News
  • Advantages of Flexographic Printing 21-04-09

    Flexography remains the most commonly used print process in the label industry. There can be no flexo label without the proper plate and therefore the proper plate making equipment. Industry leaders have stayed on top of the trends, ensuring that labels are printed in the quickest timeframe and with the highest quality. Printing is done using flexible sheets, which were initially made from natural rubber, then synthetic rubber and now mainly from photosensitive polymers. Flexographic printing is done on paper, cardboard or plastic film. Liquid inks with low viscosity are used for printing. These include water-based inks, solvents and ultraviolet (UV) curing inks. Non-absorbent substrates (films) are mainly printed using UV and solvent-based inks, but water-based inks are increasingly used due to their ecological aspects and increasing adaptability. Flexographic Printing Flexographic printing, or Flexo, is a technique for bulk printing using flexible relief plates. The manufacturer applies the ink first on the plate and then on the surface. This is a low-cost printing method, and it has progressed much since 1970 after direct laser engraving was introduced. Lithographic printing or Litho is a method of printing, initially based on the unmixable materials of oil and water. Lithography is used for anything that needs vibrant colours and is printed in large quantities. However, the printing method you’re employing needs to be useful as well as cost-effective. For custom printing, flexographic vs lithographic is an age-old debate, as these two are conventional methods in the printing and packaging industry. Nonetheless, when we speak of corrugated boxes, we need then in bulk. Bulk printing is a tedious task and does require some level of optimization. Factors like budget at hand, time constraints, quality of the print, and how boxes are going to be used - shipping or retail come into play. Printing Process Flexographic printing requires an initial setup cost. Flexo uses flexible plates mounted on a cylinder. The manufacturer uses a partially immersed ink roller to apply ink on an anilox roll. The anilox roll is a hard cylinder, usually made from steel or aluminium with a ceramic outer layer that comes with many dimples. The manufacturer uses the anilox to distribute the ink on the flexo printing plate uniformly. In the flexographic printing process, the ink is metered onto the surface of the plate by an engraved/etched roller of chrome or ceramic similar to a gravure cylinder but with a uniform distribution of cells (size, shape and depth). This roller is called an ‘anilox’. The corrugated boards run directly between the impression cylinder and the paint roller. Finally, the manufacturer runs the substrate through a dryer to prevent smudging. Flexographic printing is used on everything from food wrappers to secondary containers, such as cereal boxes to shipping cartons. The photopolymerizable material on a flexographic printing plate cross-links when ...

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  • Flexographic Product Packaging Design 21-03-23

    Digital flexographic printing is a plate making technology that uses a laser to directly expose the flexographic photosensitive polymer plates. It has the following advantages. Advantages of digital flexographic printing  ①The process is simple and the preparation time is greatly reduced. ②Exposure time is independent of pattern type and dot density. ③Replacing the separation sheet with shaded metameric material eliminates the dot distortion caused by the separation sheet processing. ④The main exposure, there is no diffuse reflection of light caused by the phenomenon of dot gain, you can get a clear dot. ⑤ Realization of direct plate making without soft film, the layout will not be flooded with dirty spots and defective. From the characteristics of the digital flexographic printing plate , digital flexographic printing plate can obtain fine, clear and high quality flexo plates. Therefore, in order to improve the quality of flexo printing, the use of digital flexographic printing plate is imperative. In order to make the designed products meet the printing requirements, flexographic product packaging design staff should pay attention to the following points when designing. 1. In the use of color, should be as simple, bright, bright colors If the design of the product overprinting too many colors, will cause the color dim. Due to the larger amount of flexo printing dot expansion, small dot loss is more serious, the pattern in a certain area overprinted color version too much, each color version of the problem of dot expansion or loss, dot expansion or extinction network phenomenon will be repeatedly flooded, making the picture dim, the lack of highlights and the middle tone sector, dot transition uneven, very disgraceful. Therefore, in the same full expression of the design of the draft conditions, should be as far as possible to reduce the number of printed colors to a minimum, which is very beneficial for the bulk production of printing manipulation, quality control and cost control. 2. Try to use spot colors to make up for the lack of four-color printing Many customers of packaging products always ask the design staff in the design of their products made of yellow, magenta, cyan, black four colors overprinted more than ten colors of the manuscript, but sometimes not only through the three primary colors or conventional four colors can simply show the entire color world, additional ports with a spot color long and short necessary, but also long and short an effective method. One-sided exaggerated overprinting overlay color is not desirable. Flexographic printing machine is ideal for printing large areas of the field and spot colors, flexographic printing machine mostly six or eight colors, only four colors will cause the unit idle, and four-color printing effect than offset or gravure, affecting the quality of flexographic products. 3. Should not use too fine lines and too smal...

