Flexographic Printing: 6 Advantages And 5 Disadvantages
Flexographic Printing is especially popular in the packaging industry because it is one of the fastest, most affordable, and most versatile printing methods. Although it is widely used in modern industries, it is not without flaws.
The following sections highlight the advantages and disadvantages of flexographic printing, helping to assess its potential benefits for your company.
6 Advantages Of Flexographic Printing
| Advantage | Sub-Point | Description |
| Versatility with Materials | Wide Range of Materials | Flexographic printing can work with a wide range of materials, including plastic, metallic films, paper, cardboard, and corrugated materials, making it versatile for various printing needs. |
| Printing on Uneven Surfaces | The flexible relief plates in flexographic printing allow it to adapt to uneven or rough surfaces, producing high-quality prints even on challenging materials. | |
| High Speed and Cost-Effectiveness | Fast Production | Flexographic printing operates at high speeds, making it suitable for bulk production in packaging, labeling, and newspaper printing. |
| Low Setup Costs | Once the printing plates are created, the setup cost is lower compared to other printing methods, and its efficiency reduces long-term costs. | |
| Cost-Effective | While the initial cost for flexographic plates is high, the long-term cost-effectiveness is significant, with plates being able to perform millions of impressions, reducing the cost-per-unit produced. | |
| Eco-Friendly | / | Flexographic printing uses water-based and UV curable inks, reducing environmental impact compared to solvent-based inks. Additionally, modern machines minimize material waste and energy consumption. |
| High Precision and Quality | High Registration Accuracy | Flexographic printing ensures high registration accuracy through advanced alignment systems, reducing misprints and inconsistencies. |
| Adaptability for Complex Effects | Flexography can achieve complex processes such as applying metallic foils, varnishes, and embossing, making it suitable for branding and packaging. | |
| Multifunctionality | / | Flexographic presses can perform multiple functions in a single pass, including printing, laminating, varnishing, and die cutting, which improves efficiency and reduces manufacturing costs. |
| Ideal for Packaging | Flexographic printing is the industry standard for packaging, ideal for flexible covers, cartons, labels, and corrugated boxes, and widely used for fulfilling large-scale packaging demands. |
Versatility with Materials
Wide Range of Materials
Flexographic printing is renowned for its versatility in regard to substrates it can print on. Plastic and metallic films, paper, cardboard, and even corrugated materials are all substrates that a flexographic printing machine can work with. This is the quintessential printing solution in case you are looking to cater to several different printing requirements.
Printing on Uneven Surfaces
Flexography is probably the ideal printing method for rough and uneven surfaces, unlike most other methods of printing. Flexible relief plates, used by the flexo printing machine, can bow and give way to the contours of different materials. As a result, quality prints are produced even on challenging surfaces.
High Speed and Cost-Effectiveness
Fast Production
Flexographic printing technology was developed to take advantage of mechanical capabilities. In packaging, labeling, and newspaper printing industries, a flexopress is more than capable of bulk printing at economical speeds.
Low Setup Costs
Once the required printing plates are created, flexo/braille printing machines offer economical initial costs in comparison with other conventional forms of printing. Efficiency in the printing operation minimizes idling which helps to cut costs in the long term.
Cost-Effective
Flexographic printing is one of the best economical options for large production runs. The initial cost for the flexographic plates is expensive, however, in the long run, they pay for themselves with increased versatility. Significantly for reducing the average cost-per-unit produced, a plate can be used for millions of impressions.
Eco-Friendly
Compared to solvent based inks, water based and UV curable inks have less negative environmental impact. Furthermore, many 4 colour flexo printing machines are constructed with features that help reduce the amount of material wasted and the amount of energy consumed, making flexography a cleaner form of printing.
High Precision and Quality
High Registration Accuracy
The risk of misprints and inconsistencies in modern flexographic printing is greatly reduced by the use of advanced systems for alignment of colors and graphics, which are standard features of modern flexographic Printers.
Adaptability for Complex Effects
Adaptability for Industrial Complexity Effects Flexography is often perceived as inferior to digital printing, however, it can achieve high value in the areas of branding and packaging. In addition to printing, modern technology allows for complex processes, such as the application of metallic foil, varnishes, and embossing to be performed with ease.
Multifunctionality
Multifunctionality Flexographic presses are capable of multiple functions in a single pass. A single pass can produce print images, laminating images, applying varnish, and die cutting. Such automation cuts down the time to manufacture items and helps in lowering costs incurred from further finishing.
Ideal for Packaging
Flexographic printing is the industry standard for packaging. Flexo printing is used extensively in vertical form which packs flexible covers, cartons, labels and even corrugated boxes. 4 colour flexo printing machines are highly efficient and therefore, widely used for fulfilling the tremendous demand of packed items.
5 Disadvantages Of Flexographic Printing
| Disadvantage | Description |
| High Plate Production Costs | Flexographic printing requires custom plates for each color, which can be expensive, especially for small-volume printing. |
| Quality Issues with Highlight Areas | Flexo printing can struggle with fine details and highlights, making it less suitable for highly detailed images compared to digital and offset printing. |
| Limitations for Complex Artworks | Flexo printing can be difficult for intricate and multi-colored designs. The setup time and cost increase, and some detailed designs may not work well in flexo printing. |
| Limited Color Accuracy | Flexo printing uses a standard set of ink colors, which may not match some colors as accurately as digital printing, making color matching harder. |
| Not Ideal for Short-Run Projects | Flexo printing is not cost-effective for small batch production because of the high setup costs and time spent on preparing the plates, making digital printing a better option for short runs. |
High Plate Production Costs
The greatest disadvantage with flexographic printing stems from the high plate costs. Unlike digital printing where the setup costs are nearly none, flexo printing incurs costs for custom plates made for every colour, which has the potential to be costly when there is a small volume of printing.
Quality Issues with Highlight Areas
Range of Issues Influencing Quality Standards Print quality in flexography is optimal, however, is still needs improvement with highlights and details. The trade-off for flexography is it can print images with reasonable accuracy, but not at the same level as digital and offset printing, which makes it not suitable for detailed images.
Limitations for Complex Artworks
Shortcomings Relevant to Detailed Artwork Flexo printing requires the use of multiple and complex designs that are highly colored with more than one plate. This increases both the setup time and cost. Additionally, some of very intricate designs may not make it through the flexo printing machines which makes their use in highly detailed graphics not possible.
Limited Color Accuracy
Limited Range of Color Value Measurements In flexographic printing, standard set of ink colors is used. This may lead to inaccuracy with some colors. Colors can be matched in the way they needed to be in digitally printed output, in flexography this is not possible without some progress.
Not Ideal for Short-Run Projects
Not Constructed for Shorter Length Projects For short run projects, flexographic printing is not the best option due to high set up costs along with time spent preparing the plate. Small batch production is often simpler and more cost effective to do with digital printing.
Conclusion
Because of its versatility, speed, and cost-effectiveness, flexographic printing is an excellent choice for high-volume printing. It excels in packaging applications and demonstrates impressive quality on various substrates. Its cost, color accuracy, and detail artwork limitations remain problematic, though.
Consider your production needs and budget before investing in a flexographic machine to determine if flexography is the answer to your business needs. The correct equipment can greatly enhance operational efficiency, whether it is a 4 colour flexo machine for packaging or a flexopress for large format printing.
Knowledge of the advantages and disadvantages of flexographic printing enables businesses to make better informed decisions regarding their printing solutions which in turn helps optimize production processes.
References
Flexography: Advantages & Disadvantages
What is Flexographic Printing and What Are Its Pros and Cons?
Pros and Cons of Flexo Printing
