The Ultimate Guide to Flexible Packaging Printing

Our latest blog explores some of the different printing technologies and methods used in Flexible Packaging.

As a leading manufacturer and converter of flexible packaging, Multiplastics understand that choosing the right printing method is crucial for your brand's visibility and product appeal. In this post, we'll explore the various printing methods available:

1. Flexographic Printing (Flexo)

Flexographic printing, commonly known as flexo, is one of the most widely used methods for flexible packaging. It involves a flexible plate made of rubber or photopolymer, which is mounted onto a cylinder. The ink is transferred from the plate to the substrate in layers, creating high-quality prints.

Advantages:

• Cost-effective: Particularly for large runs, as the plates are durable and can be reused.

• Versatility: Suitable for printing on various substrates, including plastic films, paper, and metallic foils.

• Fast production speeds: Ideal for high-volume orders

2. Rotogravure Printing

Rotogravure printing, or gravure, is known for its exceptional print quality and rich colours. This method uses engraved cylinders, where the image areas are etched below the surface. The cylinders pick up ink from a reservoir and transfer it directly onto the substrate.

Advantages:

• High-quality and detailed prints: Excellent for complex designs and fine text.

• Consistent colour: Provides uniform ink distribution, making it perfect for large areas of colour.

• Durability: The engraved cylinders are long-lasting, suitable for very large print runs.

• Cons: Expensive outlay on engraved cylinders.

3. Digital Printing

Digital printing is a newer technology that has revolutionised the packaging industry. Unlike traditional methods, digital printing doesn't require plates or cylinders. Instead, it uses digital files to transfer images directly onto the packaging materials.

Advantages:

• Short runs and quick turnaround: Ideal for limited editions, promotional items, or prototypes.

• Personalisation and customisation: Perfect for campaigns that require unique designs for each package.

• Minimal setup costs: No need for plates, making it cost-effective for smaller orders.

• Cons: Expensive when compared to flexographic printing.

4. Offset Printing

Offset printing is a popular choice for high-quality image reproduction. This method uses a series of rollers to transfer ink from a plate to a rubber blanket, and then onto the substrate. It is particularly effective for printing on paper-based substrates.

Advantages:

• High-quality prints: Capable of producing sharp and vibrant images.

• Cost-effective for large runs: The initial setup cost is offset by the efficiency in long production runs.

• Commonly used for printing brochures, cartons, and labels.

5. Screen Printing

Screen printing, also known as silk screening, involves pushing ink through a mesh screen with the help of a squeegee. Each colour requires a separate screen, making it less efficient for designs with many colours.

Advantages:

• Rich, vibrant colours: Especially suitable for bold designs and opaque finishes.

• Durability: The ink layer is thicker compared to other methods, providing long-lasting prints.

• Versatility: Can be used on a wide range of materials, including textiles and plastic films.

• Commonly used for printing promotional bags and clothing.

Choosing the Right Method

Selecting the appropriate printing method for your flexible packaging depends on several factors, including the type of substrate, design complexity, budget, and production volume.

Flexographic and rotogravure printing are excellent for large-scale production with high-quality requirements. In contrast, digital printing offers flexibility for short runs and personalised designs.

At Multiplastics, we specialise in helping businesses choose the best packaging solutions to enhance their brand presence. If you're interested in exploring these printing methods for your packaging needs, please contact us for more information or a consultation.

Stay tuned to our blog for more insights into the world of packaging!