Esko has introduced Auto PlatePatcher within its Flexo Front End platform, targeting automation of plate patch creation in corrugated flexographic prepress. The solution has received the Innovation Excellence award at the FPPA Excellence in Flexo Awards.
In corrugated post-print flexo, patching is a critical step where multiple image elements are arranged onto carrier sheets or merge plates prior to exposure and mounting. This process directly influences mounting time, press readiness, registration accuracy, and plate material utilisation, yet is traditionally dependent on operator judgement.
Auto PlatePatcher replaces manual layout planning with algorithm-driven optimisation. The system analyses job parameters, mounting capacity, and production constraints to generate patch configurations aligned with real-time operational priorities. It can increase patch density to maximise plate usage in standard runs or reduce patch count to accelerate mounting under tight deadlines.
The module supports patching at both job and individual colour separation levels while maintaining strict registration tolerances required for corrugated board printing. It also consolidates patches from the same job onto common merge plates, improving handling efficiency and reducing tracking errors during plate processing and mounting.
Integration is enabled through compatibility with existing Patch Workflow Files (PWF), allowing converters to retain established production settings. The system supports both manual and automated mounting environments and interfaces with standard cutting and mounting equipment.
By standardising patch layout decisions, the solution improves consistency, reduces operator dependency, and enhances material utilisation—addressing key efficiency and scalability challenges in high-mix corrugated production environments.