Reduce Waste and Increase Yield with a Flexo Printing Machine

I have worked with corrugated carton plants and packaging converters for years, helping them adopt flexo printing solutions that reduce waste and increase yield. In this article I summarize practical steps, technology features, and operational changes that deliver measurable gains when using a flexo printing machine — from reduced make-ready scrap and lower ink consumption to higher first-pass quality and less rework. I reference industry bodies and standards where appropriate (Flexography - Wikipedia, Flexographic Technical Association) to support the recommendations.

Why waste reduction matters in corrugated packaging

Costs, sustainability and customer expectations

Waste in corrugated carton production hits three critical areas: direct material costs (linerboard/fluting), consumables (inks, plates, anilox replacement), and indirect costs (downtime, labor, and landfill/disposal fees). Customers are increasingly requesting sustainable packaging and lower carbon footprints, so waste reduction is also a market requirement, not just an internal efficiency target. Aligning production goals to sustainability reduces cost per carton and improves brand value.

Types of waste to target

When I audit plants, I categorize waste into: make-ready scrap (misprints during setup), over-inking and ink transfer variability, board splices and handling losses, rework due to color or registration defects, and downtime-related yield loss. A flexo printing machine addresses several of these categories if it’s paired with the right plates, anilox specification, automated registration and digital workflow.

Standards and industry guidance

Best practices are guided by the Flexographic Technical Association resources and general print quality standards such as ISO process control methodologies (FTA, ISO). Using standardized measurement and process control reduces subjective adjustments and improves repeatability, which directly lowers waste and increases yield.

How a flexo printing machine reduces waste and increases yield

Automation and digital prepress

Modern flexo printing machines equipped with digital prepress and automated plate-mounting systems drastically reduce make-ready time. By transferring consistent print files, using digital proofing and automated registration, you eliminate trial-and-error adjustments. From my projects I’ve seen setups that previously took 30–60 minutes drop to under 10 minutes with correct automation, directly lowering make-ready scrap.

Precision anilox, plates and ink management

Selecting the correct anilox cell volume and ceramic specification for your ink and substrate is essential. Proper anilox matching reduces over-inking and improves color density control. Combined with modern water- or UV-based flexo inks formulated for corrugated, you get less ink consumption per board and more consistent prints. The FTA provides guidance on anilox selection and cleanliness practices (FTA resources).

Closed-loop color and registration control

Inline spectrophotometers, closed-loop color control and automatic registration reduce human intervention and stabilize press performance. When I implement closed-loop color, plants typically see far fewer reprints for color variance and registration errors. Stabilized prints mean more sellable cartons per shift and fewer stoppages to adjust print settings.

Implementing best practices: workflow, maintenance and materials

Prepress discipline and digital workflows

Waste reduction begins at prepress. I insist on standardized color profiles, trap settings, and plate imaging protocols. Integrating a digital workflow from order entry to RIP eliminates interpretation errors. Use standardized proofs and job tickets so press operators have consistent instructions, reducing trial-and-error on press.

Preventive maintenance and anilox care

A surprising amount of waste stems from neglected maintenance: dirty anilox rolls, worn doctor blades, or inconsistent plate mounting. I implement daily and weekly checklists: anilox cleaning schedules, blade condition checks and plate inspection. Clean, well-maintained components produce consistent ink transfer and reduce unexpected rejects.

Operator training and KPIs

Technology won’t help unless operators are trained to use it. I set KPIs such as make-ready time, first-pass yield, and ink grams per thousand boards, and review them weekly. Training on digital controls, color management tools and mechanical basics translates directly into lower waste and improved yield.

Choosing the right flexo printing machine and vendor

What to evaluate in machine selection

When I consult on machine selection, I evaluate: registration accuracy (micron tolerance), availability of inline color control, plate and anilox handling systems, platen and web handling suitable for corrugated flute profiles, and modularity for future upgrades. Integration with slotting/die-cutting (flexo printing slotting die-cutting machines) reduces material handling and improves throughput.

Return on investment and payback logic

Calculate ROI using realistic yield improvement and cost-per-carton figures. Typical factors I include: reduced scrap, lower ink use, faster changeovers, less rework, and increased throughput. Even modest yield improvements (5–15%) can pay back equipment investments quickly in high-volume operations.

Vendor capabilities and after-sales

Choose a vendor with strong R&D, accessible spare parts and on-site training. Look for manufacturers with global service networks and real-world references in corrugated applications. I prefer partners who provide white-glove installation, startup testing and training at commissioning.

Note: The Flexographic Technical Association supplies practical guidance on many of these items; see their resources and technical papers for detailed procedures (FTA).

