Types of flexographic printing presses: A complete guide

What is flexographic printing?

Today's flexographic printing technology, based on relief plates and fast-drying inks, allows images to be transferred to a wide range of substrates using a modern printing process. Flexo printing is characterized by its high speed, efficiency, and versatility, making it indispensable in the packaging, publishing, and labeling industries.

Definition of flexographic printing

The basic operation of flexographic presses relies on a rotary printing process that applies ink to raised images on flexible plates to transfer designs onto substrates. The process delivers exceptional results in high-volume production because it works with both absorbent and non-absorbent materials. The combination of water-based, solvent-based, and UV-curable inks makes it an environmentally friendly choice for many organizations.

Common flexo applications

The applications for flexo printing are many and varied. Manufacturers prefer Flexo as their first choice for printing both food packaging and beverage labels, as well as corrugated boxes and flexible films. Flexo printing materials such as paper, plastic, and metal foils are essential because of their ability to work with these materials for industrial applications that require durable and high-quality print output. Within the packaging industry, flexo printing delivers colorful visual results together with accurate shapes for all surfaces, including uneven ones.

The 3 main types of flexographic printing presses

The three main configurations of flexo presses are stack, central impression (CI), and in-line. The different types of flexo presses operate with different configurations that offer specific advantages for certain applications. Let's look at the details.

Batch flexo press

Among all flexographic presses, the most common configuration is the stacked flexographic press. The printing units of this configuration are arranged in a vertical stack, with units positioned on top of each other. Each unit in this configuration is easily accessible, making the press ideal for short production cycles and quick set-up changes.
The stacked press demonstrates exceptional performance when used to print on flexible materials such as plastic film and paper. Accurate registration is a challenge, especially when printing on elastic materials. Their affordability and ease of use make the stack press a preferred choice for small to medium-sized businesses.

Central Impression (CI) flexo press

The central impression flexo press, also known as a CI press, has a large central impression cylinder surrounding several printing units. This unique configuration provides precise registration control, making it the first choice for printing flexible products, including films and foils.
The CI press operates at high speeds and delivers consistent print quality, making it ideal for producing long runs of products. The high initial cost and larger footprint of these presses are offset by their precise operation and technical efficiency, which attracts many industrial manufacturers.

In-line flexo press

The printing units of in-line flexo presses are arranged horizontally in a single straight line. With the printing units arranged in a straight line, this configuration is ideal for printing on rigid materials such as corrugated board and cardboard. The in-line configuration allows easy integration of additional production steps such as die-cutting and laminating, making it suitable for complex printing operations.
In the packaging sector, in-line presses are often used to produce high-quality prints on large, bulky materials. Large and complex in-line printing systems struggle to achieve maximum efficiency on short production runs or with smaller operations.

Key factors to consider when choosing a flexo press

Selecting a suitable flexo press requires evaluation of four key elements: material type, print quality standards, production output requirements, and financial resources. The following sections examine important factors when selecting a flexo press.

Material Type

The choice of flexo press depends very much on the specific material you are printing on. A central impression press should be the first choice when working with flexible films, as it offers better registration control. For corrugated printing, an in-line press is the most appropriate solution.

Print quality requirements

The print quality levels of flexo presses differ according to their specifications. A CI press is the best choice for projects that require accurate color reproduction. A stack press is for applications that do not require exacting standards.

Production volume

Production volume determines the choice of press. Production volumes determine whether high-speed CI presses or stack presses should be used, as stack presses are best suited to small production runs. In-line presses operate at medium to high production levels because they perform complex manufacturing operations.

Why flexography is a popular choice

Flexo printing is one of the top printing methods because it offers many benefits to manufacturers. Manufacturers have chosen flexo printing because of its many benefits.

Speed and efficiency

The main advantage of flexo presses is their ability to produce at high speeds while maintaining excellent print quality. Due to their speed, these machines offer optimum performance in high-volume production scenarios.

Versatility across materials

The flexographic printing process works on a variety of flexographic printing materials, including paper, plastic, and metal foil. Flexo printing is effective because it works with a wide range of substrates within packaging applications.

Environmentally friendly inks and sustainability

Flexo printing uses environmentally friendly water-based and UV-curable inks. The inks produce lower levels of volatile organic compounds (VOCs), reducing the environmental impact of the printing process.

Conclusion

Three distinct flexo printing press types exist, including stack type and central impression, as well as in-line presses. The different flexo printing press types offer distinct benefits that match particular material requirements. Your understanding of flexo printing press types for flexible films, corrugated boards, and other materials will help you choose the best option.

Keshenglong & Shinko serves as a dependable source for flexo printing machine supplies, which provide high-quality presses to fulfill individual requirements. Contact us to explore our products and services and learn how we can help you achieve excellent printing quality and efficiency.