Press release submitted on behalf of Esko.
Esko, Gent, Belgium, a global provider of integrated software and hardware solutions that accelerate the go-to-market process for packaged goods, has 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 leads 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 artifacts 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 UV-A 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 an optional integrated UV-A/UV-C 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.”
The new Esko XPS Spark 4835 will be on display at Esko World in New Orleans from June 3-5 2026, and is available for order now. It will also be presented during a special XPS Spark launch event at DuPont in Neu-Isenburg, Germany on June 17th and 18th. For more on the new XPS Spark 4835 visit www.esko.com
Additional info – benefits breakdown
The new Esko XPS Spark boasts a range of features, including:
• Homogeneous exposure – patented kaleidoscopic optics ensures that UVA light is evenly distributed across the entire plate surface, eliminating hotspots and shadows that are common with traditional bank exposure systems
• Round Top in/out and Flat Top in/out – The XPS Spark uses single-side UVA LED exposure, supporting both Round Top and Flat Top dot plates. The achieved dot shape – flat or round – is plate type dependent.
• Optional UV Finisher – The optional integrated UV finishing drawer can be added to the XPS Spark to complete the plate exposure process in a single device. It uses UVA/C light to finalize the plate after LED exposure, eliminating the need for a separate finishing unit.
• Air-cooled system – The XPS Spark uses an air-cooled UVA LED exposure system, which eliminates the need for complex water-based cooling. The inventive heat dissipation technology (patent pending) is a cornerstone for the low energy consumption and a guarantee for stable plate quality. The design simplifies installation and maintenance while keeping the system compact and cost-effective.
• Open system – The XPS Spark features a fully open exposure parameter system. While the XPS Spark doesn’t include predefined plate parameters, it supports all flexo plate vendors, who can provide optimized settings. Users can further fine-tune and adapt settings to meet specific production needs, ensuring flexibility and precision across any workflow.
About Esko
Esko is a global provider of integrated software and hardware solutions that accelerate the go-to-market process of packaged goods.
For each stakeholder in the process, Esko solutions enable them to work efficiently and deliver right-first-time packaging and marketing content on time, every time.
Our goal is to make it easier for CPG and pharma businesses to manage their packaging, labeling, regulatory and marketing content. With our packaging management platform, brand marketing and packaging teams can increase their productivity, reduce costs and save time.
For packaging and label trade shops, premedia service providers and printer converters, we digitize, automate, and connect the entire print production process with software and hardware solutions for CAD design, prepress processes and flexo platemaking.
For more information, please visit www.esko.com.
