SONORA – global solution for sustainable printing from global manufacturing

In 2026, offset printers worldwide will continue to pursue greater production efficiency, lower costs, and improved operational sustainability – not least because their customers are increasingly demanding resource-saving, energy-efficient production methods and the use of eco-friendly materials. Kodak offers a solution to this with KODAK SONORA Process Free Plates. Since launching its first commercially successful process-free plate in 2005, Kodak has achieved several significant innovation milestones, making SONORA Process Free Plates suitable for virtually all offset printing applications. Today, over 6,000 printing companies use SONORA Plates, and the adoption of these plates by sheetfed and web offset printers continues to grow around the globe. 

A whole host of advantages is fueling this trend: It enables print service providers to become more sustainable without compromising on productivity or print quality. With SONORA Plates, the consumption of electricity, water, developer, replenisher and gumming solution, and clean-out finisher associated with traditional plate processing is reduced to zero. Since there is no chemistry and no plate processor in need of cleaning and maintenance, there are also no waste chemicals or contaminated effluents to be disposed of. The use of process-free plates also eliminates flaws and variability associated with wet plate processing. This leads to faster, more reliable make-readies and no press downtime and paper waste due to processing defects. Ultimately, this means cost savings for printers in both platemaking and the pressroom. 

To meet continued global growth in demand, Kodak has implemented a regionally distributed plate manufacturing strategy. Kodak operates state-of-the-art factories in Columbus, Georgia, Osterode, Germany and Gunma, Japan. In addition to SONORA Process Free Plates, other products from Kodak's plate portfolio are manufactured at these plants to meet regional market demand. 

Fabrication in various regions of the world ensures a smooth and rapid supply of Kodak plates to printers. Moreover, the proximity of production to usage provides sustainability benefits compared with transporting plates from distant countries or continents. 

“The local manufacturing we have throughout the globe is a key differentiator for us. It allows us to be locally focused to meet the distinct needs of each region, since market requirements and regulatory provisions vary,” explained Laura Cole, VP Pricing and Product Management, Kodak. She added, “Kodak remains committed to keeping local plate production in the U.S., where we are the sole remaining manufacturer. This commitment also helps us navigate tariff-related challenges. We'll continue to expand manufacturing and do whatever we can to meet customer demand in the U.S., but also on a worldwide basis.” 

In response to a significant surge in demand for SONORA plates in the U.S., Kodak recently increased its local production capacity for process-free plates. At the Columbus plant, manufacturing SONORA Plates has been expanded to a second, re-engineered plate manufacturing line, ensuring reliable and fast delivery of high-quality process-free plates to customers across the Americas. To achieve these and other production improvements and to keep pace with the latest developments, Kodak invests millions of dollars in its manufacturing facilities every year, according to Laura Cole: “Our continuous investments enable us to produce to the highest standards to deliver top-class quality our customers expect from Kodak.” 

Sven Freyer, VP Print Manufacturing, Kodak, cites current examples of targeted investments: “We just recently made a significant investment in our Columbus plant and installed new chiller units, which enable us to cool the full facility for our SONORA Plate products, because the manufacturing process requires stable temperature conditions. Furthermore, the technical optimization of the finishing and packaging area is planned for 2026, which will benefit the efficiency and reliability of the supply chain.” 

Kodak's strategy of local plate production in various regions of the world is appreciated by customers around the globe, such as Roto France, a leading French magazine and catalog printer. The renowned web and sheetfed offset printing company has switched its entire production to SONORA Process Free Plates. Sylvain Roux, Production Manager, commented: “The fact that Kodak manufactures SONORA Plates in Europe and delivers them over relatively short distances is crucial for us, as it ensures availability, reliability of supply, and sustainability. We thank Kodak for their support over the past five years in our ambitious and high-quality transition to 100% SONORA Plates. This commitment helps us minimize our environmental impact, which is very important to our discerning customers.” 

In the U.S., where the use of SONORA Plates has increased enormously, domestic manufacturing is also highly valued. For example, Boone Newsmedia (BNI), a company that owns 91 newspapers along with websites, shopping guides and magazines in twelve states, has converted its print production to process-free with Kodak. All three BNI printing sites endorsed SONORA News Process Free Plates as an ideal, efficiency-boosting solution for their operations. According to K.O. Bennett, Production Manager, a key factor in the decision was Kodak’s status as the only remaining manufacturer of lithographic printing plates in the United States, providing BNI with confidence in a stable, domestic supply chain. 

The Japanese packaging printer Godo Co., Ltd. values the opportunity to utilize high-quality SONORA plates manufactured locally at Kodak's Gunma plant. As a full-service provider of eco-friendly, custom packaging solutions, Godo employs both conventional and LED-UV offset. The company emphasized, “Our expertise in delivering high-quality, high-value, multi-variety, small-lot, and quick-turnaround packaging has led us to adopt SONORA Process Free Plates. This move not only enhanced our environmental performance but also resulted in labor savings and cost reductions. Furthermore, the local manufacturing of the plates by Kodak ensures a reliable supply chain while minimizing carbon emissions associated with transportation – an advantage that supports our commitment to sustainability.” 

These customer examples make one thing clear: With an efficient global plate manufacturing network, Kodak ensures reliable availability and consistently high product quality from a dependable partner.