Photopolymer in flexo printing: origins of the most used printing technique. Flexo 24 gets you the latest technologies to ORDER the best flexo plates! NOW!

The name flexography itself comes from the flexibility of the relief plate which is used in flexo printing. Flexography is a direct rotary letterpress printing similar to typography but direct print, and employs resilient raised-image printing plates made of rubber or other light-activated resins.

Flexography (or flexo printing) is mostly used for printing different kind of packaging, flexible Packaging or self-adhesive labels and typically employs a flexible printing plates which has prominent characters engraved on it.

(Flexography timeline: from its origin in 1857 to 1985).

Moving forward of 200 years means using up-to-date technology thanks to www.flexo24.com. Try it!

The most important feature of flexo printing is flexibility, which allows flexo to print on almost any kind of substrate:

• paper,
• plastic,
• cellophane,
• metallic films.

Flexo is widely used for printing on non-porous substrates, which are mostly employed for food packaging.

What is the story of flexo printing and its main features?

Early stage of flexo printing.

The first flexo type printing presses were patented in the late 19^th century.

At first, flexo printing was rudimentary in quality because of

• limitations in ink control (they smeared easily)
• and in rubber printing plates:

The idea of using rubber printing plates originated in the US 70 years before its actual use for commercial aim and might have been inspired by a rotary printing machine used for tapestry.

The first rotary press with rubber plates was employed by a paper bag printing company - the Bibby, Baron & Sons, today known as Welton Bibby & Baron.

They used inks made of dyes and sugar dissolved in water, but since water-based inks smeared easily the device was called “Bibby’s Folly”, and some years later it was defined as “a monstrosity from a mechanical as well as an ink standpoint”.

But it was only the first rudimentary attempt to flexography.

The first technological improvement: aniline printing.

In 1905, C.A. Holweg ( a French company from Alsace, Lorraine) developed a printing press which used a synthetic aniline dye dissolved in alcohol to print on paper bags. This was the beginning of the aniline process.

Since these inks dried very fast Holweg managed to attach the press to a bag-forming machine, giving birth to the first continuous operation for printed paper bags.

• Hence he received British patent no. 16519 for the first aniline press
• and after World War I he started to sell and export his printing presses to US.

In 1928 Potdevin produced a different kind of aniline printing press: plates were mounted on canvas and held in place on the cylinder by a shafts and reels system.

The introduction of corrugated boards: new market perspectives.

At the beginning of last century, corrugated board was introduced in packaging market..

• Langston found his way in a combination of rubber plates, oil-based inks and corrugated cardboard; although this combination cannot be considered the first example of flexo printing, it still can be considered as the first step leading to it and one of its leading market.
• In 1909 the first plates made of vulcanized rubber were created to print on corrugated cardboard.

In 1914 the Interstate Commerce Commission declared corrugated board as an official packaging material because of “its protective capabilities similar to [those] of wood”; this affirmation caused a decreasing demand for wood packaging and a boom in corrugated board packaging, which also meant an increasing demand for its printing.

The development of flexo printing machines’ market.

At first there were two different kind of flexo printing machines:

• the stack type (sold by Holweg or Windmoeller & Hoelscher)
• and the central impression type (sold by Strachan and Henshaw).

However, since flexo printing machines had an easy design and construction, many printers tried to build they own printing machines – as well as they tried to mix their own inks and prepare their own rubber plates, all factors which leaded to a poor quality printing.

The “do-it-yourself” period went on until 1935.

The first printing machines were extremely messy, and that was also their main problem. Being no ink metering mechanism inks splashed everywhere and pooled on the floor; the situation was awkward for the printing operator as well, as it was potentially dangerous. A rough ink metering was accomplished by increasing or decreasing the pressure between the inking roll and the fountain roll (both were usually made of rubber) and the excess of ink flowed back into the ink pan.

The inked roller transferred the ink to the printing plate, which in turn passed the ink to the web in what was known as “kiss impression”.

There was no device to control ink circulation, and printing machines hadn’t any kind of splash guards either.

"Gummidruck" and the plummeting of printing sales.

From 1915 the future of flexo printing started to take shape.

Papers with new different properties started to spread:

• greaseproof,
• waterproof,
• and alkali-proof paper.

allowed to pack products which had been impossible to pack before, for example meat and soap, and increased the surfaces available for flexo printing.

During that period cellophane was introduced by DuPont and became the first non-absorbent packaging on the market. Water-based inks were left aside because aniline inks proved to fix better on surfaces, improving printing quality.

Yet aniline inks raised a big issue: aniline was toxic and Gummidruck was mainly employed in printing food packaging. In the Fourties, the American FDA (Food and Drugs Administration) forbade the use of aniline ink in food packaging and the markets plummeted.

A technological turning point: from "Gummidruck" to Flexography.

Flexo printing was in the edge of fading until 1949, new:

• safe
• and nontoxic

inks were allowed for food packaging printing, which made flexo printing available again.

TODAY WE CALL IT FLEXOGRAPHY.

In spite of the FDA’s decision, flexo market was still limping along slowly. Printers realized that costumers needed a new name for gummidruck, so that it wouldn’t remind them of toxic inks.

