Roto France Impression reaps the benefits of using Kodak Sonora Process Free Plates

Founded in 1972, Roto France has a strong tradition in web offset production, operating three heatset web offset presses capable of printing up to 80 pages per cylinder revolution. Since 2020, the printer’s capabilities have been enhanced with a convertible 9-color sheetfed press in B1 format, complete with a varnishing unit for printing covers and very short runs. This impressive printing capacity processes approximately 32,000 tons of paper annually. To ensure reliable performance of the presses and minimize costly downtimes, the printer’s prepress department has to work efficiently to provide a consistent supply of printing plates to the pressrooms.

Kodak CTP technology is essential

Roto France has relied on thermal CTP technology and offset printing plates from Kodak for over 25 years. Today, three large-format Kodak Magnus VLF Platesetters are in operation. Each platesetter is automatically supplied with plates by a Multi Cassette Unit (MCU), which holds up to 300 plates in four cassettes. The platemaking department produces around 1,000 plates every week in sizes between 8-up and 40-up.

Sylvain Roux praises the consistent stability and uniformity of the CTP imaging results, which he attributes to the high-quality Kodak Squarespot Imaging Technology with its precise dot reproduction and accurate registration. “Imaging accuracy is critical for consistent, repeatable high print quality and a wide color gamut, and that’s exactly what Squarespot Technology offers us,” he emphasizes. “Our Magnus VLF Platesetters do not require daily checking or linearization; it is sufficient to do this once a year. This is an enormous efficiency gain and ensures the print quality of our sophisticated weekly and luxury magazine editions.”

As a responsible printing company committed to protecting nature and the environment, Roto France has held Imprim’Vert certification since 2007 and PEFC certification since 2009. The company has consistently aimed to lead in the adoption of sustainable, resource-efficient technologies while minimizing its environmental impact. Roto France prioritizes waste separation and recycling, utilizes heat recovery systems, and has implemented various initiatives to reduce energy consumption. “To further improve our sustainability, for example, we use vegetable oil-based inks and have switched from UV-curing varnishes to water-based acrylic varnishes in cooperation with our customers. In addition, we now use Kodak Sonora Process Free Plates on all our presses, which means we have eliminated plate processing with its consumption of water, electricity, and chemicals,” explains Sylvain Roux.

Printing with Sonora Plates: a highly valuable sustainability asset

In 2022, after a test and validation phase on the sheetfed press and a 16-page web offset press, the larger-format web presses were also converted to Sonora Process Free Plates, making it possible to print runs of up to 450,000 impressions without changing plates.

“The benefits were immediately apparent as we shut down the plate processors,” says Sylvain Roux. “We experienced direct savings on water and electricity. We eliminated processing chemicals, maintenance and cleaning of the plate processors, which previously took up to half a day per week per machine. We also no longer needed Quick Bake ovens, freeing up space around the CTPs. Our platemaking process was significantly streamlined, and our prepress staff enjoyed a more comfortable working environment.”

The fact that Kodak manufactures Sonora Plates in Europe and delivers them over relatively short distances is crucial for Roto France, ensuring availability, reliability of supply, and sustainability. “We thank Kodak for their support over the past five years in our ambitious and high-quality transition to 100% Sonora Plates. This commitment helps us minimize our environmental impact, which is very important to our discerning customers,” concludes Sylvain Roux.