What is flexographic printing

Flexographic printing is a versatile printing technique that uses flexible relief plates and fast-drying inks. This method enables printing on a wide range of substrates. Flexo printing is particularly widespread in the production of packaging, labels and various products requiring exceptional quality, durability and adaptability. 

This article will give you a better understanding of how flexographic printing works, its advantages and its field of application. You'll also see how to choose your flexographic printing partner based on your needs, as well as strategies for maximising efficiency.

History and evolution of flexographic printing

Origins of flexographic printing

The origins of flexographic printing date back to the 1890s, with the invention of the first flexographic press by Bibby, Baron and Sons in England. In the early 1900s, other presses using this type of plate printing appeared in Europe. In 1951, the process was renamed “flexographic printing”, inspired by the flexibility of the plates in their field of action.

Modern advances in flexographic printing

The 1970s marked a major technological advance with the introduction of photopolymer plates, increasing production speed. Digital technology in the 1990s revolutionised flexographic printing, enabling better print quality and less waste. 
The 21st century marks a turning point for flexographic printing, which is committed to environmental sustainability, through the use of water-based and biodegradable inks, solvent-free printing processes, recyclable materials and energy-efficient machinery.

The flexographic printing process

How flexographic printing works

Flexographic printing is comparable to using a rubber stamp. The process begins with the use of a photopolymer plate, attached to synchronously rotating impression cylinders. This plate receives ink from an anilox roller intricately engraved with thousands of tiny cells designed to retain and transfer a precise amount of ink onto the flexible printing plate. The printing substrate is then fed into the press via another cylinder, called the impression cylinder, which exerts pressure to ensure constant contact between the flexographic plate and the substrate. 

Materials and inks used

The flexographic method can be applied to a wide range of materials or substrates, while inks differ according to the printing media. 
Paper and cardboard can be used for a wide range of products, from labels to cardboard packaging. Depending on ink quality and absorption, paper can be coated or uncoated.
Plastic, known for its durability and flexibility, is used for packaging and other printing. It often requires specific inks and plates for effective printing. 
Metal films are composed of a metallic layer and are used for decorative and functional purposes, including labels and security devices.

Steps in the flexographic printing process

The flexographic printing process takes place in three main stages: prepress, inking and printing, and postpress.

Pre-press: this involves designing the artwork using software and preparing the flexographic plates. Once the design is ready, it is transferred to the plates using a direct digital system. The plates are then cut, mounted and aligned on plate cylinders.

Inking and printing: ink is delivered from the ink fountain to the anilox rollers by a metering system, and a doctor blade is then used on the rollers to remove excess ink. Anilox rollers then transfer the ink to the flexo plates. The plates then deposit the ink on the final substrates. 

Post-press: finishing touches and enhanced quality control are applied to the finished product. Printed substrates are dried, then cut, folded, laminated, varnished or embossed as required. Finished products are checked for defects or errors before being packed, shipped or stored.

Advantages of flexographic printing

Printing on a variety of substrates

The versatility of flexo printing makes it ideal for a wide range of products requiring various types of substrates (food packaging, newspapers, books, bags, plastic and metal films, etc.). Flexographic printing can meet a wide variety of demands, since it adapts to substrates of different shapes, sizes, thicknesses, and textures.

High-speed production and efficiency

Flexographic printing is renowned for its production speed and efficiency. The use of fast-drying inks, including solvent-based, water-based or UV-cured, significantly reduces production time. The print web is in constant contact with the substrate, enabling fast, efficient production and reducing waste from unnecessary prints.

Profitability

Particularly advantageous for large print runs, flexographic printing is renowned for its cost-effectiveness. Printing plates are durable and reusable, reducing the frequency of replacements. The process also finishes, laminates and varnishes, for example, and minimises the need for external service providers and machinery.

Environmental benefits

Flexographic printing is environmentally friendly, using sustainable inks and materials as well as eco-friendly practices. The solvent-free inks used, for example, offer superior adhesion and resistance to abrasion, chemicals and humidity, reducing the need for additional treatments. The use of recyclable materials such as paper, plastic and metal also reduces the environmental impact of the process.

Scope of flexographic printing

Packaging

Packaging, an important application for flexographic printing, plays a vital role in protecting, preserving and promoting products. Flexographic printing excels in packaging because of its ability to print on a wide range of materials and substrates. It produces high-quality packaging, with vivid colours and special effects such as metallic, holographic or fluorescent finishes. Here are just a few examples of packaging produced using flexography:

• Food packaging
• Medical and pharmaceutical packaging
• Labels with metallic finish

Labels

Labels represent another important application for flexographic printing. They convey important information such as ingredients, instructions, warnings and barcodes to consumers and the supply chain. 
The types of label produced by flexographic printing are as follows:

• Adhesive labels, available in different colours, shapes, sizes and finishes, with variable data such as barcodes and QR codes.
• Heat-shrink sleeve labels are made from a plastic film that shrinks when heated.
• Hanging labels are attached to the product by a string, thread or loop, providing information about the product and enhancing its appeal and value.

Other fields of application

Because of its flexibility, flexo printing can also be applied to other types of items, including:

• Newspapers: flexographic printing can handle low-quality paper in large quantities, printing on both sides with a variety of colours and tones.
• Wallpaper: flexographic printing can print different patterns, textures and finishes.

Choosing the right partner for flexographic printing

Points to consider

Technology: opt for a flexographic printing company with advanced prepress softwareand  equipment. The company you choose should offer a variety of solutions for your printing needs, delivering outstanding results, and have a solid track record.

Expertise: Look for a company with a team of seasoned professionals with extensive knowledge and experience in flexographic printing. This expertise guarantees optimum performance of the flexographic printing process. 

Customer Service: Choose a company with a customer-centric approach, committed to meeting your needs and expectations. Excellent customer service is essential to building a lasting relationship of trust with your flexographic printing partner and ensuring your satisfaction and loyalty.

Why choose Miller Graphics?

Miller Graphics is an innovative and reliable provider of pre-press solutions for packaging printing. With over 40 years' experience in the industry, Miller Graphics serves a diverse customer base across sectors including food and drink, cosmetics, chemicals, and gardening.

Conclusion

This article has provided a comprehensive overview of flexographic printing, covering its definition, functionality, benefits and applications. In addition, it has provided guidance on choosing an ideal flexographic printing partner, highlighting Miller Graphics as a formidable ally in achieving your printing goals.

Flexographic printing is a fast and economical method, capable of adapting to a wide range of printing materials. The technique is renowned for its ability to produce high-quality graphics in large numbers. Its application mainly extends to packaging and labels.