Narrow vs Wide Web Flexo Printing: Technical Comparison & Selection Guide

Preface

When you enter the field of flexographic printing, one question may come to your mind: why do printing machines take substrates of different widths? In flexo printing, the width of the substrate defines the process to be used in the printing process. Here, we concentrate on two essential types: narrow web flexo printing and wide web flexo printing.

Despite the fact that they may seem to be similar, each of them has its benefits and uses. Whether you need a quick turnaround on label production or the most suitable technology for high volume flexible packaging, it is important to distinguish between narrow and wide web flexo printing.

In this guide, we will discuss the advantages and disadvantages of both approaches to assist you in selecting the most appropriate technology. This knowledge will prove useful to anyone who is just starting in the printing industry or anyone who wants to enhance their knowledge. Well, let’s start and discover the world of flexo printing!

Flexographic Printing 101: What is Wide Web or Narrow Web?

To begin with, Before diving into the specifics, it is necessary to explain the meaning of wide web and narrow web flexo printing. Both are classified under flexographic printing, a printing technique that employs flexible printing plates to transfer ink to the substrate.

Wide Web Flexo Printing is the process that is carried out on a wider printing press which is usually 16.5 inches and above and is used in printing large rolls of paper, plastic films and other flexible materials. This is suitable for uses such as cartons, food packaging, plastic bags, and large labels. Wide Web printing is used for wide web printing for large production and large runs since it is faster than other methods of printing.

On the other hand, Narrow Web Flexo Printing is used for small web widths, below 17 inches and is mostly used on small substrates such as labels, tags, films, envelopes, paper bags and small packaging. Narrow web printing is more efficient for smaller batch runs and provides better accuracy for detailed images. This type of printing is usually applied when high quality of the print is essential, especially in such segments as labels and flexible packaging.

The Critical 5-Dimensional Comparison

When it comes to flexographic printing, narrow web and wide web flexo printing do differ in five crucial areas: speed of printing, accuracy of printing, type of inks used, setup and changeover time, and cost. Let’s break them down:

Printing Speed

In terms of productivity, wide web flexo printing has been known to have the upper hand. These machines are capable of printing large areas at once, and thus, do not require much time to set up and change materials. Therefore, wide web printers can achieve print at a rate of 1000 feet per minute (fpm) and can print a large number of prints in a short time. This is especially important for industries that require high volume runs, such as packaging of products that are produced in large numbers. This makes it possible to produce large quantities in a short period and at a relatively low cost, especially in a competitive market.

On the other hand, narrow web printing offers a lower output speed because of its smaller press widths, usually reaching speeds of 500 to 800 fpm. Narrow web printers are ideal for precision but may take time to complete large jobs as compared to wide web presses. Nevertheless, for short runs or jobs where turnaround time is critical, narrow web flexo printing may still be a fairly fast printing process.

Printing Precision

In this aspect, narrow web printing has an advantage over the other types of printing. Narrow web flexo printers are famous for their ability to print fine details and are ideal for jobs that require high precision such as labels and small packaging. Due to the small size of the print area, narrow web presses are more precise and can handle intricate details, with some presses being capable of printing at 400 LPI. This precision makes it possible to replicate intricate designs and small fonts in the best way possible without any distortion.

On the other hand, while wide web flexo printing is able to produce high quality prints, it is not as detailed as the narrow web printing and is not as precise. This is because the printing plates are larger and the web width is wider, which results in slight inaccuracy especially at high speeds. Nonetheless, the improvement in technology, however, has enhanced the accuracy of wide web presses and permits competitive accuracy to be achieved in even high volume runs.

Ink Types

The choice of ink is very important in the printing process as well as in the quality of the final product. Wide web flexo printing is versatile in terms of the inks used, where it can use UV, water based and solvent based inks and can print on various substrates like flexible packaging, cartons, and pouches. This is particularly important for large scale packaging runs since it offers the necessary flexibility to accommodate the various needs of the products.

Narrow web printing, on the other hand, employs a different set of inks that are compatible with the substrates and are used in small scale production. Commonly used have UV and water-based inks, which are used to ensure the best quality of the prints. Although there are fewer ink options for narrow web presses, they provide high color quality and gloss, which is suitable for short runs and complex graphics.

In conclusion, both methods use similar types of ink but the type of ink to be used depends on the production requirements, such as the type of substrate, environmental factors and the level of accuracy required.

Setup and Changeover Time

In any printing environment, time taken to set up the press and change over from one job to another is a critical factor. Narrow web flexo printing is faster in setup and changeovers, which usually take 30 to 60 minutes because of the smaller size of the press. This speed is suitable for short runs or jobs that require frequent changeovers because it is fast.

On the other hand, wide web flexo printing may take up to 2 hours of setup time, more so when changing inks or materials. This extended changeover time can affect the production cycle, particularly in environments that require frequent turnovers to meet the market demands.

