What are Flexo Presses? Learn How Flexo Printing Works
What are Flexo Presses?
The Flexographic (flexo) printing press is one of the most efficient and consistent printing tools available in the market today, suitable for all medium and long-run print applications. Flexo continues to be the most popular of all web-fed technologies used throughout the printing industry.
Understanding Flexo Printing Presses
A flexo press uses flexible photopolymer printing plates to imprint images across a wide range of surfaces, making it one of the most efficient methods for large volume requirements. Used widely for labels and packaging, flexo printing is reliable and provides consistently high-quality print results.
How Flexo Presses Work
The printing method is similar to letterpress in how it works, except that ink volume is governed by a laser engraving inking roller – called the anilox roller. The process is relatively simple in theory, using a relief image plate, mounted onto a rotating cylinder, collecting then depositing ink onto the substrate with each revolution.
Key Components of Flexo Presses
The printing plates are made from flexible polymer material and are resilient enough to withstand millions of impressions. They can even be re-used several times if stored correctly. The process can be roll-to-roll or roll-to-sheet and is capable of production speeds over 150 meters per minute, using UV cured inks and a wide range of optional in-line operations & embellishments available.
Flexo Printing Plates
Although originally made from rubber, today’s flexo plates are manufactured from photopolymer materials and are usually exposed using ‘computer to plate’ (CTP) technology. The exposed design forms a relief image on the flexo plate, which is then applied to a print cylinder and loaded into the flexo press. With each revolution of the cylinder, ink is transferred from the anilox roller onto the flexo plate and, in turn, onto the substrate. This method enables high-speed, high-quality print, with consistent repeatability.
Flexo Inks
Flexo inks need to be fast-drying and are generally water-based, solvent-based, or UV cured. The type of work, length of run, and often substrate type would determine the optimum ink type. The flexo process enables the use of different ink viscosities, allowing specialist inks to be used for applications such as security print, light-fast outdoor labeling, fluorescent & metallic effects, etc. There is also the availability of food-grade ink for food packages and environmentally friendly inks.
Substrates for Flexo Printing
A flexo press can print on porous substrates such as cardboard, paper, and fabric, and non-porous materials like plastic, cellophane, metallic, and foil. The substrate is fed into the press in roll form, from the unwind unit. The tension of the substrate is then carefully monitored and controlled, allowing multiple colours to be simultaneously printed in-line and in register with each other.
In-line Applications and Enhancements
Flexo printing is often combined in a single operation with other in-line processes, such as laminating, varnishing, metallic foil embellishment, rotary silk screen printing, digital printing, die-cutting, embossing, slitting, sheeting, etc. Additionally, chilled rollers can be used to control the substrate temperature when printing onto heat-sensitive materials.
Choosing the Right Flexo Press
When you are looking to expand your printing capacity, speak to us about the right flexo printing press for you. Expect high quality and consistency, as these two go hand in hand with all the products we offer. Consider what type of printing needs your customers have and then select a press specification that suits your requirements. Flexo remains the leading technology employed in the mass production of printed images. For cost-effectiveness and reliability, it is still unsurpassed.
Conclusion
Flexographic printing presses offer unparalleled efficiency and versatility, making them a cornerstone of the printing industry. Explore our flexo printing solutions to enhance your production capabilities today!
