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Flexo Printing Techniques

Flexography, or flexo, printing is a type of printing that incorporates a flexible relief plate. The printing plate is a modern day letterpress and can be used to print onto not only paper, but plastic, cellophane and metallic films. The printing plate is typically made of rubber or photopolymer. It's particularly popular for printing onto food packaging labels. There are a variety of tips and tricks to make the process easier.
  1. Detecting Plate Bubbles

    • While using the printing plate, bubbles can often form under the surface and ruin the print. To find bubbles, inspect the impressions left on the plate in between splicing reels. If you notice any light spots, there̵7;s a possibility of a bubble on the plate. Another way to identify bubbles is to listen closely during the printing process. If there is a sudden increase in noise, it's likely there's a bubble on the plate.

    Removing Rubber and Photopolymer Plates

    • Oftentimes the printing plate will stick to the mounting tape during the printing process. To avoid a stuck rubber plate, mix together 3 parts wood shellac to 1 part propyl alcohol in a glass. Brush the mixture on the back of the plate before placing mounting tape on top of it. For a photopolymer plate, mix together equal parts extender and propyl alcohol. Brush this mixture onto the plate before placing tape on it.

    Unwinding Rolls

    • If you print on a large scale, you may occasionally unwind rolls to the point that the surface comes close to the ground. Static electricity can cause the rolls to pick up particles from the ground and transfer them to the printing plate. If you find this happening, unwind the roll from the bottom of the printing press instead of the top, the rolls will come into contact with the drum instead of the plates. This will allow your plates to stay clean for a longer period of time.

    Liquid Photopolymer vs. Sheets of Photopolymer

    • If you̵7;re working on a project that will require varying levels of plate thickness or an unusual thickness level, consider using liquid photopolymer instead of sheets of photopolymer. Both substances come in direct contract with the negative during the printing process. However, precast sheets are manufactured at predetermined levels of thickness. On the other hand, liquid photopolymer can be altered to create custom levels of thickness.


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