Litho Vs Flexo: 5 Key Differences

When it comes to printing, there are several options available, but two of the most popular methods are lithography and flexography. Both these printing techniques are widely used in the industry and have their own set of advantages and disadvantages. 

In this article, we will explore litho vs flexo highlighting the key differences between lithography and flexography, so you can better understand which printing method is best suited for your needs. From the type of printing plates used to the level of detail each method can achieve, we will cover the top five differences between litho and flexo printing. Let’s dive in.

Litho Vs Flexo: Differences In Printing Process

Lithography and flexography are two popular printing processes used in the commercial printing industry. While they share some similarities, they differ in their printing techniques, equipment, and applications.

Range of Application

Lithography, also known as offset printing, involves printing on a flat surface using ink and a printing plate. The printing plate is typically made of aluminum and has a pattern of ink-receptive and ink-repellent areas that create the desired image. 

Flexography, on the other hand, is a rotary printing process that uses flexible printing plates made of rubber or polymer. The plates have raised images that are inked and then transferred to the printing substrate, which is typically made of flexible materials such as paper, film, or plastic. 

Flexography is known for its ability to print on a variety of surfaces, including non-porous materials such as plastics and metals. This makes it well-suited for printing on packaging materials, such as bags, boxes, and labels.

Printing Plate

A printing plate is a critical component in both lithography and flexography printing processes. In lithography, the printing plate is typically made of aluminum and coated with a photosensitive emulsion. The image is then transferred onto the plate using a laser or other light source, with the emulsion hardening in areas exposed to light. 

The plate is then washed with a chemical solution to remove the unhardened emulsion, leaving behind a raised image that is used for printing. In flexography, the printing plate is typically made of rubber or photopolymer materials. 

The plate is created by applying a photosensitive polymer to a substrate, then using a laser or other light source to harden the polymer in areas that will create the desired image. The plate is then washed with a chemical solution to remove the unhardened polymer, leaving behind a raised image that is used for printing.

Ink Applying Methods

Ink-applying methods differ between lithography and flexography printing processes. In lithography, ink is applied to the printing plate using a roller. The roller applies the ink evenly to the raised areas of the plate, while the non-printing areas repel the ink. The plate is then pressed against the substrate, transferring the ink to the paper.

In flexography, ink is applied to the printing plate using an anilox roller. The anilox roller has a pattern of tiny cells that hold a specific amount of ink. As the roller rotates, it transfers the ink to the raised areas of the printing plate. The plate is then pressed against the substrate, transferring the ink to the paper.

Litho Printing Vs Flexo: Differences in Cost 

Both methods have their own advantages and disadvantages in terms of cost. Litho printing is a more expensive process due to its intricate and lengthy process, while flexographic printing is a more cost-effective method that involves using flexible plates and fewer colors.

Flexo Vs Litho Printing: Differences in Substrates 

Flexo printing is a versatile method that can print on a variety of materials, including paper, plastic, metal, and more(Learn: What difference between inline Flexo Printing Machine and Offline Flexo Printing Machine for Paper Bag Making Machine). The flexible printing plates used in flexo printing can conform to the surface of the substrate, allowing for precise printing on uneven surfaces. 

Litho printing, on the other hand, is best suited for paper and cardboard materials. While it can print on other substrates, the results may not be as precise or long-lasting compared to flexo printing. Ultimately, the choice between flexo and litho printing for substrates depends on the specific materials and printing requirements.

Litho Vs Flexo: Differences in Inks

Lithography uses oil-based inks, which are viscous and require a longer drying time. These inks produce a rich, vibrant color, making them ideal for printing high-quality images and text. 

On the other hand, Flexography uses water-based inks, which are thinner and dry quickly, making them ideal for printing on non-porous surfaces like plastic and metal. These inks produce a more muted color, but they are durable and resistant to fading, making them ideal for printing on packaging materials. 

Overall, the choice of ink will depend on the printing requirements and substrate used for the job.

Litho Printing Vs Flexo: Differences in Image Quality

Lithography and Flexography are two printing methods that differ in the quality of the image they produce. 

Lithography is a high-resolution printing process that uses plates made from aluminum or polyester to transfer images onto paper. This method produces sharp, detailed, and high-quality images with vibrant colors, making it ideal for printing photographs, artwork, and illustrations. 

