How to reduce waste and improve yield on a flexo printing machine?

1. How can automation reduce waste in flexo printing?

Automation streamlines the setup and quality control phases of flexographic printing, significantly reducing material waste. For instance, implementing automation in work preparation can decrease the time required for a 4-color print job change from 168 minutes to just 18 minutes. This efficiency minimizes the amount of material used during setup, leading to substantial cost savings.

Additionally, automation ensures consistent process parameters, such as ink viscosity and web tension, which are crucial for maintaining print quality and reducing defects. By automating these controls, printers can achieve higher first-pass yields and reduce the need for reprints, further decreasing waste.

2. How does integrating flexo printing with other systems help in waste reduction?

Integrating flexographic printing machines with downstream processes like lamination or slitting can significantly reduce waste. For example, by connecting the printing machine directly to the lamination line, the need for intermediate winding is eliminated. This integration ensures better tension control and repeat length management, resulting in a final product that meets customer specifications without excess material usage.

Such integration also streamlines the production workflow, reducing the chances of errors and defects that can lead to waste. By creating a seamless process from printing to finishing, manufacturers can enhance efficiency and product quality.

3. What role does tension control play in reducing waste?

Proper tension control is vital in flexographic printing to maintain consistent repeat lengths and prevent defects. Variations in substrate tension can lead to misregistration and image distortion, resulting in waste. Implementing automated tension control systems at various points in the printing process allows for real-time adjustments, ensuring optimal tension and reducing material waste.

Moreover, consistent tension control contributes to higher first-pass yields by minimizing defects and the need for reprints. This not only reduces waste but also improves overall production efficiency.

4. How does managing repeat length contribute to waste reduction?

Managing repeat length is crucial in flexographic printing to ensure that the printed material meets customer specifications without excess waste. Factors such as substrate tension, drying temperature, and machine stability influence repeat length. By carefully controlling these variables, printers can achieve consistent repeat lengths, reducing the need for reprints and minimizing material waste.

Additionally, maintaining consistent repeat lengths ensures that the final product is of high quality, meeting customer expectations and reducing the likelihood of returns or rejections due to defects.

5. How can contamination control improve yield and reduce waste?

Contamination, such as dust and debris, can negatively impact print quality and lead to waste. Implementing contamination control measures, such as installing sheet cleaners in the press units, can significantly reduce the amount of dust on the flexo presses. For example, after installing a sheet cleaner, one company reported a 40% reduction in dust on their flexo presses.

By maintaining a clean printing environment, manufacturers can improve print quality, reduce defects, and enhance yield, leading to less waste and higher profitability.

Conclusion: Advantages of Keshenglong & Shinko

Keshenglong and Shinko offer advanced flexographic printing solutions that incorporate automation, integration capabilities, and precise tension control to help manufacturers reduce waste and improve yield. Their equipment is designed to streamline the printing process, enhance print quality, and increase operational efficiency, providing a competitive edge in the packaging industry.

References

• Acelli Group. (2020). How to solve the problem of waste reduction in the printing process.

• PakFactory. (2025). Reducing waste in flexographic printing for dairy packaging: A practical playbook.

• Flexographic Technical Association. (2021). How today’s flexographic presses target efficiency with fewer people, less waste & continuous support.

• Weducon. (2024). Beyond recycling: Reducing production waste in packaging and printing.

• Keshenglong & Shinko. (2025). Company website.