How Flexo Printing Works: A guide from Keshenglong&Shinko

What is flexographic printing?

Flexo is a rotary printing technology that uses flexible relief plates to transfer ink from a plate to a substrate. Flexo is characterized by its ability to efficiently handle high volume runs while maintaining consistent output quality. What are the features that make it so effective, and how does it work? Let's break it down.

How does flexographic printing work?

Activating high-quality prints requires a precise combination of precision engineering and advanced materials within the flexo printing process. The following is a step-by-step breakdown of how this process works:

• Pre-press preparation

Design creation precedes printing, where designers break down the design into discrete color elements. The color reproduction process relies heavily on this step for accurate results. The design leads to the production of flexible printing plates, typically using rubber or photopolymer materials. The flexographic printing process relies on these plates to transport images during the printing process.

• Plate mounting

The prepared plates are mounted on the printing cylinders. The elastic nature of the plates allows them to conform to the shape of the cylinder, ensuring proper contact with the substrate. Printing equipment requires proper plate mounting to ensure consistency of print throughout mass production.

• Inking

The flexo press uses a special inking system. The screen roller acts as a cylinder containing tiny engraved cells that distribute specific amounts of ink from the ink fountain to the printing plate. Uniform ink distribution depends on the anilox roller to achieve high-quality prints.

• Printing

The press transports substrates (paper, plastic, and film materials) through which the inked plates apply images. The flexible structure of the plates allows them to work with different surface types, making flexographic printing suitable for different flexo substrates such as corrugated board, labels, and flexible packaging.

• Drying and finishing

The substrate completes the drying process to solidify the ink after printing. The production process continues with optional finishing steps, including laminating, cutting, and folding based on product specifications.

Advantages of flexo printing

Flexo printing is the preferred printing method for many industries because it offers several advantages. These are the main benefits of flexographic printing:

High-speed production

Flexo printing is characterized by its exceptional speed capabilities for manufacturing operations. The latest flexo presses operate at speeds of up to 2,000 feet per minute, making them suitable for industrial production requirements.

Versatile materials

The flexo printing process allows companies to print on paper together with plastics, foils, and metallic surfaces. Flexo's multi-material compatibility allows it to be used in applications ranging from food packaging to the production of industrial labels.

Environmentally friendly and cost-effective

The need for environmental sustainability has led flexographic printing to adopt water-based inks while minimizing waste. Both environmental friendliness and cost reduction are achievable with this printing method.

Flexo Printing Applications

Flexographic printing is an effective and versatile process that can be used for a wide range of applications. Below is a list of the most common applications:

Packaging Industry

Flexographic printing has become an essential solution for the packaging industry because it offers excellent printing capabilities on plastic films and flexible materials, including food and beverage packaging and pharmaceutical labels. The printing process on plastic film materials becomes excellent through flexographic printing technology because it allows for the development of picturesque designs.

Labels and stickers

Flexo printing technology is a leading method of producing high-quality labels and stickers. The flexographic printing process provides both retail and industrial applications with durable prints of exceptional sharpness.

Other uses

In addition to labels, flexographic printing can be used to produce packaging, wallpaper, newspapers, and corrugated boxes. The printing process can work with a variety of surfaces and materials, making it suitable for a wide range of businesses.

Future trends in flexo printing

The flexo printing industry is constantly evolving, with new technologies and trends shaping its future, and there are several important trends to watch:

Technological advances

The flexo process is seeing improvements with digital platemaking and advanced ink formulations that increase operational efficiency and print accuracy. The key role of automation is to bring together faster production runs and reduce the need for manual labor.

Sustainability in flexo printing

The industry is changing its practices in response to growing environmental concerns. Standard practices for the flexo printing process now include biodegradable inks and environmentally friendly flexo presses, as well as waste reduction for sustainability.

Conclusion

The packaging and label industries rely on Flexo printing for its versatility in modern printing applications. Companies around the world choose this technology because of the flexibility of the flexo printing process along with its extensive material handling capabilities. The flexographic printing process allows companies to maximize their production capacity while exploring various potential applications.

Keshenglong&Shinko provides customers with state-of-the-art flexographic printing equipment and solutions. Our company applies industry experience to deliver customized solutions that help customers achieve their production goals. Contact us to learn more about our products and services.