Flexography, on the other hand, is a fast and efficient printing method that is commonly used for printing on flexible packaging materials. While Flexo can produce high-quality images, they may not be as sharp and detailed as those produced by lithography due to the nature of the printing plates used in the process. 

Advantages and Disadvantages of Flexographic and Lithographic Printing 

The part of the blog makes a comparative analysis of the characteristics of the two printing methods. In this chapter, the advantages and disadvantages of the two printing methods will be summarized in order to choose.

Flexographic Printing

This part will introduce the advantages and disadvantages of Flexographic Printing respectively.

Advantages

• ● High-speed production: Flexographic printing is a high-speed printing method that can produce large volumes of prints quickly. 
• ● Versatility: Flexographic printing can be used to print on a wide variety of substrates, including paper, plastic, and metallic films. It can also print on non-flat surfaces, such as cups or bags.
• ● Cost-effective: Flexographic printing is a relatively cost-effective printing method compared to other printing methods like gravure or digital printing. It also requires less setup time and labor, making it more efficient.

Disadvantages

• ● Limited color range: Flexographic printing can only print a limited number of colors at a time, typically up to six colors. 
• ● High setup costs: Despite being cost-effective for large production runs, flexographic printing can have high setup costs, including the creation of printing plates and the cost of ink.
• ● Environmental concerns: Flexographic printing can produce significant amounts of waste, including ink and substrate waste, which can have a negative impact on the environment if not disposed of properly.

Lithographic Printing

The advantages and disadvantages of lithographic printing will be introduced in this part.

Advantages

• ● High-quality prints: Lithographic printing produces high-quality prints with sharp, crisp images and fine details. This is because the printing plates are capable of reproducing even the smallest details of the original image.
• ● Large color range: Lithographic printing can produce a wide range of colors, including special colors like metallics, fluorescents, and spot colors. This allows for greater flexibility in creating unique designs and effects.
• ● Versatility: Lithographic printing can be used to print on a variety of substrates, including paper, cardboard, plastic, and metal. It can also print on a wide range of sizes, from small business cards to large posters and billboards.

Disadvantages

• ● High setup costs: Lithographic printing requires a high initial investment in the form of printing plates, which can be expensive to create. This makes it less cost-effective for small print runs.
• ● Slow printing speed: Lithographic printing is slower compared to other printing methods, such as flexographic or digital printing. This can make it less suitable for large production runs with tight deadlines.
• ● Environmental concerns: The chemicals used in lithographic printing, such as solvents, inks, and cleaning agents, can be harmful to the environment if not disposed of properly. Additionally, the water used in the printing process needs to be treated before disposal.

How to Choose Between Flexographic Vs Lithographic

When choosing between flexographic and lithographic printing methods, there are a few factors to consider. 

Volume

First, consider the volume and complexity of your printing job. If you have a large volume of simple designs, flexographic printing may be the more cost-effective option. 

However, if you have a smaller volume or complex designs that require high-resolution printing, lithographic printing may be a better choice.

Material

Another factor to consider is the type of material you will be printing on. Flexographic printing works well on a variety of materials, including plastic, paper, and metallic films, while lithographic printing is best suited for paper-based materials.

Budgets

The best choice depends on your specific printing needs and budget. Consider consulting with a printing professional to help you make an informed decision.

KETE: Your One-Stop Solutions Supplier For Flexo Printing Machines 

At KETE, we know that flexo printing is essential for businesses looking to create stunning packaging designs that will capture their customers’ attention. That’s why we offer a comprehensive range of high-speed flexo printing machines, including stack type, ci type, and unit type, with options for both water-based and solvent-based inks.

We know that every business has unique needs when it comes to printing, which is why we offer color registers that support 2-10 colors. Whether you need simple designs or complex artwork, KETE has got you covered.

Our commitment to quality doesn’t stop with label printing machines. We also offer a range of related equipment, such as slitting machines, Rotogravure Printing Machines, and laminating machines, to ensure that your entire printing process is seamless.

At KETE, we’re passionate about providing our customers with the best flexo printing solutions on the market. Whether you’re a small business or a large corporation, we have the expertise and experience to help you achieve your printing goals.