The Challenge Of Printing On Flexible Packaging

Renowned for its lightness and versatility, flexible packaging provides consumers with an on-the-move solution that jigsaws perfectly into their busy lives.

Flexible packaging is becoming a popular alternative in recent years. Made from materials such as film, foil, or paper, flexible packaging offers important advantages: considerably less material is required compared to rigid packaging, such as bottles or containers; weight-to-cost and weight-to-resource ratios are superior to other forms of packaging; and flexible packaging can be printed more quickly, boosting productivity.

Flexible packaging, therefore, is highly efficient, creates low waste, and offers exceptional cost-effectiveness. But is there a catch?

The Challenge Of Printing

Flexographic printing can deliver high resolution and fantastic graphics on flexible packaging, which is particularly important for the food industry.

However, the process of flexo printing must be managed differently compared to printing on paper & Board substrates because of some unique challenges:

Ink

When printing flexible packaging, the inks must be compatible with the substrate, as some materials tolerate heat more effectively than others, while some absorb ink more readily.

The chosen ink must be adjusted in line with the qualities of the substrate, particularly considering the pH level of the ink: different substrates require specific pH levels so that the ink adheres to the material rather than drying too quickly or slowly. Some plastics will need to be treated (Corona) before printing to improve quality and ink adhesion to the substrate. For best results Corona treat on-Line whilst printing.

Also, the viscosity of the ink must be carefully set, as incorrect levels will lead to inconsistencies such as foaming, smears, fisheyes, halos, or uneven colours.

Food safety is an important factor to consider, inks need to be low migration and certified for food use. Talk to your Ink supplier about the specific application.

Printing Plates

During the printing process, flexible substrates are prone to movement. The different thicknesses of these materials can affect the quality of the print.

To combat the problem, the tension on the printing machines must be checked before each print run, and printing plates must be maintained to prevent uneven inking, inconsistent print, image bleeding, or dirty prints.

Contamination

The constant operation of machinery in the printing process can generate static electricity, which encourages dust and other contaminants to gather on the substrate. With flexible packaging such as film, particles will adhere more readily, affecting the quality of the printing process. So consider investing in Web Cleaners & Anti-static bars through the Printing press.

How Focus Label Can Deliver Printing Solutions For Flexible Packaging

At Focus Label, we design and supply a range of equipment for the efficient and cost-effective printing of flexible packaging, for food, meat coverings, and protective wrapping or film.

Our Centraflex flexographic machines can deliver high-quality printing on the most challenging substrates, including flexible packaging, offering up to 6 colours , 330mm wide and a choice of drying systems (IR , UV or LED UV with Chillers ). This press is the machine of choice for meat tube casings.

Alternatively, the eFlex & Proflex modular range of presses can be adapted for a broad range of production needs and boasts servo drive and line shaft technology. With roll-to-roll and roll-to-sheet capability, these printing presses can deliver up to 10 high-quality colours and offer IR or UV drying systems.

We understand that, before committing to investing in a printing press for flexible packaging, you’ll want to see our different models in action. Therefore, we offer a free, no-obligation demonstration to give you a valuable insight into our printing solutions and the chance to learn more from our experienced staff. Get in touch to find out more.