What are flexographic printing in packaging?
Flexography is a printing process that uses flexible photopolymer plates to print on a variety of substrates including plastic, metallic films, cellophane, and paper.
Flexographic printers in packaging utilize flexography, a versatile printing process that employs flexible relief plates to imprint designs on a wide array of substrates, such as plastic, metallic films, cellophane, and paper. This type of printing uses only 1 layer of material to print on. For example, it would print on corrugated board (board + fluting).
This adaptability makes flexographic printing a popular choice in the packaging industry, capable of accommodating different materials and printing requirements. The technique is well-suited for high-volume runs and delivers consistent, high-quality prints, making it integral for producing visually appealing and durable packaging that meets the diverse needs of products and brands.
Flexography is generally cheaper than offset printing. However, the print quality will be poorer. It is also harder to produce some effects of tint when printed directly onto the substrate. Flexo image plates are also generally cheaper to create, and they can be reused multiple times before replacement.
To learn more about other types of printing for packaging, check out digital printing or offset printing.
Flexographic Printing Process
1. Design Preparation: Packaging designs are prepared on graphic design software and checked over to ensure they meet specifications for flexo printing such as bleeds and color separations.
2. Plate Production: Designs are prepared by exposing the plate to UV light through a film positive such that the image areas are hardened and non-image areas are soft. The final result is a flexible photopolymer plate.
3. Print Press Setup: The photopolymer plates are mounted into the flexo print press and settings are adjusted to account for the specific substrate and design.
4. Ink Preparation: Depending on if you will be using processed or spot colors, the ink will be prepared to ensure any custom colors are accurate. As flexo print inks are often water-based, they will also be checked for the appropriate viscosity.
5. Printing: During the print process, the substrate is fed through rollers where the flexible plates will transfer ink onto the final substrate. The press often has integrated drying systems that allow the ink to dry quickly.
6. Finishes: After printing, the packaging may undergo any other finishing processes such as die-cutting, folding, laminating, foil-stamping, or any other additions needed.
Why choose flexo printing?
- Versatility: Flexo printing can print on a variety of substrates, making it suitable for a variety of packaging types like labels, bags, and corrugated boxes.
- High Speed: The process is capable of high-speed production, making it ideal for large runs, which is essential for mass production in packaging.
- Economical Choice for Large Orders: While initial setup costs can be higher, flexo printing becomes cost-effective for large production runs due to its fast printing speeds and low ink usage per unit. As the flexo print uses photopolymer plates as opposed to metal plates for printing, the more efficient plate production process allows for reduced production costs.
- Better Quality Than Digital Print: Printed using a press printer, the result allows for higher image quality compared to digitally printed packaging.