Flexographic Printing (Flexo Print)

Flexographic printing, commonly known as Flexo, is a versatile and widely used method in the packaging industry. It involves using flexible relief plates, typically made of rubber or photopolymer, to transfer ink onto various substrates, including paper, plastic, metallic films, and cellophane. The process starts with creating a master plate that has the desired image or text in relief. Ink is then applied to the raised areas of the plate, which is subsequently pressed against the substrate to create the print.

Flexo stands out for its ability to print on a wide range of materials, including non-porous surfaces, making it ideal for packaging. Compared to Litho and Digital printing, Flexo is known for its high-speed production capabilities and cost-effectiveness for large runs. Its quick-drying inks, often water-based, contribute to faster turnaround times. Flexo is particularly advantageous for printing continuous patterns, such as those used in packaging films and labels.

What Is Flexo Printing Commonly Used For?

Flexo printing is a versatile and efficient printing method, commonly used for a variety of packaging and labelling applications:

• Flexible Stand-Up Pouches: Ideal for food and beverage products, Flexo printing provides high-quality, durable prints on flexible packaging materials.

• Labels: Frequently used for product labels, Flexo printing ensures sharp images and text on various label materials, including paper and synthetic substrates.

• Mailing Bags: Used for printing on mailing bags, Flexo offers quick and cost-effective solutions for shipping and logistics companies.

• Corrugated Boxes: Perfect for printing on corrugated cardboard, Flexo delivers consistent and high-quality prints for shipping and retail packaging.

These applications highlight Flexo Printing’s ability to handle diverse materials and produce high-quality results.

Flexographic Printing: Pros and Cons

Benefits:

• High-speed production, ideal for large print runs: Ensures large quantities are printed quickly, meeting tight deadlines and reducing lead times.

• Capable of printing on a wide range of substrates: Versatile for various materials like paper, plastic, metallic films, and cellophane, catering to diverse packaging needs.

• Cost-effective for long runs: Initial setup costs are spread over large volumes, reducing per-unit cost, ideal for bulk printing.

• Uses quick-drying inks, often water-based: Speeds up production and supports environmental sustainability with reduced volatile organic compounds (VOCs).

• Efficient for continuous patterns and large areas of solid colour: Provides consistent, high-quality results for packaging films and labels with seamless designs.

• Eco-friendly ink options available: Offers sustainable inks like water-based or UV-curable options, reducing environmental impact.

Drawbacks

• Initial setup costs can be high: Custom plate creation is expensive, posing a barrier for small print runs or limited budgets.

• Less suitable for very detailed or high-resolution prints: Limited in achieving fine details compared to digital printing.

• Colour consistency can be challenging to maintain: Requires careful monitoring to avoid variations in ink viscosity, substrate, and speed.

• Limited flexibility for last-minute design changes: Time-consuming and costly to make changes once plates are created.

• Plate creation time can be lengthy: Delays the start of the printing process, impacting quick turnaround times.

• Requires skilled operators for optimal results: Skilled operators are essential to manage the equipment and materials effectively, necessitating training and experience.

Digital Printing

Digital printing is a modern method that directly transfers digital images onto various substrates using inkjet or laser printers. Unlike traditional printing methods, digital printing does not require printing plates. Instead, it uses electronic files and prints directly from digital sources. This process involves the deposition of ink or toner on the substrate, which is then cured or set by heat or UV light.

Digital printing methods, including inkjet and xerography, account for approximately 15% of the total volume of print in the world. The printers you have at home typically rely on digital printing, using toners and cartridges rather than plates.

‍Inkjet Printing: Inkjet printers produce images by propelling diminutive drops of ink out of print heads. They can print on a wide variety of substrates, such as paper, plastic, canvas, or even floor tiles. Inkjet devices are most commonly used for printing signage, posters, books, and photo books. A significant benefit of inkjet printing is the ability to print variable data, such as mailing addresses or coupon codes, which cannot be achieved through flexographic printing. This makes inkjet printing favourable for shorter-run projects without the need for printing plates or origination costs. Sometimes, a combination of flexographic and digital print is used depending on the project type.

‍Xerography: Xerographic printers, such as laser printers, create images by selectively applying a charge to a metal cylinder known as a drum. The electrical charge attracts toner particles, which then adhere to the medium being printed on. To ensure the toner has properly adhered to the substrate, it passes through a fuser that melts the toner into the medium. This process, originally developed by Hungarian physicist Pál Selényi in 1942, led to the development of the Xerox 914, the first commercial automatic copier.

Digital printing is highly flexible and efficient, making it ideal for short runs and custom projects. It allows for quick turnaround times and is perfect for on-demand printing. One of its significant advantages is the ability to easily make changes or updates to the design without the need for costly and time-consuming plate creation. Digital printing also supports variable data printing, enabling personalised packaging solutions.

Compared to Flexo and Litho printing, digital printing offers superior flexibility and is particularly advantageous for small to medium print runs, as well as projects requiring high levels of customisation. 

What Is Digital Printing Commonly Used For?

Digital printing is commonly used for a variety of packaging applications due to its flexibility and efficiency. Here are some typical uses:

• Flexible Stand-Up Pouches: Digital printing allows for high-quality, custom designs on flexible packaging materials, making it ideal for products that require vibrant and detailed graphics.

• Labels: Perfect for short runs and customisation, digital printing is often used for product labels, offering the ability to produce variable data printing for personalised and targeted marketing.

• Carton Board: Digital printing is used for printing on carton board, suitable for packaging in various industries including food, beverages, cosmetics, and pharmaceuticals. It ensures high-quality prints and allows for quick changes in design.

Digital Printing: Pros and Cons

Benefits:

• Quick turnaround times: Eliminates the need for plate creation, allowing faster production and delivery, ideal for on-demand printing and meeting tight deadlines.

• High level of customisation: Supports variable data printing, enabling personalised and highly customised packaging solutions, useful for targeted marketing campaigns.

• No need for plates: Reduces setup costs and allows easy design changes and updates without additional expenses.

• Eco-friendly options: Uses less waste and fewer chemicals, supporting the use of eco-friendly inks and substrates for sustainable practices.

• Ideal for short to medium runs: Cost-effective for short to medium print runs, making it excellent for small businesses and limited edition packaging.

Drawbacks:

• Higher cost per unit for large runs: More expensive per unit for large print volumes compared to traditional methods like Flexo and Litho.

• Limited substrate compatibility: Not always compatible with all types of substrates, especially some specialised materials, limiting its application range.

• Quality variation: Variations in print quality can occur, particularly for very high-resolution or colour-critical jobs.

• Slower printing speed for large volumes: Slower than traditional methods for large print volumes, affecting production efficiency for bulk orders.

• Potential for lower durability: Depending on the substrate and ink used, digital prints can sometimes be less durable than those produced by traditional methods, impacting suitability for certain packaging applications.

Sustainability Considerations

Sustainability is a critical factor in the modern packaging industry, with increasing demand for eco-friendly solutions:

To summarise: Flexo printing is known for using energy-efficient presses, though it can generate waste during setup. Litho printing involves chemical usage and waste during plate creation. Digital printing minimises waste but it can be energy-intensive. Each printing method has its own sustainability strengths and weaknesses, but ongoing technological advancements are making all three options more environmentally friendly. For instance, all inks are sustainable these days, making each method an eco-friendly choice.