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Are you able to see a difference on a light table between a "good" film and the films that you measured and found to be lacking density?

You should inspect closely and compare the Black Blocks visually on a light table and on top of each other. Did the solid Black lose density and actually turn Grey? Seems you are using a Transmission Densitometer, measuring Dot Percentage. What make and model is it? Does it have an integrated...

Even if one finds all the main ingredients (some of which may well be secret), finding the exact proportions will take a lot of trial and error. And than, one will need to find the correct replenisher formula as well as rates of replenishing to compensate for oxidation as well as rates of...

Well, you may be new or just don't remember- we stick to our Old Rule: We refuse to accept/pay for products we don't like!

How about Virtualizing your old computer? I "future-proofed" all our older 32 bit Windows systems by turning them into Virtual Machines. Since then, I can easily run all our old apps anytime, under a modern 64bit windows OS. But I admit, I still keep the old boxes "just in case"...

Careful examination of the film on a light table with a strong magnifying glass/microscope is the first step to narrow down and indicate where to start an elimination process.

OK, I see... In my experience you need to rip and expose at a higher resolution to get well formed 1 mil lines. Is 4000 dpi your maximum res?

If these are thin Black marks parallel to the direction of travel, they are likely caused by the heat generated when the moving film bends and rubs against rough spots on metal surfaces, such as deflectors etc. A large sheet of 7 mil film is rather stiff and when its' emulsion rubs against metal...

And than, I printed it again - in NEGATIVE! I am making a point, RIGHT?

Why not find that Buzzer and tame it first?

Quoting an Engineer Safety doc: "Note: The laser interlock system is equipped with a buzzer. If a failure is detected in the operation of the laser interlock system, the buzzer is activated and the laser is shut off." I would try to replace the Lotem Interlock Board located in the distribution...

The CPU is typically a generic SBC (Single Board Computer). It was not manufactured by Scitex/Creo. On most of them you can find the manufacturers' name/logo and the boards' model number/code. Use these to search for an SBC on Ebay.

I am not familiar with your processors' model, seems you have a "modern" interface on which you can read messages however, the basics stay the same: You should verify if the level sensor in the developer bath is working correctly. One way of doing that is switching the wires with the Fixers'...

Thanks Ulrich, But, if Illustrator saves history inside the pdf and that info is not available to us, then such behavior is clearly counter-productive. Beyond that, why would Acrobat strip any info "silently" when a file is simply saved AS IS? BTW, I believe Acrobat doesn't strip the native...

Whenever we produce a PDF that seem abnormally large, we re-save that PDF using Acrobat (no change to any parameter). In many cases the new PDF file size diminishes significantly. I have no idea why this happens.

I am not familiar with this type of equipment but the description may hint towards a Backlash issue.

"... Actually, we expected the CMYK 4 color rendition as shown on the Pantone Bridge fan book. We keep the original designers' PMS specification just because it's much easier to find that swatch in the fan book..."

Esko FlexoPerfection is very good for that.

Since the Xante unit is a toner based printer, it is not suitable. The AB Dick DPM unit is basically an imagestter exposing polyester plates. I am not familiar with that technology, other forum members may be able to comment from real life experience. Personally, I suspect that its' not capable...

No, this type of toner based printer is not capable enough to produce the high resolution and precision required for quality reproduction of such an intricate guilloche pattern. A film imagesetter (CTF) or a CTP device is required.