Process-Free vs Traditional CTP Plates: Which Is Right for You?

What Are Traditional CTP Plates?

Conventional CTP (Computer-to-Plate) plates require a multi-step chemical processing workflow after exposure:

This process relies heavily on chemical developers, large volumes of water, and dedicated processing equipment like developing machines. According to industry statistics, if all CTP processes in China were calculated at approximately 2 litres of waste liquid per square metre, the annual volume of waste liquid generated would be enormous.

What Are Process-Free Plates?

Process-free plates, as the name suggests, eliminate the chemical processing step entirely. After being imaged on a CTP device, they go directly to the printing press without any intervening development, washing, or gumming. The process involves just two steps: exposure and printing — dramatically simplifying the workflow.

Most process-free plates use thermal imaging technology: the laser heat physically alters the coating in the image areas, creating an ink-receptive surface. The non-image areas are then removed on-press through physical means — with zero chemical emissions and no hazardous waste, exhaust gas, or residue.

Key Differences at a Glance

Top 3 Advantages of Process-Free Plates

1. Environmental Compliance Made Easy

Eliminate hazardous chemical waste and wastewater entirely. According to Kodak data, printers using process-free plates can save significant amounts of water annually. No more worries about local effluent discharge regulations or costly waste disposal contracts.

2. Cost Savings That Add Up

No processor to buy, maintain, or repair. No chemicals to reorder. No waste to dispose of. According to industry consulting data, a mid-size commercial printer could save around $195,000 USD over five years — by eliminating the need to invest in processing equipment, maintain it, or purchase and dispose of chemicals.

3. Consistent, Predictable Quality

By removing the variables of chemical concentration and temperature, process-free plates deliver more uniform dot reproduction from plate to plate. Additionally, process-free plates eliminate the need for processors, avoiding mechanical variables such as roller pressure fluctuations and roller wear that can affect plate quality.

Important Considerations Before Switching

While the benefits are compelling, a successful transition requires attention to a few details:

• Curve Recalibration Is a Must: Because the imaging mechanism differs, your existing colour curves will need adjustment. Work with your plate supplier or prepress team to recalibrate before full-scale production.
• Adjust Handling Habits: Process-free plates are more sensitive to fingerprints. Gloves are recommended. Also, when mounting on press, engage the dampening rollers first, then the inking rollers.
• Strict Storage Conditions: Follow the manufacturer's recommended temperature and humidity ranges — typically 10–25°C with 40%–60% humidity.
• Print Durability Meets Most Needs: Mainstream process-free plates deliver 100,000 impressions for commercial sheetfed printing and 200,000 impressions for commercial web printing. Premium products (e.g., Kodak Sonora XTRA) can achieve 250,000 impressions on sheetfed presses and 400,000 impressions on web presses.

Who Should Upgrade Now?

✅ Ideal Candidates

• Printers facing stricter environmental inspections
• New facilities that can build workflows around process-free technology
• Mid-to-large operations focused on long-term cost reduction

⏳ Who Might Wait?

• Printers with older equipment and no immediate compliance pressure
• Shops unwilling to invest time in curve recalibration and operator training

Conclusion: The Future Is Clearer — and Greener

The shift toward process-free plates is not just an environmental trend; it's a genuine business opportunity to reduce costs, simplify operations, and future-proof your print shop.

BOCICA is at the forefront of this transition. As a specialised printing plate manufacturer, we offer a full range of high-quality process-free plates. More importantly, we provide free sample testing and full technical support to help you recalibrate curves and fine-tune your workflow — ensuring a smooth, worry-free upgrade.