How flexo printing revolutionising the industry

What is flexographic printing?

Flexographic printing, often referred to as flexo printing, is a rotary relief printing technique that utilises flexible rubber or photopolymer plates to transfer ink onto a substrate. It is favoured for printing on materials such as plastic, foil, paper, and cardboard. Flexographic presses use fast-drying inks, allowing for rapid production speeds and high-volume output.

The flexographic printing machine market is poised for steady growth, driven by increasing demand for high-speed and cost-effective printing solutions. Advancements in automation and eco-friendly inks are expected to further propel market expansion through 2034.

Advantages  

The growing popularity of flexographic printing machines is no coincidence. They offer numerous advantages that make them a preferred choice for businesses looking for cost-efficient and high-quality printing solutions. Here are some key benefits:

Versatility in substrate printing: One of the biggest advantages of flexographic printing is its ability to print on a wide range of substrates. Whether it is flexible packaging, corrugated boxes, shrink sleeves, or food packaging, flexo printing provides excellent results across different materials.

High-speed printing: Flexographic printing machines are known for their high-speed capabilities, making them ideal for large-scale production. With advancements in automation and inline processing, these machines can print thousands of units per hour, ensuring quick turnaround times.

Cost-effectiveness: Compared to other printing methods like offset or digital printing, flexographic printing offers significant cost savings. The cost of printing plates is lower, and once they are created, they can be reused multiple times, making flexo printing an economical option for bulk production.

Eco-friendly printing: Sustainability is a major concern for modern industries, and flexographic printing is increasingly adopting eco-friendly practices. Water-based and UV-curable inks reduce harmful emissions and waste, making flexographic printing a greener alternative to traditional methods.

Consistency and quality: The latest advancements in flexographic technology ensure consistent print quality with vibrant colors and sharp details. New-generation flexo presses incorporate digital enhancements, improving registration accuracy and minimising errors.

Applications  

Flexographic printing is widely used across various industries due to its adaptability and efficiency.

Some common applications include:

Packaging printing: From flexible pouches and food wrappers to corrugated boxes, flexo printing dominates packaging production.

Label printing: High-speed label printing for consumer goods, beverages, and pharmaceuticals is a significant use case for flexographic printing.

Newspapers and magazines: Many newspapers and publications utilise flexographic printing for economical, high-volume printing.

Retail and promotional materials: Shopping bags, banners, and other promotional items are efficiently printed using flexographic technology.
 
Latest innovations  

The flexographic printing industry continues to evolve, integrating digital enhancements and automation to improve performance.

Some of the latest trends in flexo printing include:

Hybrid printing technology: Many manufacturers are combining flexographic printing with digital capabilities to achieve the best of both worlds. Hybrid presses enable short-run flexibility while maintaining the speed and efficiency of flexo printing.

Improved ink technology: With advancements in water-based and UV-curable inks, flexographic printing has become more sustainable and environmentally friendly. These inks offer improved adhesion, faster drying times, and enhanced colour vibrancy.

Smart automation and IoT integration: Flexographic printing machines now come equipped with smart automation features and IoT capabilities. Real-time monitoring, predictive maintenance, and remote diagnostics help optimise productivity and reduce downtime.

Users

Here are some notable narrow-web flexo converters in India and what sets them apart:

Sai Paks: The company specialises in high-quality label and flexible packaging printing with a focus on sustainability. Known for precision, quick turnaround, and innovative printing techniques.

Letra Graphics: The company is a pioneer in self-adhesive label printing, leveraging advanced narrow web flexo technology for high-end labels with special finishes like embossing and foil stamping.

Seljegat Printers: The company is renowned for high-speed, high-precision label printing, catering to FMCG, pharma, and liquor industries. Uses UV flexo and hybrid printing technologies for premium output.

Mudrika Labels: The company offers a combination of flexo and digital printing for highly customised labels, focusing on security features and variable data printing for anti-counterfeiting.

Unick Fix-A-Form & Printers: The company is known for producing complex multi-page labels (booklet and leaflet labels) using narrow web flexo technology, serving pharma and agrochemical industries.

Pragati Pack India: The company is known for its excellence in print quality, innovation in label embellishments, and investment in the latest flexo presses to produce premium-quality labels for top brands.

Manipal Technologies: The company has expertise in high-volume narrow-web flexo printing with a strong presence in security printing, holographic labels, and tamper-evident packaging solutions.

Uflex: The company is a major player in flexible packaging with advanced flexo printing capabilities.

Creative Flexo: The company offers high-quality flexographic printing for labels and packaging.

Jupiter Laminators: The company is known for high-end flexo and gravure printing solutions.

Pin Mark Blocks: The company provides flexo plate-making and printing services.

Flexo manufacturers in India 

Here are a few notable flexo press manufacturers in India:

Multitec Aids is a leading manufacturer of narrow-web flexo presses for labels and packaging.

Pelican Rotoflex specialises in CI flexo presses and wide web flexographic printing machines.

Alliance Printech offers narrow and mid-web flexo printing presses.

Flexo Image Graphics (FIG) supplies flexo printing equipment and solutions.

Kody Equipments manufactures wide-web flexo printing machines for flexible packaging.

Choosing the right machine

When selecting a flexographic printing machine, several factors need to be considered. These include:

Print volume requirements: Choose a machine that aligns with your production needs.

Substrate compatibility: Ensure the machine can handle the types of materials you need to print on.

Automation features: Look for features like inline finishing, automated plate changing, and real-time monitoring for maximum efficiency.

Ink options: Opt for machines that support eco-friendly ink options for sustainable printing.
 
Conclusion

With continuous advancements in automation, sustainability, and hybrid technologies, flexo printing remains a preferred choice for businesses looking to enhance their printing capabilities.

As the demand for flexible packaging and high-quality printing continues to grow, flexographic printing machines will play a crucial role in meeting industry needs. Investing in the right flexo printing technology can help businesses stay competitive, ensuring efficiency, quality, and sustainability in their operations.