Esko unveils XPS Spark 4835 for efficient flexo plate exposure

BELGIUM – Esko has introduced the XPS Spark 4835, a compact plate exposure unit aimed at packaging converters and trade shops. 

The device integrates single-side UV LED exposure with an optional UV finishing component, all in one space-saving design. 

Launched on the first day of Labelexpo Europe 2025 in Barcelona, the unit addresses needs for precision and lower energy use in flexo platemaking.

In a statement, Esko GM flexo Eddy Fadel highlighted the focus on helping customers cut energy consumption and replace older exposure systems. 

“We are developing solutions and innovations that help our customers achieve their own sustainability objectives through reducing energy consumption and replacing bank exposures in the market,” Fadel said. 

He added that development occurred in record time, with external testing set to start later in 2025 ahead of a global release in the second half of 2026.

The XPS Spark 4835 supports both round-top and flat-top dot plates, using air-cooled UVA LED technology to simplify installation and maintenance without water-based cooling. 

Its patented kaleidoscopic optics ensure even light distribution, avoiding hotspots common in traditional systems. 

An optional integrated drawer handles UVA and UVC finishing, streamlining the process by eliminating separate units.

According to Esko director of flexo product management Pascal Thomas, the unit offers intuitive controls and flexible parameters for users upgrading from analog setups or expanding operations. 

He explained that the full LED surface accelerates exposure while improving energy efficiency and reducing costs. 

Thomas also noted the compact footprint suits space-limited environments, allowing businesses to maintain quality without compromises.

The system provides consistent plate quality that surpasses analog bank exposures, contributing to less waste from tubes and supporting broader sustainability goals in production.

It remains compatible with plates from various vendors, who supply optimized settings, while users can adjust parameters for specific workflows.

Demonstrations of the XPS Spark 4835 took place at Esko’s booth during the event from September 16 to 19 at Fira Gran Via convention center, drawing attention from industry attendees. 

Recent updates confirm ongoing interest in the unit’s potential to enhance operational efficiency in label markets.

This launch comes amid growing demand for tools that minimize environmental impact in packaging, with the XPS Spark positioned as an accessible option for mid-sized operations seeking reliable performance.

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