10 Things You Need To Know About The Flexo Plate
What Is The Flexo Plate?
The plate mounting flexo printing is defined as a flexographed inked plastic or rubber plate that can print on a diverse range of materials such as: paper, flexible packaging, corrugated cardboard, plastic and film. This plate is a photosensitive polymeric plate containing a raised image that is capable of holding onto the ink. The inked parts are transferred onto the substrate being printed on in the process. The oldest flexo plates were made of rubber, nowadays it is common for them to be made of a polymeric material to enhance their durability and printing quality.
Why Use Flexographic Printing Plates?
Flexographic plates have their merits that make them’s posible focus for different printing activities. The following include: increase printing speed for all substrates. They also allow the use of different types of inks like, water, solvent and U.V inks. Most importantly, their flexibility enables them to be used for the printing of packaging, labels or newspapers where the surfaces are not even.
How Do You Mount A Flexo Plate?
A plate mounting tape flexo printing must first be mounted to the transfer cylinder prior to begin printing. The importance cleaning of the plate/sleeve in order to obtain a set bond strength between the plate/sleeve and the tape designed for mounting plates varies based on these styles below:
| No. | Step | Description |
| 1 | Clean the Print Cylinder | Ensure the print cylinder is free from dust, particles, and other contaminants to avoid damage and ensure proper adhesion. |
| 2 | Apply Plate Mounting Tape | Put the plate mounting tape onto the print cylinder, ensuring that it holds the plate firmly. |
| 3 | Mount the Adhesive Flexo Plate | Carefully place the adhesive flexo plate onto the mounted tape, ensuring no distortion occurs. |
| 4 | Implement Mounting System | Use a system that prevents the formation of air pockets and ensures even pressure distribution for optimal bonding. |
Why Are Flexo Plates Distorted?
There can be various distortions in flexo plates due to a number of reasons like faulty exposure while making the plates, poor tension during mounting, or stretch while the plate is wrapped on the printing cylinder. To reduce distortion, printers must make sure to calculate the distortion factor for the plate and check that the relief depth is adequate. This is done through the known values of the cylinder diameter.
How To Tell A Bad Plate On Flex Printing？
Quality of print will not be consistent from one sticker to another with the use of defective flexo plates due to the following reasons:
| No. | Issue | Description |
| 1 | Apparent Injuries | Surface-level divots such as cracks, scratches, and tears can disturb the ink transfer, leading to inconsistent prints. |
| 2 | Exposure Adjustments | Plates may be overexposed (too hard) or underexposed (too soft), causing poor image quality. |
| 3 | Ink Transfer Problems | Smudged or faded colors, and blank spaces with no ink indicate a defective plate. |
| 4 | Insufficient Relief | Poorly defined raised relief causes blurred prints, affecting the print clarity. |
How Do You Store Flexo Plates?
Flexographic printing plate storage should be in such a way that their quality is preserved for as long as possible, as outlined in the following recommendations.how to flexographic printing plate storage
| No. | Storage Recommendation | Description |
| 1 | Keep Away from Sun and Humidity | Store flexo plates in a dry, cool environment, away from direct sunlight and extreme humidity to preserve their quality. |
| 2 | Keep Plates Flat or Rolled | To prevent creasing, store plates either flat or rolled with a wide diameter. |
| 3 | Use Protective Sleeves or Containers | Prevent dust accumulation and mechanical damage by storing plates in protective sleeves or containers. |
| 4 | Rotate Plates Periodically | Rotate plates from time to time to prevent distortion and maintain their shape. |
How Do Printing Plates Work?
Flexographic printing plates Function by transferring color from an anilox roller to a substrate. Factors such as the elevation of the relief image, ink, and ink-free spaces are available to be applied. The steps including:
| No. | Step | Description |
| 1 | Application of Ink | Ink is applied to the printing plate, typically using an anilox roller, which ensures a consistent layer of ink. |
| 2 | Removal of Unwanted Ink | A doctor blade removes excess ink, leaving ink only in the raised areas of the plate’s relief image. |
| 3 | Contact with Substrate | The plate makes contact with the substrate, transferring the ink from the raised areas of the plate to the material. |
| 4 | Drying the Ink | After the ink is transferred, it must be allowed to dry to produce a permanent print. |
What Are The Best Flexo Plate Material?
Various flexo plate materials are used based on usage.
Photopolymer Plates: Offers the most popular with timeless durability while giving quality. Rubber Plates: Developed for older systems, not so used in recent prints.
3D Printing Flexo Plates: Start of a new decade, high demand later on with accuracy and creativity.
How To Clean The Flexo Plate?
The flexo printing plate cleaning accurately guarantees less amount of time until appears, flexo prints needed.
| No. | Step | Description |
| 1 | Use Flexo Plate Cleaning Solution | Apply a suitable flexo plate cleaning solution to effectively break down ink residues. |
| 2 | Gently Scrub the Plate | Use a soft brush or cloth to gently scrub the plate, removing leftover ink residues. |
| 3 | Dry the Plate | Allow the plate to dry thoroughly with water after cleaning to avoid any moisture damage. |
| 4 | Avoid Over-rubbing | While rubbing is allowed, avoid excessive pressure to protect the surface and avoid damaging the plate. |
How Thick Is The Flexo Printing Plate?
What are the flexo printing plate thickness：
| No. | Thickness Range | Recommended Use |
| 1 | 1.14 – 1.70 mm | Ideal for label and flexible packaging printing. |
| 2 | 2.54 – 2.84 mm | Recommended for general packaging and corrugated board printing. |
| 3 | 3.94 – 6.35 mm | Ideal for direct printing on corrugated boxes, as it is better suited for rough surfaces. |
Conclusion
To achieve the desired outcome in flexographic printing, one must understand its principles along with the factors impacting the quality of the flexo prints. Everything starts from mounting or storing the printing plates to the materials they are made of. Each step is important in ensuring the success of the print. Printers will achieve greater operational efficiency and protract the service life of their flexo plates if they adopt the recommended standards of plate mounting, cleaning, and maintenance. This will guarantee that the quality of production is consistent and remains high.
References
What Are Flexographic Printing Plates
Flexographic Printing Plates: Which Is Right for You?