After a poll in 1951, conducted by the Mosstype Corporation’s president Franklin Moss, the process received many possible names and among them “flexograph” was a possible choice. Finally, by the end of October 1952 the 14^th Packaging Institute Forum, which took place in Commodore Hotel in New York City, chose the name “Flexography” for the process.

Flexo today: an evolving technology.

Although until the Nineties Flexography was less precise or in some cases like Offset printing it still has some interesting features, as it allows:

• to use a wider range of inks, also water-based inks,
• to print on a wider variety of packaging materials, such as plastic, ALU, cartons and acetate films;
• to shorten production time and cost thanks to low viscosity inks, which dry faster.

One century after its birth and alternating development, flexography is an effective and still growing printing method, as well as the most flexible.

From 1990 important advances have been made, positively affecting the quality of:

• flexo printing machines,
• printing plates (It appears the photopolymer in flexo printing),
• printing unities,
• drying methods,
• different types of ink, of which are mainly used:
  
  • solvent
  • and water-based inks,
  • UV inks
  • and electron beam inks.

All these positive features matches with practicality, production speed and moderate investments – more than offset printing..

Towards innovation: an ongoing job.

Most recent advances in flexo are connected to photopolymer plates regarding:

• their materials;
• how they are produced.

Companies such as Asahi Photoproducts, Kodak, Dupont, MacDermid pioneered plates production and produced important progresses in:

• digital flexo plate
• faster processing and washout
• reprographic screening techniques to get higher tonal values.

All these innovations allows flexo to grow and rule in many printing branches such as

• labels and,
• packaging,
• new materials such as cartons.

Lately the direct-to-plate digital systems support a better images reproduction and reduce response time from computer to printing proof and final printing.

Laser-engraved anilox rolls contributed to improve printing quality thanks to their control on ink quantity transfer.

Obtain high detailed print colour image is now possible with some of the most sophisticated printers – with the support of a skilled operator – allows to reach high-level technology quality.

An important development is the still-growing ability to reproduce higher tonal values, giving another solution to the dot gain compensation typical of the flexo print.

Flexo 24: flexo’s future in innovations.

Thanks to the experience gained since 1978 by Nu-Maber, leading company in flexography , Flexo 24 was born in 2018 as the first e-commerce in the world for online platemaking.

It's the flexo service leads to a fully digital world, which gains a fast, intuitive and high-quality technology beyond comparison.

Start now and become a Flexo 24 customer: create your own plate!

Flexo print revealed by all the videos serie to explore the world of flexo.

It is important to understand every feature of the flexo printing system – for labels or packaging– through its many essential contents to approach it without compromise.

Ongoing development in technology, care for details and a human capital standing out for professionalism and dedication: Flexo 24 has a know-how from over 40 years of experience in the field of photopolymer plates and flexo printing. For these reasons we now want to share with you all our secrets about the flexo world!

Flexo print revealed: all the videos to express your creativity and suit your print requirements.

By watching the videos of Flexo 24’s web series you will access various contents, like:

• information about flexo and the technology innovations of this field,
• useful tips for creatives, graphic designers and project supervisors,
• a tutorial to help you with the configuration of your plate for flexo printing, the configuration of your plate for flexo printing,
• with the creation of a file suitable for flexo printing,
• with the flexo calibration test and more besides!

Go to the Flexo 24 Youtube channel and check out all the videos from the web series!

You can view the Flexo 24 videos directly from this page or you can click on the icon in the screen and go to the Flexo24 Youtube page.

You can then follow the official Flexo 24 channel: click on SUBSCRIBE!

Through the exclusive contents we will discover Flexo 24’s distinctive high-level technology quality.

The complete web series of Flexo 24 – your partner in flexo:

• tutorial and insights on flexo printing,
• guides for the creation of your files suitable for flexo.

Flexo print with Flexo 24 – Ep. 0.1 – TRAILER

For Flexo 24 flexo printing means professionalism, high technology and top quality of the final product. Flexo 24 is the key to suit all the new production requirements of Creatives, Graphic designers and Project supervisors and can match the modern printing standards for packaging and labels.

About Flexo 24 - Flexo 24, Ep. 1.

Today, printing challenging 10-colour images is really possible: this is a great goal for packaging and for any other printed products. But Flexo 24 marks the beginning of a new era for flexo printing.

The constant evolution of plates – Flexo 24, Ep. 2.

Sets of printing plates supplied in 24 or 72 hrs, but 30 years to become what we are today: expertise and professionals to offer a top quality service.

Printing plates with a look to the future – Flexo 24, Ep. 3.

Flexo 24 is constant research and development. A technical department equipped with ever-evolving automated systems. Top quality materials for excellent digital plates. Our experts always know how to meet your needs in flexo.

High-tech flexibility – Flexo 24, Ep. 4.

A great technical expertise in flexo is the base of Flexo 24’s success. An exclusive B2B e-commerce that can count on next-generation production equipment.

Flexo 24: flexo print revolution – Flexo 24, Ep. 5.

