What is flexographic printing?

Flexographic packaging is popular among manufacturers all over the world. Let's take a look at the most popular options using this technology.

• Doy-pack. This is a bag with a flexible bottom that allows the product to stand securely even with a light product inside. Additional options include notches for easy opening, a reusable zip lock for convenient storage of the bag contents after unpacking.
• Sachet package (three-seam package). Very popular due to the low cost of the solution. Suitable for any bulk products, including spices, as well as goods that need to be packed manually.
• Stabilo bag. A package with four sealed side faces and a three-dimensional bottom that flattens under the weight of the filling. Used for packaging coffee and other bulk products.
• Gusseted bag. A package with side folds and a back seam in the center. Also most often used for coffee.
• A package with a back seam. This is a rectangular or square package with a back seam in the center, but without side folds. It is usually used for snacks, semi-finished products, and products that require manual packaging.
• Roll packaging. A large-circulation batch that is subsequently cut into individual units at the customer's production site. The optimal solution for large and medium-sized enterprises that pack cereals, pasta, salt, sugar, cookies, and candy.

Advantages of flexo printing

• Flexographic printing can be used to decorate food packaging, as the ink does not come into contact with the food product during the packaging process since, it is located between the film layers or on top of the film.
• Universal. The method is suitable for both thin materials (foil from 5 microns, paper from 40 g/m2) and thick materials (cardboard, corrugated cardboard). This makes the scope of flexographic technologies as wide as possible.
• Economical. Thanks to the special features of the printing plates used, ink consumption is optimized. Clichés of the right size also minimize waste and reduce the cost of the order.
• Efficient. Modern equipment distributes inks evenly over the entire image plane, so the picture is of high quality.
• Modifiable. Customizable printing lines allow you to add modules for lamination, embossing, corona finishing, etc.
• Cost-effective. Flexographic printing uses flexible, run-resistant plates that are optimal for medium and large runs. Moreover, clichés that have been washed off the ink can be used for subsequent orders of the company if properly stored.

However, this method of applying an image has some drawbacks that you should know about in advance.

• Relatively high cost of small runs. Unique forms are made for printing each individual order, which makes the price of a small volume of packaging materials insufficiently profitable.
• Poor quality of transmission of the smallest fonts. This is due to the specifics of flexographic plate production.
• Image quality may vary within a batch. However, this can be prevented thanks to modern equipment, precise settings and digital control.

What is important to consider when choosing flexo printing?

Flexography, like any other packaging design technology, has its own peculiarities. It is important for the client to take them into account at the stage of approving layouts and making edits.

• Color reproduction features. To use high-quality flexographic printing, layouts that do not contain complex shades transitions and, halftones are best suited. This is due to the specifics of image application.
• Choosing fonts. It is not recommended to use serif letters and fonts with very small point size. The transmission of such fine elements may not always be of high quality. However, in the design of modern packaging, fonts of this type are rarely used.
• The nuances of brightness. Since very liquid inks are used to apply the image (the consistency is close to water), it is difficult to achieve expressive light colors. A slightly brighter result is obtained when using inks with UV curing.
• Hardness and structure of the material. When using very thin paper (about 40 g/m2), modified inks are used to ensure they do not leak through the pores of the substrate. Although flexographic technologies are suitable for sufficiently thick materials, the softness parameters are of great importance - on average, it is 30 Shore units.

Flexo printing is a modern, high-performance and environmentally friendly method of decorating flexible packaging materials. It is especially beneficial if the client plans to order a medium or large run. Rivne Flex has extensive experience in manufacturing packaging products decorated with flexographic technologies. We use the latest equipment, multi-stage printing lines, and high-quality consumables. You can order packaging for any goods (food and non-food products, household chemicals, etc.), manual packaging or automatic lines.