Flexography, or flexographic printing, is a versatile and fast printing process based on the use of flexible, relief-engraved plates, similar to a giant stamp. Unlike methods such as offset or digital printing, this technique provides solutions for a wide range of applications, including packaging, labels, and products that require flexible substrates like paper, plastic film, or cardboard. The inks used, whether water-based, solvent-based, or UV, ensure optimal quality depending on the substrate and consumer needs.
Flexographic machines, or flexo machines, are designed for high-speed production while minimizing environmental impact through modern cleaning systems. This method is especially valued for its ability to produce high-resolution prints on machines with vibrant colors and precise application, even on irregular surfaces. Widely used by flexographers, this process is ideal for large-scale production, offering competitive cost-quality ratios that meet consumer demands for diverse products. Finally, flexography continues to evolve with technological innovations, making its use even more accessible and efficient across many industrial sectors.
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Why use flexographic printing ?
Flexographic printing is a machine-based printing technique with numerous advantages, making it an essential solution for manufacturing packaging and other printed items. For more information, visit this link https://blog.millergraphics.com/what-is-flexographic-printing.
Versatility and substrate diversity
The method stands out for its ability to print on a wide range of substrates, such as paper, plastic films (PE, PP, PET), cardboard, adhesive labels, and even metallized materials, thanks to the expertise of a skilled flexographer. This flexibility allows flexo machines to provide tailored solutions to meet the varied needs of clients in sectors such as food packaging, cosmetics, and pharmaceuticals, offering outstanding resolution for diverse applications.
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Print quality and color fidelity
Using relief flexographic plates and water-based, solvent-based, or UV inks, flexography ensures sharp, precise printing, even for complex designs. The inks used ensure excellent color rendering, meeting the design and readability requirements of each product.
Speed and productivity
Modern machines offer exceptional printing speeds, reaching up to 600 meters per minute, making them ideal for high-volume production. Additionally, preparation and job changeover times are reduced due to the ease of mounting flexo plates, optimizing work cycles for greater productivity.
Environmental respect and sustainability
Flexographic printing also stands out for its low environmental impact. Water-based inks and LED or UV drying systems help reduce energy consumption and harmful emissions. Furthermore, this method generates less waste and promotes the recyclability of printed substrates, making production more sustainable with the aid of waste and emission reduction agents.
Adaptability and customization
Lastly, flexography is a flexible solution that caters to specific client needs. Whether for colored stickers, custom packaging, or applications requiring fast and efficient printing, this method adapts to the demands of consumers and businesses, all while ensuring an excellent cost-effectiveness ratio. For more information, it also offers customized solutions based on each project’s requirements.
By combining versatility, production speed, print resolution, and environmental responsibility, this method has become an essential process in the global printing and packaging industry.
The stages of flexographic printing
Flexographic printing relies on a well-structured series of steps, combining modern solutions, efficient equipment, and the work of an experienced team to produce high-resolution results. Flexographic printing allows printing on a wide variety of substrates, such as sheets, plastic films, or stickers.
Preparation of flexographic plates
The first step is to create the plates, also known as clichés, which are essential for high-performance printing. Please note that these plates, typically made of polymer or rubber, have relief areas corresponding to the parts to be printed. They are prepared by exposing a photosensitive base to a specific light and then developing the relief designs, a process often carried out by a group of specialized experts. Each printing color requires a separate plate, such as Cyan, Magenta, Yellow, or Black. These plates are then mounted onto cylinders to ensure a perfect match with the intended design.
Inking and anilox system
Once the plates are ready, the inking step begins with the use of the Anilox cylinder. This cylinder, often covered in ceramic, determines the amount of ink applied through its calibrated cells. The cylinder turns in an ink reservoir, transferring ink to the relief areas of the plates. Several types of inks are used depending on the application:
- Water-based inks: environmentally friendly, reducing the ecological footprint.
- Solvent-based inks: fast-drying and cost-effective, but with environmental implications.
- UV inks: requiring less energy and ensuring optimal performance.
A doctor blade or cleaning system removes excess ink to avoid waste and ensure sharp printing.
Printing and transfer to substrate
With the inked plates, flexographic printing begins. The substrate (sheet, film, or other material) is fed into the flexo machine. The cylinder carrying the plates presses the ink directly onto the substrate, ensuring precise transfer with uniform pressure. The printed substrates then pass through drying systems, based on UV or hot-air technologies, to permanently set the colors.
Cutting and packaging
Once printing is complete, the flexographer proceeds to a cutting stage to achieve the required dimensions or shapes. A cutting plate, equipped with specific cutting edges, is used to separate stickers or packaging from excess material, a process known as die-cutting. The printed rolls are then packaged into rolls ready to be delivered to clients or used for later purposes, with the help of a packaging agent to ensure optimal distribution.
Flexographic printing is a fast, flexible process suitable for various applications. Please note that it enables the production of high-performance packaging and stickers with a reduced environmental footprint, thanks to modern solutions, efficient cleaning systems, and optimized use of inks and machines. For more information, this method continues to offer considerable benefits across different sectors.
Common applications of flexographic printing
Thanks to its flexibility and speed, flexographic printing stands out as an ideal solution for various industrial and commercial applications. Used globally, this printing technique adapts to numerous products and substrates, guaranteeing relevant production and optimal efficiency.
Flexible packaging
One of the major uses of flexographic printing is in flexible packaging, especially popular in the food industry and consumer goods. The machine allows printing on substrates such as plastic films, pouches, or paper-based materials, offering solutions suitable for fast, large-scale production.
Food packaging, such as snack pouches or fresh product packaging, benefits from vibrant printing and resistant colors. Flexography also guarantees barrier coatings that preserve the freshness of food.
Chip bags or stand-up pouches, thanks to flexo printing, feature eye-catching graphics that attract consumers in-store. Finally, plastic film-based solutions are printed with great precision for durable and aesthetic packaging.
Product and beverage labels
Flexography excels in the production of labels for various types of products. Stickers for bottles, cans, or other containers are printed in high resolution, resistant to moisture and temperature variations. The use of water-based, solvent-based, or UV inks adjusts the characteristics according to the specific needs of each client.
Rigid packaging and cardboard
In addition to flexible packaging, flexographic printing is also widely used for rigid substrates such as corrugated cardboard. Each application meets the demands of the logistics packaging and consumer goods sectors, ensuring an optimal quality-speed ratio.
Industrial uses
In diverse fields such as pharmaceutical or cosmetic packaging manufacturing, flexography offers tailored options thanks to its ability to print vibrant colors, work quickly, and use specific hues for technical products, making it a preferred choice for any industrial group.
Thus, flexography stands out for its ability to offer diverse printing options on modern machines, adapted to various products ranging from food packaging to stickers. Thanks to the professionalism of the specialized team, the flexographer, and the dedicated production agent, this method continues to have a significant impact on global markets due to its efficiency, performance, and adaptability.
