Consultation Services
Optimise Flexographic printing process in your Factory…
Pre-Production Optimization
Design for Flexo
- Ensure designs are optimized for flexographic printing
- Consider factors like image resolution (minimum 300 DPI), colour separation (CMYK or spot colours), and trapping
- Use design software like Adobe Illustrator or Photoshop to create and edit designs
- Consider design elements like line screens, screen angles, dot gain, and ink spread
Choose the Right Materials
- Select suitable substrates, inks, and plates for the specific print job
- Consider factors like substrate type (paper, film, foil, etc.), ink type (water-based, solvent-based, UV-curable, etc.), and plate material (photopolymer, rubber, etc.)
- Consult with suppliers and manufacturers to ensure compatibility and optimal performance
- Consider material properties like tensile strength, durability, chemical resistance, and printability
Create Accurate Proofs
- Generate precise proofs to verify design, colour, and layout before production
- Use digital proofing systems or colour management software to create and manage proofs
- Consider using physical proofing methods like inkjet or laser printing for specific applications
- Ensure proofs are accurate and reliable, considering factors like colour accuracy, image resolution, and layout accuracy
Plate Making and Mounting
Optimize Plate Quality
- Use high-quality plates with optimal resolution and durometer hardness
- Consider factors like plate resolution (minimum 300 DPI), durometer hardness (Shore A or D), and plate material (photopolymer, rubber, etc.)
- Use plate making software to create and edit plate designs
- Consider plate properties like image reproduction, ink transfer, and durability
Accurate Plate Mounting
- Ensure precise plate mounting to prevent errors and minimize waste
- Use plate mounting systems or registration pins to ensure accurate registration
- Consider using laser alignment systems for precise plate positioning
- Ensure plate mounting is secure and reliable, considering factors like plate registration, tension, and pressure
Use the Right Adhesives
- Select suitable adhesives for plate mounting to prevent plate lift or movement
- Consider factors like adhesive type (pressure-sensitive, heat-activated, etc.), adhesive strength, and durability
- Ensure adhesives are applied correctly and consistently, considering factors like adhesive application, drying, and curing
Ink and Coating Management
Select the Right Inks
- Choose inks compatible with the substrate, plate, and printing conditions
- Consider factors like ink type (water-based, solvent-based, UV-curable, etc.), ink viscosity, and colour strength
- Consult with ink suppliers and manufacturers to ensure compatibility and optimal performance
- Consider ink properties like colour accuracy, ink transfer, and durability
Optimize Ink Formulations
- Adjust ink formulations for optimal colour strength, viscosity, and drying properties
- Use ink formulation software to create and edit ink formulations
- Consider factors like ink pigment load, binder and solvent composition, and additives
- Ensure ink formulations are consistent and reliable, considering factors like colour accuracy, ink viscosity, and drying properties
Manage Ink Inventory
- Implement efficient ink inventory management to minimize waste and reduce costs
- Use inventory management software to track and manage ink inventory
- Consider factors like ink usage, shelf life, and storage conditions
- Ensure ink inventory is accurate and up-to-date, considering factors like ink availability, lead times, and supplier reliability
Printing Press Optimization
Maintain Press Condition
- Regularly maintain and clean the printing press to prevent contamination and ensure optimal performance
- Use press maintenance schedules and protocols to ensure consistent maintenance
- Consider factors like press cleaning, lubrication, and wear reduction
Optimize Printing Parameters
- Adjust printing parameters like speed, pressure, and temperature to achieve optimal print quality
- Use printing parameter optimization software to create and edit printing parameters
- Consider factors like printing speed, pressure, and temperature
- Ensure printing parameters are optimized for the specific print job, considering factors like substrate type, ink type, and plate material
Use the Right Anilox Rolls
- Select anilox rolls with the correct cell count and volume to ensure optimal ink transfer
- Consider factors like anilox roll cell count, volume, and material
- Ensure anilox rolls are clean and well-maintained, considering factors like anilox roll cleaning, storage, and handling
Quality Control and Monitoring
- Implement Quality Control Checks: Regularly inspect printed materials for defects, colour accuracy, and register accuracy, using quality control checklists and protocols.
- Use Monitoring Systems: Utilize monitoring systems like print inspection cameras and colour management software to detect errors and optimize the printing process.
- Analyze and Adjust: Continuously analyze print quality data and adjust the printing process as needed to maintain optimal results.
Waste Reduction and Sustainability
- Minimize Waste: Implement efficient waste reduction strategies, such as recycling and reusing materials, to reduce waste and minimize environmental impact.
- Use Eco-Friendly Materials: Opt for eco-friendly materials, like biodegradable inks and recyclable substrates, to reduce environmental impact.
- Reduce Energy Consumption: Implement energy-efficient practices, such as using LED lighting and optimizing press energy consumption, to reduce energy consumption.
Training and Education
- Provide Operator Training: Ensure printing press operators receive comprehensive training on the printing process, quality control, and waste reduction, to ensure optimal performance.
- Stay Up-to-Date with Industry Developments: Participate in industry events, conferences, and workshops to stay informed about the latest flexographic printing technologies and best practices