AI and 4000 ppi resolution bring Esko CDI Quartz XPS into gravure territory

Esko has rolled out its CDI Quartz XPS ecosystem globally, combining 4,000 ppi resolution and AI-driven screening to match gravure print quality in flexographic packaging.

Closing the gap in flexible packaging

For decades, the packaging printing industry has operated under a rigid hierarchy: gravure for premium, high-volume flexible packaging, and flexography for everything else. But the technical ceiling of flexo has been rising steadily, and Esko's global deployment of the CDI Quartz XPS ecosystem in 2026 effectively shatters it. By integrating artificial intelligence with unprecedented hardware capabilities, the Belgian technology provider is giving converters a legitimate tool to match gravure quality without sacrificing the operational agility inherent to flexo.

The numbers behind the print quality

The core of this technical transformation lies in the data. The CDI Quartz XPS operates at a 4,000 ppi imaging resolution, which is nearly double the current industry standard. When paired with 2,000 lpi Q-Cells microstructures, the system fundamentally alters how ink transfers to the substrate. Esko has introduced variable highlight Q-cells (VQ) and stochastic Q-cells (SQ) to ensure unrivaled screening accuracy. On the press, this translates to sharper details, smoother gradients, and a solid-area smoothness that historically required the engraved cylinders of a gravure press.

Artificial intelligence on the converting floor

What makes this ecosystem particularly relevant for today's converting facilities is its AI-driven foundation. The Esko research team has embedded artificial intelligence to calculate thousands of imaging variations before a flexo plate is ever exposed. This predictive capability optimizes ink laydown autonomously, reducing makeready times and minimizing the trial-and-error waste that eats into profit margins. It is a shift from reactive adjustments to proactive, intelligent platemaking.

Sustainability and operational efficiency

Beyond print fidelity, the CDI Quartz XPS addresses the pressing need for sustainable production. The system is highly optimized for water-based ink workflows, a critical transition for flexible packaging converters facing strict environmental regulations. By achieving an increased density of up to 0.7 compared to non-surface structured solids, the Quartz technology allows printers to use lower volume aniloxes. The result is a verifiable reduction in ink consumption of up to 20%, proving that high-end quality and material efficiency are no longer mutually exclusive.

The integration of the XPS Crystal LED UV exposure unit is a critical component of this ecosystem. By replacing traditional mercury tubes with a UV LED array, the system provides absolutely uniform exposure through preset parameters with a single click. This consistency is paramount when dealing with 4,000 ppi resolutions. Furthermore, the XPS Crystal technology has previously achieved Dematerialization certification from GreenCircle, boasting a staggering 92% reduction in waste and up to 59% energy savings for converters. When combined with the Quartz imager, the environmental and economic benefits compound significantly.

Market availability and legacy integration

Commercially available in plate sizes 4835, 4260, and up to 5080, the combined imager and UV LED exposure unit standardizes the generation of Crystal Screens. As Eddy Fadel, general manager of Esko Digital Flexo Solutions, noted during the rollout, this top-of-the-line solution raises the bar on quality to the highest level, enabling flexo printers to achieve optimum results consistently. The transition from legacy systems to the Quartz ecosystem is designed to be seamless, maintaining compatibility with existing Esko software so converters can run legacy jobs without ripping them again.

Esko has successfully engineered a platform that not only anticipates the future of intelligent platemaking but delivers immediate, tangible ROI through ink savings and reduced waste. Will the widespread adoption of 4,000 ppi AI-driven flexo finally render gravure obsolete in the short-to-medium run flexible packaging market? Follow The Paper for daily news, market signals and key updates from the global paper, corrugated and packaging industry. — Sigue toda la actualidad del sector en www.thepaper.ai