Packaging

Esko announces worldwide commercial availability of next-generation flexo exposure system

Wednesday 03. June 2026 - Esko has today (2 June) 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 modernize plate production with solutions that combine quality, simplicity, sustainability, and operational efficiency,” said Eddy Fadel, Esko GM 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.”
 
“Addressing a critical market need”
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 analog 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 plate-making process and cutting energy consumption by up to 80% compared to conventional UV tube bank systems,” he said. “This is enabled by its fully optimized 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 minimizes heat loss,” added Pascal. “Combined with the removal of tube replacement waste, this results in a more sustainable, quieter process with no odor 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 optimize and fine-tune settings according to their individual workflows and production requirements.
 
Quality and speed meet ease of use
“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 minimize 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 color 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 program 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, Prepress 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 minimizing 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.”