Plate production for corrugated board printing
to a new level -
with automation, sustainability and consistency
XSYS is driving the transformation to a high-performance future with the next generation of flexo platemaking technologies for corrugated printing.
Traditional prepress workflows in the corrugated board sector continue to rely heavily on manual labour. This is not due to a lack of innovation, but to the size, thickness and weight of the flexo plates for pre-print liners and corrugated board, which make automation difficult. As a result, many prepress departments are more like artisan workshops than modern production facilities.
With the Catena+ complete workflow and the integration of ThermoFlexX imaging technology, XSYS offers true one-touch flexo plate production for the packaging industry. Firstly, plate handling is reduced to a minimum: The FlexTray simplifies the transfer from storage to imaging. Once the plate has been inserted into the FlexTray and snapped into place, no further manual intervention or parameter input is required. All settings are automatically synchronised between the Catena+ modules - for a consistently error-free process.
The ThermoFlexX TFxX80D platesetter protects the operator with comprehensive safety technology: automatic loading of the plate onto the drum, imaging without taping, seamless handling of partial plates using a vacuum pusher and a feed mechanism for particularly thick plates. During imaging - up to 12 m²/h - two imaging heads intelligently control the workload and skip areas that do not need to be imaged. On completion, the plate moves over a bridge directly into the Catena-E 80 UV LED exposure unit - without suction chambers or contact with the LAMS light-sensitive layer.
A robot arm then lifts the board, rotates it 90 degrees and automatically guides it through the Catena-WDLS washer, dryer, light finisher and stacking machine. Internally integrated is a punching module for pinbar assembly, a conveyor lift for the drying and light curing phases, and the pinbars return automatically to the front of the washer. Finally, high-precision, fully exposed panels are ready for further processing.
With innovations for more sustainability
Sustainability is a key manufacturing goal in the age of Industry 5.0: technological advances should always go hand in hand with ecological responsibility. XSYS is shaping this change through intelligent automation, advanced panel technologies and smart process optimisation - less waste, lower emissions and improved resource efficiency without compromising on quality.
Automation and the elimination of manual adjustment errors significantly reduce the reject rate, minimising material waste and lowering operating costs at the same time. The ProServX software module provides real-time tracking of plate and consumable usage, clear dashboards and automated reports as well as a REST API interface for MIS/ERP integration - for complete traceability and precise billing.
EcoFillX technology reduces detergent consumption by up to 30 % by automatically applying fill patterns to areas that do not need to be exposed. This process not only reduces the use of chemicals, but also extends the service life of the machines and improves the air quality in the working environment.
Leading the way with eco-optimised printing plates
In combination with the nyloflex® eco plate family, XSYS offers all-round sustainable flexo production. The digitally and solvent produced nyloflex® eco FAC plates are designed for corrugated post print, while the eco ACT plates cover a wide range of paper and cardboard substrates. According to the manufacturer, they reduce the proportion of fossil raw materials by up to 29 %, reduce the carbon footprint by 10 % and accelerate washing and drying times for further energy savings.
The outstanding performance of nyloflex® eco plates was recognised with the „2025 Sustainability Excellence Award“ from the Flexographic Technical Association (FTA), the „Excellence in Flexo Pre-Press Award“ from the Flexographic Prepress Platemakers Association (FPPA, USA) and the Gold Award for Corporate Environmental Management at the FIA UK Awards. These honours underline XSYS's pioneering role and commitment to responsible manufacturing.