Flexible Packaging Printing: Types, Benefits, and Troubleshooting Explained

Flexible packaging refers to any package or part of the packaging whose shape can be readily changed. These include include bags, pouches, liners, seals, and other such designs using manipulation. It is of great significance in areas like food and drug packaging due to its versatility and material efficiency. As of 2020, the value of the global flexible packaging industry was approximately 160.8 billion dollars and is predicted to increase due to convenience and eco-friendly practices.

Usually, manufacturers shun applying either blank or clear packing for their products because there are crucial details which has to be printed. In the US, the FDA’s Nutrition Labeling and Education Act as well as the EU’s Food Information to Consumers Regulation stipulate that food, drinks and drug products must feature several essential information such as nutritional information, expiry dates, composition and warnings. It is clear that packaging printing is not merely a preventive concern about legal liability but adds more value to packaging such as enhancing marketing strategies. It is able to grab customers’ interest, improve presence of the product on the shelf as well as depict essential product story. Whether you are a business that is engaged in packaging printing or a business with products, it is critical to know the importance of printing on flexible packaging.

Types of Printing for Flexible Packaging

Across the various types of flexible packaging, numerous printing technologies are available. With printing options ranging from flexography to lithography, you can effectively add vibrant colors, detailed text, and striking graphics to your packaging, ensuring it stands out while meeting all compliance requirements.

Flexography

Flexography, often referred to as “flexo,” is a popular choice for flexible packaging printing. Flexo printing is a relief printing technique that employs flexible photopolymer plates mounted on rotating cylinders and fast-drying inks. As the substrate passes through the press, ink is transferred from the plate onto the material, allowing for rapid production speeds.

It allows printing on a wide range of substrates from paper and plastic films to metallic and cellophane materials, even some unusual materials, making it indispensably valuable across several sectors, including food packaging, retail bags, and even industrial wrapping.

Flexo printing is not only versatile but it’s also packed with numerous benefits that make it a standout choice in the industry:

● Cost-Effectiveness: Particularly for long runs, it delivers economies of scale, reducing per-unit costs.

● High-Speed Production: Its rapid setup and swift drying inks ensure quick turnaround times.

● Improved Image Quality: Advancements such as HD flexographic printing provide crisp, vibrant, and detailed graphics that compete with traditional offset printing.

● Low Maintenance and Easy Setup: The process involves fewer steps and is more straightforward compared to other printing technologies.

Digital Printing

When quick turnaround and customization are necessary, digital flexible packaging printing comes to the rescue. Digital printing print graphics, photos, and text on the plastic film substrate directly utilizing inkjet technology. Digital press is quite handy and with just a few clicks one can have it printed on. This method is not only efficient but also creativity oriented, allowing for dynamic and variable content. Brands are able to design the packaging to suit specific marketing campaign periods or for limited periods, adapting rapidly to changing consumer demands.

The benefits of digital printing are as follows:

● Low Setup Costs: Initial costs are reduced heavily since there are no plates that are required to be made only an ink jet printer.

● Sustainability: By curtailing unnecessary waste because of the accurate usage of inks and the avoidance of carton and paper labels, it positively contributes to the cause of sustainable packaging.

● Faster Turnaround: Quick setup and job changes allow for the reduction of lead time in production processes.

● High Print Quality: As technology advances, digital printing offers vibrant colors and sharp details that compete with traditional methods.

Rotogravure Printing

Rotogravure printing is the best method of image reproduction as it is very high quality. employs engraved cylinders to transfer ink on the packaging material. The cylinders are normally made of copper and on the surface of these cylinders, there are small cells that are engraved to hold the ink. When the cylinder rotates, the ink is then transferred from the cells onto the substrate in the process.

Although it is expensive in the first place because of the cylinder preparation, gravure printing is the most effective and high-quality printing method for large and long runs, especially for industrial packaging and other high-volume industries such as food, cosmetics, and printed flexible packaging for pharmaceuticals.

The key benefits of rotogravure printing include:

● High Quality Image: It is capable of producing very good quality prints with bright and clear colors and very high resolution as compared to other printing techniques.

● High-Speed Production: Intended for long runs, rotogravure can run on a continuous basis without compromising on the quality of the prints.

● Uniform Consistency: Ensures that the final prints are of the right color and that the prints are consistent even when printing many copies at a time which is important for branding.

● Durability and Longevity: Engraved cylinders have a longer life span and can be used for several print runs hence making it cheaper for repeated work.

Lithography

Lithography is often referred to as offset printing. It is a well-established printing method that uses the concept of oil and water non-mixing to transfer images on the substrates.

This technique involves the use of flat plates to transfer the design on a rubber blanket which in turn transfers the ink on the packaging material. These plates are normally made of aluminum and are coated with a photosensitive emulsion which solidifies when exposed to light. The design is made by placing the plate in contact with a film or a digital file that produces a chemical reaction to form the printing image.

It is suitable for printing on flat materials and is observed more often in rigid packaging such as cardboard and paperboard, but advancements continue to make this option more accessible for flexible substrates. Enhanced capabilities to handle flexible materials such as lightweight films and thin plastics offer a new dimension in packaging.

Here are the main benefits of lithography:

● High Print Quality: Lithography is known for its ability to produce fine details with high accuracy and it is especially good at color reproduction.

● Customizable: Ideal for specific flexible package printing projects that require detailed, custom graphics and text, providing brands with unique packaging opportunities.

● Cost-Effectiveness for Large Runs: Once set up, it becomes highly economical for large-scale productions, similar to rotogravure.

● Versatile Color Handling: It can handle a wide range of colors, including spot colors and metallic inks.

How to Choose Printing Type for Your Flexible Packaging?