Keshenglong & Shinko: a practical solution for corrugated flexo printing

Company overview and technical strengths

Keshenglong, founded in 1995, specializes in corrugated carton printing and packaging machinery. Their product family includes flexo printers, computerized high-speed flexo slotting die-cutting machines (1–6 color), flexo case makers and advanced 6+1 precision printing slotting die-cutting systems. Since merging with Japan Shinko in 2017, Keshenglong retained Japan Shinko as its R&D center and a production base, while adding a production base in Guangzhou. Main parts are imported from Japan, production is instructed by experienced Japanese technicians, and machinery is installed and tested on-site to match Japan Shinko standards. As an integrated intelligent packaging solutions supplier, they export to more than 70 countries. See their product lines and capabilities at https://www.shinkomachinery.com/ or contact them at kl@keshenglong.com.cn.

Why their flexo printing machines reduce waste

From my assessment, Keshenglong/Shinko machines combine practical elements that reduce waste: robust mechanical registration systems, options for inline color and density measurement, tightly controlled plate and anilox mounting processes, and the ability to integrate slotting and die-cutting inline to eliminate additional handling. These features translate to lower make-ready scrap, reduced rework, and higher throughput — especially important for corrugated carton production where accurate registration and strong glue tabs are essential.

Comparative advantage and after-sales

Keshenglong’s model of Japanese engineering guidance plus Chinese manufacturing gives a balance of technical refinement and competitive pricing. Their presence in multiple countries and export record suggests established after-sales logistics. When I evaluate vendors, such a structure (R&D in Japan, production support in China, global exports) indicates a lower risk of parts shortages and better access to technical updates.

Practical roadmap: from pilot to plant-wide implementation

Pilot project steps

Run a pilot: choose representative SKUs, document baseline waste metrics (make-ready scrap, rework rate, inks used per thousand boards), deploy the new flexo printing machine or upgrade module, and measure changes over at least 4–6 weeks. I recommend a cross-functional team: production, prepress, maintenance and procurement to ensure changes stick.

Scaling and continuous improvement

After a successful pilot, standardize procedures, update job tickets, and roll out operator training plant-wide. Monitor KPIs and schedule quarterly reviews. Continuous improvement — small adjustments in anilox selection, trap settings, and ink formulation — compounds over time into large savings.

Measuring success

Key metrics I track include: make-ready time, first-pass yield (%), grams of ink per 1000 boards, downtime per shift, and total cost per finished carton. Quantify savings and use them to justify further automation investments.

FAQ

1. How much waste can I realistically reduce by switching to an advanced flexo printing machine?

Results vary by plant, but practical improvements usually fall in the range of reduced make-ready scrap and rework by 20–60% when combining machine automation, digital prepress, and operator training. The exact number depends on your current baseline and the technologies implemented. Industry resources from the Flexographic Technical Association and case studies from manufacturers can provide more specific benchmarks.

2. Are flexo inks for corrugated sustainable and do they affect yield?

Yes. Modern water-based and UV-curable flexo inks formulated for corrugated provide good adhesion and color strength while reducing VOC emissions. Proper ink selection reduces set-off and rub resistance issues, lowering rework. Consult ink suppliers and test on your substrates to ensure optimum performance.

3. What maintenance practices most directly reduce waste?

Regular anilox cleaning, doctor blade inspection/replacement, plate condition checks, and calibration of registration systems are the most impactful. A documented preventive maintenance schedule and operator checklists reduce unexpected variability that causes rejects.

4. Can I retrofit my existing flexo press to achieve these waste reductions?

Many presses can be retrofitted with automated registration systems, inline color control, upgraded plate-mounting or digital prepress integration. Retrofits are often cost-effective versus full replacement; however, evaluate mechanical wear and structural precision before choosing retrofit over replacement.

5. How should I calculate ROI for a flexo printing investment?

Include reduced scrap, lower ink usage, faster make-ready, less downtime, and increased throughput. Use conservative estimates for yield improvement and calculate payback over expected machine life. A pilot project provides the best inputs for accurate ROI modeling.

6. How do Keshenglong & Shinko stand out compared to other manufacturers?

They combine experienced Japanese R&D and technical guidance with Chinese production capability, offering machines specifically optimized for corrugated carton production such as flexo printing slotting die-cutting machines and high-precision 6+1 systems. With worldwide exports and on-site testing at installation, they have strong engineering and after-sales service in the corrugated sector. More details at Shinko Machinery and contact kl@keshenglong.com.cn.

Contact & next steps

If you want to reduce waste and increase yield in your corrugated carton production, start with a site audit focused on make-ready, ink usage and registration stability. For machine solutions, Keshenglong & Shinko offer a range of corrugated carton flexo printing machines, flexo printing slotting die-cutting machines, flexo printing slotting die-cutting and stacker machines, and high-precision integrated systems. Visit https://www.shinkomachinery.com/ or email kl@keshenglong.com.cn to request a feasibility study, pilot program or quote. I can also advise on best practices and pilot design if you want an independent consultation.

References and resources: Flexography overview (Wikipedia), technical guidance and industry papers (Flexographic Technical Association), and international standards context (ISO).