Esko announces worldwide availability of next generation XPS Spark 4835

Packaging Solutions

Esko has announced the worldwide commercial availability of the XPS Spark 4835, a next generation digital LED plate exposure system engineered to replace traditional UV tube bank exposure frames.

The new XPS Spark 4835 delivers consistent, repeatable plate quality, shorter exposure times, and a dramatically reduced environmental footprint – all within a compact, plug and play format tailored specifically to label converters, tradeshops, and flexible packaging producers.

‘The launch of the XPS Spark underlines our commitment to helping flexo customers modernise plate production with solutions that combine quality, simplicity, sustainability, and operational efficiency,’ said Eddy Fadel, Esko general manager flexo. ‘Thousands of flexo operations worldwide still rely on aging UV tube exposure systems that are increasingly difficult and expensive to maintain. The XPS Spark provides a future ready alternative that delivers premium exposure quality while lowering energy use and reducing waste.’

 Many conventional UV tube bank exposure systems are becoming obsolete as replacement lamps become harder to source and regulatory pressure increases around mercury containing UVA lamps under EU Directive 2011/65/EU. At the same time, degrading UV tubes knowingly lead to inconsistent exposure, variable print quality, and unpredictable production performance.

‘The XPS Spark 4835 was developed specifically to address this critical market need,’ said Eddy. ‘Positioned between conventional bank exposure systems and the Esko XPS Crystal platform, the XPS Spark is a dedicated LED exposure solution designed to make high quality flexo plate exposure more accessible.’

‘With its compact footprint, intuitive operation, and flexible exposure control, the XPS Spark makes advanced LED plate exposure accessible to a broader range of flexo users. Whether businesses are upgrading from analogue tube systems or expanding their platemaking capabilities, the XPS Spark delivers the consistency, precision, and sustainability today’s market demands, without adding unnecessary complexity.’

At the heart of the XPS Spark 4835 is patented kaleidoscopic optics technology from Esko, which ensures homogeneous UVA light distribution across the entire plate surface. This eliminates the hotspots and uneven, ‘wavy’ exposure artefacts commonly associated with tube-based (increasingly with aging tubes) and Kaleidoscope free LED systems, resulting in equal crosslinking and highly consistent print reproduction.

‘The system uses full-surface UVA LED exposure technology that delivers exposure times comparable to, or faster than, conventional bank exposure systems, without requiring warm up time,’ explained Pascal Thomas, Esko director of flexo product management.

‘The XPS Spark 4835 significantly reduces environmental impact by eliminating mercury from the platemaking process and cutting energy consumption by up to 80% compared to conventional UV tube bank systems,’ he said. ‘This is enabled by its fully optimised LED design, which removes warm up time and avoids the inefficiencies of degrading tubes, ensuring stable output with lower power use.’

‘Our patented air cooling technology eliminates the need for energy intensive chillers, while the patented, insulated plate drawer minimises heat loss,’ added Pascal. ‘Combined with the removal of tube replacement waste, this results in a more sustainable, quieter process with no odour and reduced heat generation, without compromising exposure quality or consistency.’

Designed for space constrained production environments, the XPS Spark features a compact footprint and optional integrated UVA/UVC finishing drawer that combines back exposure, main exposure, and finishing within a single unit.

The platform also features an open exposure parameter system that supports all flexo plate vendors, enabling users to optimise and fine tune settings according to their individual workflows and production requirements.

 ‘The XPS Spark 4835 has been engineered for fast installation and day one productivity,’ added Pascal. ‘A touchscreen GUI, intuitive exposure time controls, and convenient plate drawer workflow simplify operation and minimise training requirements.

‘Here at Esko we are also developing Spark Screens, a dedicated screening technology for the XPS Spark platform, designed to further enhance UV ink print quality, increase colour vibrancy, and reduce press make ready times.’

The worldwide commercial launch of the XPS Spark 4835 follows the successful completion of an extensive pre-release testing programme with customers across the globe, including in Germany, the United States, and the United Kingdom.

Meike Bamberg, pre-press (CTP), flexo and offset, Nagels Druck said the XPS Spark delivers: ‘Precise, uniform exposure, in stark contrast to the wavy exposure produced by the tube exposure unit. The benefits of even exposure are immediately apparent during printing.’

Dawn White, pre-press manager at MackayMitchell Envelope Company, USA, said: ‘The new equipment has improved both efficiency and operator ergonomics. LED exposure eliminates bulb warm up time, resulting in measurable time savings and a more streamlined platemaking process. The ergonomic drawer design reduces physical strain by minimising bending and removing the need to open and close the main exposure hood. Combined with intuitive, easy to use controls, the system is extremely user friendly and supports consistent, efficient daily operation.’