Flexo Printing
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Flexo Printing
Flexo printing is the go-to solution for cost-effective, high-speed production of corrugated boxes with basic designs, while offset printing is ideal for premium, detailed graphics.
Flexographic (Flexo) printing is a widely used method for printing on corrugated boxes, particularly for bulk packaging and shipping needs. It is cost-effective, fast, and highly versatile, making it ideal for large-scale production of boxes that require simple designs, logos, or text.
Flexographic printing is a direct printing process that uses flexible relief plates made of rubber or photopolymer to transfer ink onto substrates like corrugated cardboard. It is well-suited for printing on uneven, absorbent surfaces, such as corrugated boxes.
Types of Corrugated Boxes for Flexo Printing
Flexo printing is the go-to solution for cost-effective, high-speed production of corrugated boxes with basic designs, while offset printing is ideal for premium, detailed graphics
Shipping Boxes:
Brown kraft corrugated boxes with logos, handling instructions, or barcodes.
Retail Ready Packaging (RRP):
Simple branded boxes for store displays.
Custom Printed Cartons:
Boxes with product names, logos, and safety information.
E-Commerce Boxes:
Corrugated boxes printed with brand logos and website details.
Flexo Printing Process for Corrugated Boxes
It is well-suited for printing on uneven, absorbent surfaces, such as corrugated boxes.
- Artwork Creation: Designs are created in vector format (simple logos, text, and graphics) using software like Adobe Illustrator.
- Color Management: Limited to 1–4 solid colors (Pantone shades) for simplicity and cost efficiency. Complex gradients or images are avoided.
- Plate Making:
- Flexible photopolymer plates are made for each color.
- These plates have raised areas corresponding to the design.
- Plates are mounted onto cylinders in the flexo printing press.
- Each cylinder corresponds to one color of ink.
- Water-based inks or solvent-based inks are used for corrugated boards because they dry quickly and absorb well into the surface.
- Ink Application:
- Ink is transferred onto the flexible plate using an anilox roller that controls ink volume.
- The plate transfers the design directly onto the corrugated board.
- Substrate Feeding:
- Corrugated sheets are fed into the printing press.
- Color Layering:
- For multi-color designs, the substrate passes through multiple stations (each for a specific color).
- Drying:
- Quick drying with hot air or infrared dryers to prevent smudging.
- Die-Cutting: Printed corrugated sheets are cut into box shapes using rotary or flatbed die-cut machines.
- Folding and Gluing: The boxes are folded along crease lines and glued together for assembly.
- Quality Inspection: Ensures consistent print quality and alignment.
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