Flexographic printing is a technique that allows precise printing on almost any surface – from thin film, through cardboard, to flexible plastics. What does it involve and why is it becoming an increasingly popular solution in many industries? You’ll find the answers to these questions below!
What is flexographic printing?
Flexographic printing, often called flexography, is a relief printing technique in which flexible printing plates made of photopolymer materials transfer ink to various materials with not only smooth but also porous or uneven surfaces. This makes flexography perfect for substrates such as paper, film, cardboard, or plastics.
The history of flexographic printing dates back to the 19th century when the technology known as “aniline printing” was developed. At that time, this printing was mainly used for simple prints on packaging, but due to the low quality of inks, its popularity was limited. A breakthrough came in the 1930s when more advanced inks and flexible printing plates were introduced, significantly improving print quality. The development of flexographic technology accelerated thanks to the introduction of new printing materials and process automation. Currently, flexographic printing is widely used in packaging production and self-adhesive labeling elements.
Flexographic Printing Process: Technical Overview
Flexographic printing is carried out using machines equipped with cylinders responsible for applying ink, anilox, plate, and impression cylinders, through which the material is passed.
The whole process involves flexible printing plates being covered with ink, which is transferred to them using anilox rollers. These rollers precisely dose the amount of ink, allowing for an even and clear print. Then the flexo plate, which were previously prepared according to the graphic design, transfer the ink directly to the substrate.
All activities related to flexographic printing are carried out at high speed, and the ink used dries quickly. This makes it a technique that works perfectly for large-scale production.
Types of inks used in flexographic printing
Flexographic printing on packaging or other surfaces is done using various inks depending on the desired effect and the type of printed material. All of them consist of a colorant, a binding agent, and appropriate additives. They are divided into:
– Water-based inks, which are environmentally friendly and often used for printing on paper and cardboard,
– UV inks, which are characterized by quick drying and high durability, ideal for printing on film, synthetic materials, and thermal paper,
– Solvent-based inks, which are mainly used on plastics, characterized by resistance to external factors and chemicals.
What are the advantages of flexographic printing?
Flexographic printing owes its popularity to numerous advantages that characterize it. The most important of these is primarily the versatility of application. It can be used for printing not only paper but also films:
– Polypropylene OPP, CPP,
– Polyethylene LDPE, HDPE, MDPE,
– Polyester PET,
– Metallized,
– Polyamide-polyethylene.
Thanks to this, it allows for flexographic printing on packaging and labels of almost any type.
Another advantage of this technique is speed. Flexographic machines are capable of printing at high speeds. This allows for printing a large number of surfaces in a relatively short time. This, in turn, translates into another advantage that distinguishes flexographic printing – cost-effectiveness. Compared to other techniques, such as screen printing, flexography allows for obtaining a clear and, most importantly, durable effect with minimal financial outlay, even in the case of multi-meter films, on the surface of which there are no unsightly pattern connections or interruptions thanks to this technique. This makes its use much more cost-effective.
Additionally, flexographic printing is also environmentally friendly. The water-based or UV inks most commonly used in it, unlike solvent-based inks, are less toxic and contain significantly fewer volatile organic compounds harmful to the atmosphere. They also eliminate the need for chemical solvents. Moreover, modern flexographic machines, thanks to automation, precisely control the amount of ink used and minimize material losses. Thus, they effectively reduce the amount of production waste.
Flexographic printing – practical application
Flexography has a wide range of applications. It is particularly popular in the production of flexible packaging, cartons, and films. With its help, precise prints can be created on various types of materials.
Flexography is also the dominant technique in the production of self-adhesive labels for the food, cosmetic, and chemical industries. Its application allows for precise printing on self-adhesive films, used as attractively presenting and durable labels that not only convey information but also serve a marketing function, attracting consumers’ attention.
Flexography is also used in printing on cardboard packaging, such as retail product boxes, beverage packaging, food cartons, and corrugated cardboard packaging. It also works great for printing on stretch film and shrink film, which are commonly used for packaging food, beverages, cosmetics, and electronics.
In addition, flexographic printing is also used for printing on:
– Clothing and other fabric products,
– Decorative and interior finishing elements,
– Paper bags,
– Industrial tapes.
Flexographic printing is a technique that, thanks to its versatility of application, speed of producing high-quality prints, and the possibility of using environmentally friendly inks, is becoming the first choice for many companies needing labels and packaging for their products. Thanks to it, they gain them in an aesthetically presenting variant, with minimal financial outlay.
