Flexographic printing, often abbreviated as flexo, is a versatile relief printing method that has become a mainstay in the packaging industry. By using flexible photopolymer plates mounted on rotating cylinders, flexo presses transfer quick‐drying inks onto a wide array of substrates. Its high speeds and ability to work with both water-based and UV-cured inks make it ideal for labels, cartons, corrugated boards, and even flexible films. Today, flexo accounts for a significant portion of global print volume due to its adaptability and cost efficiencies.Get more news about
Flexo Printing,you can vist our website!
Historical Evolution
The roots of flexo date back to the late 19th century when rubber plates and alcohol-based inks were first used for simple pattern printing. Advances in photopolymer plate technology emerged in the 1950s, replacing rubber with more durable and detail-oriented polymers. The transition from solvent-based to water-based and UV inks in the 1970s and 1980s enhanced environmental performance and ink adhesion on diverse substrates. Continuous improvements in press automation, plate imaging, and drying systems have propelled flexo into the modern era of high-fidelity, high-speed production.
The Flexo Printing Process
Flexo’s core workflow can be broken down into several critical steps:
Plate Imaging • Photopolymer plates are exposed to UV light through a film negative, creating raised relief areas.
Plate Mounting • Plates are wrapped around steel or aluminum cylinders, ensuring precise registration.
Ink Delivery • A doctor blade meters ink from an anilox roller to the raised plate surface.
Substrate Feeding • Material—paper, film, foil, or board—passes under the impression cylinder, which applies uniform pressure.
Drying and Curing • Quick-evaporation ovens or UV lamps cure inks immediately, allowing for rapid rewind or downstream converting.
By controlling pressure, ink viscosity, and substrate tension, operators achieve consistent color density and sharp detail, even at speeds exceeding 1,000 feet per minute.
Inks and Substrates
Flexo’s versatility stems from its compatibility with numerous ink types and substrates:
Water-Based Inks
Eco-friendly, low-odor, and suitable for porous papers.
UV-Cured Inks
Instant curing, high gloss, and adaptable to nonporous films.
Solvent-Based Inks
Excellent adhesion on specialty films but require emissions controls.
Common substrates include:
Corrugated board
Folding carton stock
Polyethylene and polypropylene films
Aluminum and metallized papers
Matching ink chemistry to the substrate surface energy ensures optimal wetting, adhesion, and durability in end-use environments.
Applications in Packaging and Beyond
While packaging is the most prominent application for flexo, the technology extends into other segments:
• Label Production – Pressure-sensitive and wraparound labels for consumer goods.
• Flexible Packaging – Pouches, bags, and multi-layer films for food and medical supplies.
• Wallcoverings and Decorative Prints – High-volume runs of vinyl and nonwoven materials.
• Security Printing – Banknote feature lines and tamper-evident seals.
Its ability to handle both continuous web and sheet-fed formats allows converters to serve a broad spectrum of markets with a single technology platform.
