Flexographic printing for labels and packaging has resisted economic downturns and competition from digital while becoming a higher-quality, more efficient production method. Technical improvements are carrying flexo toward still higher levels of performance.
Flexographic printing is continuing to improve as a result of various developments. These include advancements in plate technology and exposure methods, improved methods to mount plates, print unit and press design, anilox rollers, inks and curing/drying systems. There will be continuing improvements in the process as suppliers continue to innovate to win share of a market that has growth prospects.
- Improved plate materials and imaging—bring CtP in-house?
- Anilox technology, link to ink and plates to boost process color—develop maximum process color gamut to minimize press downtime
- Better press control through use of independent servo motors to improve setup
Optimize prepress workflow to boost quality and turnaround. The greatest changes in flexo printing have been in prepress where plate technology has developed with enhanced imaging as flexo computer to plate (CtP) exposure has improved the reproduction quality with a greater dynamic range and more detail particularly in highlights. Quality is improving, while the time and cost of approving artwork and producing plates is reducing.
Flexo computer-to-plate is now common, with laser ablation masks and direct exposure systems allowing fine details and text to be reproduced. In addition, there have been developments in screening in order to improve highlight and shadow details.
Anilox technology, link to ink and plates to boost process color—develop maximum process color gamut to minimize press downtime. Anilox rollers have changed significantly in recent years and are a major contributor to improvements across the process in terms of quality and consistency.minimize Replacing mechanical engraving of copper (chrome plated) and steel rollers with laser engraved ceramic surfaces transformed the consistency of flexo printing by stabilizing the ink supply. Surface materials and engraving continue to improve, with higher cell counts enabling finer detail on the plate to be reproduced. Higher cell volumes and cell configurations are helping to transfer more ink to the plate, while chambered doctor blade ink systems are becoming more widespread. There are improved cleaning systems that keep the cells open, while lighter weight anilox sleeves loaded onto mandrels are replacing the cylinders with integral shafts.
Better press control through use of independent servo motors to improve setup. Modern flexo presses are capable of fast changeovers with waste measured in meters per color printed. where digital is taking share. High quality print, increased efficiency, higher productivity and improved sustainability are the desired results to for flexography.
