Flexographic printing is rapidly being adopted for many types of commercial packaging uses, but with each type some challenges may be encountered in the printing process. In this piece we will look at flexible packaging print problems.
The Flexible Packaging Association defines flexible packaging as a package, or part of a package, where the shape can be easily changed. Flexible packaging is useful for items such as bags, stand-up pouches, or liners. The FPA predicts this will be one of the fastest growing segments of the packaging industry.
Flexographic printing can provide high resolution and brilliant graphics on flexible packaging, but there are some elements of the process which must be managed differently for the non-rigid substrates.
If you are experiencing issues with flexo printing on flexible packaging, consider the following troubleshooting items:
Inks used for printing flexible packaging must be compatible with the substrate material. Some flexible materials are more heat-tolerant than others, and some are more ink-absorbing.
Ink selection must be adjusted accordingly to account for the substrate qualities.
Some print problems can be traced to the ink's pH. The packaging material could consist of anything from film, paper, and aluminum -- to composites such as polyester, polyvinyl chloride, polyethylene, and polypropylene.
Each material requires inks with varying pH levels that dry quickly or slowly, so they adhere to the substrate.
If your viscosity levels are off, then your flexible packaging print runs might have trouble with abrasion, foaming, spotty ink deposits, smeared ink or uneven appearance, uneven colors, halos, and fisheyes.
Flexible materials can be much more susceptible to movement during the print process. Different materials may have varying thicknesses which could affect the print quality.
Check the tension on your machines before every print run, and be sure to maintain your sleeves or plates properly.
Dirty, soft, worn, or loose plates can also lead to:
In an industrial setting such as a printing room, machinery in action promotes static electricity. This attracts floating dust, tiny ink particles, and other contaminants which can accumulate on the print elements and substrate.
These contaminants can compromise the quality of the entire print process.
Challenges in flexible packaging can include poor print quality, improper ink dry time, clean-up problems, and other mishaps. Tips on how to improve the process include:
Flexo printing on flexible packaging requires a delicate balance of several components. For a print run to turn out exactly as expected, all components have to be exactly right.
For more information about troubleshooting your flexible packaging printing problems, contact a flexographic printing expert at Luminite.