The expansion of the flexographic label printing market has been highlighted by the digitalization of the production process. This is not the same old flexo. In fact, the process has improved to drive efficiency while attracting the next-generation workforce.

Flexo has been required to evolve, especially as more than 80% of label jobs are still run on flexo presses.

Automation, AI, and sustainability are but a few of the trends impacting flexo. “Cloud based production management tools, which include MIS and ERP data collection, are now the norm as printers and converters pursue efficiency gains,” explains Paul Teachout, marketing and technical content specialist, Harper Corporation of America. “Real-time data collection on flexographic printing presses, including that of third-party integrations, are now providing intelligent platforms. This level of connectivity and data collection will support future implementations of AI predictive modeling for production management. This collective intelligence will support the entire operational objectives from quoting, supply chain management, asset utilization to logistics.”

“Eco-friendly and reuseable packaging solutions will be driven by consumer demand and brand owners and converters alike will need to align,” adds Teachout. “Consumers and brand owners will be looking for converters who can provide solutions for thinner raw materials designed for current market needs and support a closed loop recycling journey.”

According to Teachout, companies will continue to see a diminishing number of human resources entering the label and package printing industry. The automated processes of intelligent platforms and digital hybrid technologies will help ease this pain.

“The journey of evolving our process from a craft to a science has now provided intelligent platforms in which HMI are providing more intuitive operation for the modern press operator,” says Teachout. “Included with automated and robotic operation, these HMI functions will provide a more predictable and repeatable result regardless of operator skill set. This will also help us reduce the need for human interaction throughout the manufacturing process. This will allow us to continue to increase our efficiency resulting in lower cost, higher quality and a competitive advantage in the marketplace.”

In addition to automation and AI, the flexographic process itself has changed. Once a process of chrome and rubber, both are now a digitalized process with optimized chemistry and raw materials.

“Current anilox roller technology is made up of premium ceramic powders that yield extremely low porosity levels allowing digital fiber optic lasers to engrave any graphic image into the roller surface,” says Teachout. “Engravings can now be provided with the traditional 60-degree HEX engraving, which has been and continues to be the workhorse of flexo printing, with a channeled application technology. This improvement on the traditional 60-degree allows for an increased transfer efficiency to the plate and overcomes past challenges in the ink transfer process. Things like UV ink spitting, reticulation and air entrapment are greatly reduced providing increased performance and efficiency. The innovation of a 60-degree channeled application engraving with precise measurable volume is a major advancement.

“With the introduction of plate cell patterning that also improves ink transfer from plate to substate, the two innovations together continue to work hand in hand,” Teachout continues. “Better color saturation, less pin holing and higher opacities are being achieved. The relationship between the anilox roller and the plate has always been at the heart of our process and continues to evolve together.”

Digital printing will also impact flexo in the future. However, digital will not replace flexo in the vast majority of cases. Instead, flexo and digital will operate side by side (or together in the case of hybrid printing presses). The decision now is to determine where the most cost-effective break point is in producing a label either flexo or digital.

“I feel digital is a direct complement to the flexographic process,” states Teachout. “It has offered converters the opportunity to provide their customers with enhanced offerings and shorter lead times. The current digital solutions are now offering production speeds that rival traditional narrow web flexo presses no longer being the deciding factor in production modeling. Digital will still be the overwhelming choice for shorter runs with simple color and converting requirements. Hybrid solutions will be the choice for the mid run length with converting and decorative applications. Flexo will still be the primary process for the longer run more complex production runs. There is a fit for all and the look of the modern pressroom will continue to evolve.”

Even as the industry explores new technologies, specifically around digital label printing, the future is still bright for flexo. Flexo will continue to thrive in labels, along with other applications like wide web flexibles, corrugated, napkins, tissues, envelopes, newspapers, and more.

“Flexo is and will be a primary printing method,” states Teachout. “Digital and digital hybrid will continue its growth in the label sector and will eventually expand through others. The flexo and digital process will continue to have an intimate relationship and expand the limits of package printing, as they are a true complement to each other – but both have their space. The modern pressroom will learn to leverage these technologies as to have a choice in enhancing efficiencies. Run lengths, SKUs, customization, embellishments, and finishing requirements will all be influences in deciding appropriate production methods.

“The digital process has also had a very positive impact on the flexo process as more and more narrow web printers are accepting expanded gamut solutions,” adds Teachout. “Once the color gamut is captured from both print devices and properly profiled, it provides even greater pressroom flexibility. Either platform will produce visually comparable results. Presses can now run a four-color process job with two spot colors and switch to a five color PMS job without changing ink sets – that is true efficiency regardless of platform.”