Choosing the correct printing method is not just about picking any technique; it’s about matching the method to your specific needs, ensuring optimal results. A flexible packaging printer must align with your product’s requirements, considering factors like budget, production volume, desired image quality, material and packaging design.

Factor	Considerations
Budget	Digital printing offers low setup costs, making it economical for small orders; flexography and rotogravure are more cost-effective for large volumes due to economies of scale.
Volume	Digital is ideal for short runs due to flexibility; flexography and rotogravure are optimal for long runs with consistent quality.
Quality	Rotogravure provides high image quality perfect for intricate designs, while lithography also excels in detail and color accuracy.
Material	Flexography can handle a wide range of substrates; digital printing is excellent for flexible substrates and variable content.
Design Complexity	Consider color variety, detail level, and any special effects. Rotogravure and lithography suit detailed designs, while flexography and digital allow more flexibility in customization.

The Flexible Packaging Printing Process

Design Confirmation: It is always wise to take a moment and review the client’s pre-production design and color specifications before going to production. It is necessary to ensure that there is agreement on these aspects so that avoidable errors and wastage of material are not made later on.

Material Selection and Testing: Choose the right substrates and inks depending on the needs of the client. They should be tested before the actual printing so that they will be useful as expected during the printing process.

Press Setup: Depending on the chosen type of printing, flexography, digital or other, get your equipment ready for the process. Transfer the selected substrates and inks into the press. Ensure that all the settings are in line with the requirements of the job.

Printing and Monitoring: Start the printing process while at the same time monitoring the quality of the prints. Make it a point to check the color, position, and location of the images. In case of any problems, ensure that you solve them so as to avoid compromising the quality of the products.

Post-Print Processing: Depending on the needs of the client, the final touches such as lamination or coating can be applied to increase the durability. Optimize cutting or slitting operations to match the requirements of a certain project.

Final Inspection: Conduct a final check to ascertain if the finished products are perfect and meet the client’s specifications. After that, the printed materials should be loaded into the flexible packaging making machines to complete the production process.

Troubleshooting Common Flexible Packaging Printing Problems

During the printing process, you may encounter a variety of issues that can affect the quality of flexible packaging. Primarily, these printing defects arise from three sources: inks, mechanical components, and external environmental factors.

Ink-Related Issues

Ink Adhesion Failures: Often results from using inks that aren’t suited to the substrate. Different materials require different ink formulations for optimal adhesion.

Color Mismatch: This can happen if inks are not mixed correctly or if colors haven’t been calibrated to match design specifications.

Spotty Ink Deposition: Caused by ink drying too quickly or uneven ink flow, which can occur if the inks are too viscous or applied inconsistently.

To tackle these ink-related challenges, pay close attention to the substrate you’re using. Ensure the ink formulation matches the material, and regularly calibrate colors to match customer specifications. Keep viscosity in check by adjusting drying times or incorporating modifiers to sustain a smooth flow.

Mechanical Component Issues

Streaks or Lines: These suggest that the rollers are worn out or the equipment not cleaned well, which may scratch or interfere with the substrate.

Misregistration: If the plates or the cylinders are not placed in the right manner, then the print will not be correct. This is mostly as a result of hasty preparations or knocks during the process of making the product.

Poor Impression Quality: Mostly associated with unstable pressure levels which may be attributed to failure to adjust the press for different thickness of the substrate.

In this case, the regular maintenance is your best friend. Always ensure that rollers and plates are checked and cleaned often to avoid any accumulation or wearing out. Make sure that the components are properly aligned before you begin by using alignment tools. Set the press settings to apply even pressure across the substrate, especially if there are changes in the substrate.

External Environmental Factors

Substrate Wrinkling: High humidity is a problem here as it leads to absorption of moisture by the materials and buckling.

Incomplete Ink Drying: Fluctuating temperatures in the rooms can hinder the setting of the inks.

Fish Eyes: Substrates can also be contaminated by dust from other sources or even your equipment leading to blemishes.

To address these factors, it is necessary to keep the environment constant. Maintain temperature and humidity levels at optimum levels through the use of climate control equipment. Clean not only the print area but also your equipment to remove dust, and use the right equipment to avoid damaging the equipment. These problems do not reoccur if the environment and equipment are clean and well maintained.

How to Maximize Efficiency and Quality Control for Flexible Packaging Printing?

Efficiency in printing is made possible by increasing the efficiency of each step in the process starting from the file preparation to the final print. Using precise specifications, flexible packaging printers are able to reduce time and costs to worse waste ensuring the highest standards of quality. The adoption of online inspection systems and the incorporation of modern technologies like flexo-press machines could assist in producing quality results in printed flexible packaging products. The flexibility in the response as well as in the ability to meet the changing needs of the market is provided by the regular monitoring of the complete scheme.

Conclusion

Flexible packaging printing is a very versatile and constantly developing branch of the packaging industry, which is full of potential for creativity. As it has been seen, each type of printing has its own advantages and disadvantages. It is therefore important to keep one’s technologies and skills current in order to compete in this highly competitive field. Thus, being aware of the current innovations and trends, you can provide the most suitable printing services for various types of flexible packaging requirements. This commitment to innovation and quality helps you to continue to be one of the best printing service providers, capable of satisfying emerging market needs.

Elevate Your Flexible Packaging Business with KETE

Elevate your flexible packaging business with KETE, a leader in manufacturing top-tier printing and production equipment. We offer a wide range of machines including flexographic printing machines, rotogravure presses, label printing presses, and machines for making paper bags, plastic bags, as well as paper boxes and cups. With over 80% of our team boasting more than a decade of industry experience, we deliver premier solutions that enhance your printing efficiency and quality. Choose KETE for comprehensive technical support and after-sales service, ensuring your production line stays cutting-edge and uninterrupted.