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  • What Are Flexographic Printing Plates? 21-03-11

    Flexographic printing plates are flexible photopolymer plates used in flexographic printing to transfer ink and images onto a flexible substrate, such as paper or film. The printing plate is the key element of the flexographic printing process and the quality of the printed image depends to a large extent on the quality of the flexographic plate used. The flexographic process itself is renowned for its adaptability to printing on all types of flexible substrates, and the plate can be used and reused in millions of impressions. Here you will learn how the plates are made and how they function. The plates are carefully designed, which means that the printing surface is raised where the image is exposed. After the ink has been applied to the plate, the plate surface is the only area that comes into contact with the substrate. The area that is etched or embossed does not come into contact with the ink. Flexographic printing was originally made from rubber, but today it is made in sheet form from a photosensitive polymeric material, which distinguishes it from the fixed metal printing plates of offset printing. The plates are flexible enough to be wrapped around a cylindrical printing/plate roller. Plate processing 1) Traditional method The desired image is first exposed to the negative film using a laser phototypesetter. It is then placed directly on the surface material of the unexposed plate and held in place by a vacuum cover. The plate and film are then exposed to UV light to fix the image into the polymer material. Only the transparent areas of the negative will allow UV light to pass through, thus allowing the UV light to alter the molecular bonds in the photosensitive polymer material.  After sufficient exposure time, the plate is fixed to an oscillating platform and then immersed in a rinse tank. The rinsing solution can be water or solvent, depending on the type of plate. The unexposed areas of the polymer are then rinsed off the plate base by means of a rinsing brush. The waste polymer is dissolved into the rinse solution and then disposed of for recycling/solvent recovery. After the rinsing process, the plate is placed in a hot air dryer where the excess water/solvent is evaporated, leaving a dry plate. Post-curing with both UVA and UVC lamps is then required, after which the finished plate is ready for use. 2) Digital printing plates Today, most flexographic plates are exposed using direct "computer-to-plate" technology (CTP). In this case, the unexposed negative film is pre-laminated to a photosensitive polymer sheet so that both layers can be exposed in the same device. A computer-guided laser first exposes the negative layer and then exposes the photosensitive polymer to a UVA light source. This exposure technique produces a higher quality plate than conventional methods. The exposed plate is then processed using the processing method described above. 3)Thermal processing of flexographic plates As mentioned above, although exposur...

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News
What Is the Process of Flexo Digital Direct Plate Making?

2021-02-22

Admin

At present, flexo plate making methods are mainly divided into traditional plate making and digital direct plate making. Traditional plate in addition to the physical expansion of the network, there is also a plate soft film and plate close together when exposed to the optical expansion. Because of the diffuse reflection effect of UV light, all the graphics and dots will be expanded, so that the resolution of printing reproduction is reduced. Therefore, it is difficult to obtain the desired flexographic quality for printing using digital flexographic printing plate obtained from conventional plate making.

What is the process of flexo digital direct plate making?

Flexo digital direct plate making process is: digital imaging → back pre-exposure → main exposure → flushing erosion → drying → post-processing → post-exposure.

①Digital imaging

Imaging of the plate is a special light polymer plate, the surface of which is compounded with a layer of metameric material with complete light blocking function. First, the plate to be used is installed on the cylinder of the digital plate making machine.
During exposure, a computer-controlled infrared laser head moves in the direction of the cylinder to ablate the metameric material in the area to be imaged, exposing the photopolymeric photopolymeric layer of the plate below. Because the photopolymeric light-sensitive layer is not sensitive to infrared light, so the laser ablated where the light-sensitive material is not affected, while the parts not exposed to the laser still remain metameric material, thus forming an imaging stencil.

②Back pre-exposure

The purpose of the back pre-exposure is to increase the thickness of the plate base to ensure that the printing required for the printing force. The thickness of the plate base and the back of the pre-exposure time is proportional to the longer the pre-exposure time, the thicker the plate base; vice versa, it is thin.

Digital Flexographic Printing Plate

③Main exposure

The main exposure can be carried out in the ordinary exposure machine. Because the metameric material and photographic resin fully compounded into one, acting as the role of the negative, so the exposure does not require vacuum, and the exposure time is short, average, the network does not deform.
The main exposure, the exposed photosensitive resin layer to see the light hardening reaction, thus forming the image of the latent image, the photosensitive resin layer covered with basaltic material does not see the light, and does not occur photochemical reaction.

④Wash erosion

The metaphorical material that is not ablated away by the laser and the unhardened photosensitive polymer under it are dissolved, forming a concave vacant sector; the photosensitive polymer at the hardened area that sees light is not dissolved, thus forming a floating convex graphic sector.

⑤Drying

The flexible plate is slightly swollen and sticky and soft after erosion by washing due to the corrosion of solvent, the original straight line seems to be wavy, and the text will be distorted and deformed. Drying of the printing plate, the role is to make the residual solvent in the plate completely evaporated, so that the plate to restore the original characteristics.

⑥Post-treatment

Post-treatment is to wipe the printing plate comprehensively with clean cloth and solvent to remove the residual monomeric substances from its surface. Finally, chlorination treatment is also required to eliminate the stickiness of the printing plate and increase the hardness of the plate.

⑦After the exposure

After exposure, also known as stereotyped exposure, refers to the bottom surface of the printing plate and the front of the graphics respectively for a certain period of time "bare exposure", the purpose is to make a good printing plate thoroughly hardened, conducive to the progress of the plate folding resistance, hardness and printing resistance, but also to reduce the impact of ink and solvent on the printing plate.

The information is provided by the digital flexographicprinting plate supplier.

 


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