling up with second Catena-WDLS

In 2021, Carminati decided it was time to replace one of its outdated plate processing lines with a ThermoFlexX Catena-WDLS to ensure continued growth and enhance quality even further. The new equipment was installed by XSYS Italia at the end of that year. Less than two years later, a second Catena-WDLS has been introduced to upgrade the other processing line, giving the company a total capacity uplift of over 20%.

“Our old processing equipment had served us well, but it was time to upgrade to ensure we stay ahead of the curve. Not only do we serve our customers with the best plates for printing every day, but we also have a very active R&D laboratory, allowing us to continue innovating and lead the way in flexo printing for corrugated boxes and flexible packaging,” said CEO Carlo Carminati, son Alessandro Carminati, who founded the company in 1960.

Carminati is known for its forward-looking strategy and keen interest in pushing the boundaries with the latest technology. “We successfully installed the very first Catena-WDLS in Italy not very long ago, and now we are the first in the world to have two. This impressive setup from XSYS means we are moving to Industry 4.0 level with higher automation, best-in-class quality, faster delivery, and more sustainable operation.”

Sustainable and automated technology

ThermoFlexX Catena-WDLS integrates washing, drying, light-finishing, and stacking into one smooth process. The operator simply loads the imaged plate at the start using a pinbar system and then collects the print-ready version at the other end. This high level of automation brings numerous benefits, including reduced waste, faster processing, and exceptional quality. In addition, the system is very energy efficient, helping Carminati to reach its sustainability targets. For instance, the company reports a reduction in drying time per plate of 30 minutes compared to the old system.

The Catena-WDLS is controlled by a ThermoFlexX Graphic User Interface (GUI) displayed on an HD touch-screen for rapid and straightforward operation. All key information is clearly presented, ensuring operators can navigate the system effortlessly, with minimal risk of errors. For Carminati, these aspects fit perfectly with its commitment to Industry 4.0 production where human intervention is minimized, and each process is digitalized so the production data can be analyzed.

Advanced washing method

The first Catena-WDLS was chosen after thorough consideration of the options available on the market. Offering the highest productivity, it uses unique plate alignment when loading which avoids plate skew during transport, and an incremental mode of washing where each plate progresses through the system at a constant speed.

Working closely with the XSYS Italia team, Carminati has further developed the technology, meaning the second WDLS employs a high-productivity batch mode of washing that is ideal when various plate thicknesses need to be processed. Both methods consistently guarantee sharp, clean print.

“The Catena-WDLS is the best on the market, in particular, its softer brush technology is perfect for our sensitive plates with microcell screening. For the second machine, we collaborated with XSYS to improve the productivity of the system, so it fits our special requirements exactly. This means that the loading time has been reduced and output is faster, giving us a great advantage,” explained Mr Carminati.

Collaboration for success and more growth

The other half of the equation when investing in new equipment concerns the service and support provided by the manufacturer or supplier. XSYS Italia prides itself on its close proximity to customers, which is seamlessly complemented by the remote capabilities of the Catena equipment itself.

“The collaboration between XSYS and Carminati is very positive and productive. We are extremely proud to support them in achieving the best possible quality in flexo platemaking,” stated XSYS Italia Sales Manager Roberto Malagù. “Close partnerships are essential to success and we look forward to continuing our work with Carminati, which is a trailblazer in this market.”

“The working relationship with XSYS is excellent and I cannot fault the service from the team. Their assistance is always prompt and efficient. We have also used the remote service many times and it works very well, saving a lot of time for us and out customers,” added Mr Carminati.

He summed up the company’s position, concluding, “Our Catena-WDLS duo will allow us to reach our ambitious goals and help customers achieve excellent quality, higher sustainability, and faster time to market. This project is an instrumental part of our growth strategy and we are now fully equipped to stand at the frontline and disrupt this competitive market.”