Cost-Effectiveness

In the aspect of cost, narrow web flexo printing is cheaper for short runs or when the job requires high degree of accuracy such as in labeling or packaging. While the cost per unit may be higher for large volume jobs, narrow web presses are more cost effective for short run, specialty jobs because of the time taken to set up and the amount of material wasted. For instance, a short run job may be 20-30% cheaper on a narrow web press than on a wide web and is therefore suitable for niche markets.

Although wide web flexo printing is relatively expensive to set up and requires more equipment, it is more cost effective for large scale production. Wide web presses are ideal for high volume runs due to their faster speed and ability to handle large substrates, such as flexible packaging where the cost per unit is much lower. This makes it the most suitable for industries that require large quantities at a cheaper price.

To make this comparison easier and to illustrate the differences between the two, below is a comparison table between narrow web and wide web flexo printing:

Comparison Dimension	Wide Web Flexo Printing	Narrow Web Flexo Printing
Printing Precision	Generally lower	High printing precision, up to 400 LPI
Printing Speed	Up to 1000 feet per minute	500 to 800 feet per minute
Ink Types	UV ink, water-based ink, solvent-based ink	UV ink, water-based ink
Applicable Substrates	Suitable for large packaging substrates, including plastic films, large rolls of paper	Suitable for substrates like label paper, films, paper, etc. for small packaging
Cost-Effectiveness	More cost-effective for high-volume production	More cost-effective for small batch runs
Setup Time	1 to 2 hours	30 to 60 minutes
Impact on Production Schedule	Longer changeover time, more downtime	Faster changeovers, suitable for small batch production
Equipment Investment	Higher initial investment and more space	Lower initial investment, smaller space requirements
Maintenance & Support	Requires more technical support and maintenance	Requires less maintenance
Typical Applications	Suitable for high-volume packaging products such as food packaging, cartons, plastic bags, roll materials, medical packaging, film packaging, etc.	Suitable for small batch, high-precision printing such as labels, product labels, wine and cosmetic packaging, paper bags, file covers, tickets, etc.

Note: The data in the table may differ depending on the model of machine, its technological level, and the materials used by different suppliers. When choosing equipment, it is advisable to discuss the details with suppliers and learn more about their technical characteristics, compatibility of materials, and the services provided by the supplier and after the purchase.

How to Choose Between Narrow Web Flexo Printing and Wide Web Flexo Printing?

There are several factors that determine whether one should use narrow web or wide web flexo printing. When making the right decision, the following factors should be taken into consideration:

Job Size and Volume:

For high volume production or large substrates like cartons or flexible packaging, wide web flexo printing is more suitable because of the speed and the capability of handling large materials. For short runs, for example, labels or complex packaging, narrow web flexo printing is more versatile and accurate.

Quality vs. Speed:

If the highest level of accuracy and high quality print is required, especially for small and intricate designs, then narrow web flexo printing would be more suitable. However, if speed and large scale production is your primary concern, then wide web flexo printing might be more suitable for you.

Material Type and Adaptability:

Wide web flexo printing is generally more flexible with different substrates, particularly the flexible ones used in packaging. Narrow web printing, on the other hand, is suitable for small and intricate prints on paper, films or foil, often used in labeling, tagging and small packaging.

Cost Efficiency:

Narrow web flexo printing is generally more economical for short runs and small volumes due to less time required for setup and less amount of material wasted. However, wide web flexo printing is more cost-effective in large-scale runs because the higher speed of production lowers the cost per unit.

Equipment Investment and Space:

Wide web presses are usually larger and more expensive in terms of investment and space due to their functionality. Narrow web presses, however, are cheaper to purchase and take up less room, which is advantageous for companies with limited space.

Technical Support and Maintenance:

Think about the technical aspect of the press and maintenance. Narrow web presses may need a lot of expertise for fine work, while wide web presses may need constant maintenance because of the high speeds and large substrates, wide web presses wear out quickly and may need frequent servicing to be at their best.

Considering these factors, you can be in a position to make the right decision on the right printing solution that will suit your production and operation needs.

Explore KETE’s Solutions for Wide and Narrow Web Printing

Having understood the differences and how to select between wide and narrow web flexo printing, it is now time to identify the right equipment supplier for the best prints. At KETE, we are committed to delivering the best flexographic printing machines that are modern and suitable for various printing purposes. Whether you need the high speed and productivity of wide web printing or the high accuracy and fine tuning of narrow web printing, we have the right product for you.

We have been exporting our equipment for more than 10 years and provide our clients with not only the best equipment but also consultation, warranty for 1 year, installation on the site, and training to ensure the proper functioning of the equipment. Selecting KETE means selecting a competent partner who will help to improve your printing business, make it more effective, and be ready to fulfill the requirements of your clients. Call us today to start your journey toward more efficient printing!

Conclusion

In flexographic printing, narrow web flexo printing and wide web flexo printing are two types that are used in different applications and production. No matter if you value accuracy, cost, or time, it is crucial to know the distinctions between these two techniques to select the most suitable printing method for your project.

In conclusion, the choice of the printing method depends on the type of print job that you have in mind. It is therefore important to consider factors such as print quality, time taken to set up the printer, and the type of substrate that is required in order to make the right decision. So, with the right tools and technologies in your arsenal, you can always get the best results.