Flexo 24 improves constantly the products offered to creatives, graphic designers and project supervisors thanks to the synergy of its day-to-day teamwork.

How to order your flexo plates – Flexo 24, Ep. 6. - FULL ENGLISH -

How to order your plates in 3 steps for a top quality packaging Flexo 24 is the most effective way to start your creative or technical print in a very fast time.

PDF tutorial for flexo printing (1 / 2) – Flexo 24, Ep. 7.

The first step to purchase your plates is to prepare a correct PDF file for your flexo printing set. On Flexo24.com a software that reads your PDF and checks more than 20 graphic features is available online to help you create correctly your flexo plate.

PDF tutorial for flexo printing (2 / 2) – Flexo 24, Ep. 8.

To create a PDF file suitable for flexo you will need some simple but important tips. Flexo 24 wants to share these tips with you to be your best partner to boost productivity. After you have checked the accuracy of your PDF print file you can proceed with your order.

Flexo plates in 24 hrs – Flexo 24, Ep. 9.

Digital flexo plates with Flexo 24. Two fully automated production lines for the engraving and processing of photopolymer plates: a next-generation technology to cut production time and costs. Flexo 24 produces perfect plates for national and international customers.

How to create a flexo plate – Flexo 24, Ep. 10.

Flexo 24 provides a turnkey service:

1. manage independently your own orders for flexo plates with a guarantee of a perfect, top-quality product;
2. calculate online the price for the best plates for your substrate;
3. navigate through a dedicated platform and make your payments safely.

Flexo 24 is the perfect partner for the success of your print project.

Flexo Customer Care - Flexo 24, Ep. 11.

Customer-oriented flexo plates. You can get in touch with our customer care by phone, through the online chat, by email or through the social media to have your questions about flexo answered.

Calibrated flexo printing machines – Flexo 24, Ep. 12. - FULL ENGLISH -

Calibrated flexo printing machines thanks to the calibration test by Flexo 24, the best system to set your compensation curve for the dot gain value. Set it from the first stage of your order to purchase flexo plates for packaging or labels.

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Flexo plates for every substrate – Flexo 24, Ep. 13.

Flexo for packaging, labels or flexibles printing? Flexo 24 provides plates suitable for the main 5 flexo substrates: paper and paperboard, plastic film, aluminium and adhesive paper, carton, tissue. Next-generation flexo machines and field experts are the key for Flexo 24’s success and uniqueness!

Tutorial on substrates in flexo printing – Flexo 24, Ep.

Flexo print on paper? Be it on calendered or on rough paper, Flexo 24’s digital photopolymer plates will always guarantee the best print results in flexo and the best colour performance. Get top-quality results without compromise.

Flexo plates for labels – Flexo 24, Ep. 15.

To each print application its own plate! Printing on labels always requires extra care not only in selecting the features of the right flexo plate, but also when you prepare your file at the pre-press stage, which requires some caution.

Tutorial on tissue printing: no secrets! - Flexo 24, Ep. 16.

Flexo print on tissue? Though tissue is very similar to paper, its main features are roughness and absorbency. The production of a flexo printing plate for this type of substrate requires some specific care when you create your file.

How to get successful packaging results – Flexo 24, Ep. 17.

Packaging-mania! The plate makes a difference in flexo printing. Choose yours according to the substrate you will be printing on!

Flexo specialists / professionals – Flexo 24, Ep. 18.

For Flexo 24 flexo printing means professionalism. Supervised workflows, certified measurement tools, care for every detail. Order your plates online with Flexo 24, it’s easy and fast.

What is the moiré effect? – Flexo 24, Ep. 19.

Rely on our specialists if you want to be sure to achieve excellent print results! Flexo 24 guarantees to supply products studied in every single detail using top-quality materials with a confidence from over 30 years of experience in the flexo market. Plates and photopolymer digital plates at the highest level.

Tailored flexo print – Flexo 24, Ep. 20.

Packaging, plastic film or paper printing: with Flexo 24 productivity is under control! Your flexo plates can be tailored to meet the most unusual requirements.

Purchase your flexo plates online – Flexo 24, Ep. 21.

With Flexo 24 graphic studios and production managers can easily start the production of flexo plates with just a few clicks with the guarantee of getting a top-quality product.

How to increase production at lower costs – Flexo 24, Ep. 22.

The engraved plates are incredibly versatile and can print on many different types of substrate. This is one of the reasons why many printers shifted their production to flexo printing. And on top of that, flexo printing allows to increase production at lower costs with a guarantee of optimization of production times and costs.

The human capital – Flexo 24, Ep. 23.

Flexo 24 is not just modern e-commerce, innovative procedures and cutting-edge technology, but it is mainly a team of specialists always at your service. At Flexo 24 we are ‘flexo’ people, and we are ready to answer any of your questions and doubts.

Flexo 24: evolution in progress – Flexo 24, Ep. 24.

We made a precise choice: providing our customers with flexo plates to get the best print results. Evolution is always in progress at Flexo 24: we are confident that tomorrow, just like today, we will be able to offer the best solution for your flexo application on any substrate.

Start now and become a customer of Flexo 24: make up your own plates!