Flexographic printing, commonly known as flexo, is a fast, versatile, and cost-effective printing method used extensively in the packaging and labelling industries. From food wrappers and shipping boxes to plastic bags and bottle labels, flexo printing is behind many of the printed materials we encounter daily. What makes this method so popular is its ability to print high volumes on a wide range of substrates with consistent quality and speed. But how exactly does flexographic printing work? This article breaks down the process step-by-step and explains the key components that make flexo an essential part of modern printing.
What Is Flexographic Printing?
Flexographic printing is a rotary relief printing process that uses flexible plates, quick-drying inks, and fast-moving presses to produce high-quality prints on a variety of materials. Unlike traditional printing methods such as offset, flexo uses soft plates made from rubber or photopolymer. These flexible plates wrap around cylinders and print easily on uneven or flexible surfaces.
Printers often favour flexographic printing over offset printing for packaging applications because it offers high-speed production, operational efficiency, and versatility with non-porous materials like plastic, metallic films, and cellophane—surfaces that offset printing typically struggles to handle without special treatments. Additionally, flexo’s use of fast-drying inks and modular press configurations allows for seamless inline finishing processes like laminating and die-cutting, streamlining production in ways that offset presses usually require separate equipment or steps to achieve.
How It Work?
To understand how flexo printing works, it’s important to look at the individual steps involved in the process, as well as the machinery that drives it.
- Design and Plate Creation
The process begins with the design phase. Graphics are prepared using digital design software and then separated by colour. Each colour in the design requires a separate printing plate. These plates are typically made from photopolymer and are produced using a combination of imaging and UV exposure techniques. The final plate has raised areas that correspond to the parts of the image that will receive ink. - Mounting the Plates
Once created, the flexible printing plates are mounted onto the plate cylinders of the flexo press. These cylinders are part of a rotating press system that continuously feeds the substrate (such as film or paper) through multiple print stations, each representing one colour in the design. - Inking with Anilox Rollers
One of the most critical components in a flexographic press is the anilox roller. This engraved ceramic-coated cylinder controls how much ink is delivered to the plate. The roller contains thousands of tiny cells that hold and meter a consistent amount of ink. The ink is transferred from an ink reservoir or chamber to the anilox roller, and then to the raised portions of the plate.
The use of the anilox roller ensures precision in ink volume, which is crucial for maintaining colour consistency and print quality across a production run.
- Substrate Feeding
The substrate is usually fed through the press in roll form. As it moves through each colour station, it comes into contact with the inked plate. The flexible plate presses against the substrate, transferring the ink to the surface. This process repeats at each station for each colour until the full image is printed.
Flexo presses can accommodate a wide variety of substrates, including paper, film, foil, and corrugated board. This makes the process incredibly adaptable for different types of packaging and labelling applications.
- Drying Between Colours
Flexographic inks—often water-based, solvent-based, or UV-curable—are designed to dry quickly. After applying each ink, the press moves the substrate through a drying unit—typically using infrared, hot air, or UV lamps—before sending it to the next station. This quick drying prevents smudging and allows for immediate application of subsequent colours. - Finishing and Converting
After applying all the colours, the press may send the substrate through additional finishing processes. Many flexo presses have inline systems for laminating, die-cutting, embossing, or slitting. These finishing steps prepare the printed material for final use, such as forming it into a pouch, applying adhesive to a label, or converting it into packaging form.
Key Advantages of the Flexographic Process
- High-Speed Production: Flexo presses can operate at very high speeds, making them ideal for large-volume production.
- Material Versatility: Able to print on a broad range of substrates, including non-porous and flexible materials.
- Low Waste: Minimal setup waste and high efficiency during long runs.
- Quick Drying: Fast-drying inks allow for rapid production and finishing.
- Inline Capabilities: Many additional processes can be integrated directly into the printing line.
Challenges in Flexo Printing
Despite its many benefits, flexo printing does have challenges:
- Plate preparation can be time-consuming and expensive, making short runs less economical.
- Flexo traditionally has slightly lower resolution than offset or gravure printing. However, newer plate and anilox technologies have significantly reduced this gap.
- Keeping colours perfectly aligned at high speeds requires precise machine calibration and skilled operators.
Flexographic printing is a fast, reliable, and adaptable method widely used in the global packaging and labelling industry. Its efficiency and versatility make it a key choice for high-volume production. It can print quickly on a wide range of materials with consistent quality, making it a top choice for manufacturers. Its efficient process also helps reduce waste, adding to its appeal for high-volume production. With advances in plates, automation, and eco-friendly inks, flexo printing continues to improve. It now offers higher print quality and more sustainable options than ever before.
At Printer’s Parts and Equipment, we understand the importance of quality when it comes to print finishing. We are committed to providing our customers with reliable, high-quality materials that deliver exceptional print results. Visit our website or contact our customer service team to explore our wide range of laser toners from reputable brands. Our knowledgeable staff is ready to assist you in your printing needs.
