137 Modern Day Printing Methods: Flexography

Introduction

If you were to look around your surroundings right now, you would be able to find a product or package that has been directly or indirectly affected by flexographic printing. Whether it might be the label on the back of your phone or the packaging of the bag of chips you are eating, these are all influenced by this printing method. Since the beginning of printing methods dating back to Gutenberg in the mid-fifteenth century AD (Rees 2006), different kinds of printing methods have been created and evolved through the years. The flexographic printing process’s integration into everyday packaging profoundly shapes societal norms and consumer behaviors through its cost-effectiveness, versatility, and efficiency in mass-producing labels, wrappers, and cartons for diverse products, reflecting its significant impact on modern consumption patterns and brand recognition.

History

Although printing methods have been around since the fifteenth century with Gutenberg, this process has been around since the late nineteenth century. Until the 1950s, this printing method was named “aniline printing in reference to the kinds of inks typically used in the process” (Gomez 2000).  When this process first began, it started with an idea of printing with rubber plates. This differentiated this rotary press from the rest of printing methods out there. One of the first packaging materials used with this press was corrugated boards. With this unique type of material, it made it difficult to print on with other printing methods which gave way to a new method. With this method, it involved rubber plates, oil-based inks, and corrugated boards. This type of material cannot directly be considered a part of flexographic printing, but it inspired more in this method (Gomez 2000).

Steps within the Process

 The science behind this process is intricate and multifaceted. Before printing can commence, a meticulous design must be created and refined on a computer. Flexography offers two primary color processes: the versatile four-color process, capable of rendering any image with realism, and spot colors, which provide precise color matching and nuanced variation through halftones.

Once the designer ensures the design’s integrity, it progresses to the critical prepress stage. Here, meticulous quality checking and proofing are conducted by printing experts, who scrutinize every detail to ensure color accuracy and eliminate potential printing flaws. This meticulous process not only ensures a flawless final product but also relieves the press operator of concerns during printing.

Following quality assurance, the process advances to platemaking, a pivotal step where the image is transferred onto photopolymer plates. These plates, comprised of flexible layers, precisely capture the image on one side while maintaining structural integrity on the other. Depending on the design’s complexity and color requirements, multiple plates are created to accurately reproduce the image. Once the image is successfully imprinted on the plate, it is mounted onto a cylinder, ready for production.

Plate mounting in flexography involves the precise attachment of a flexible printing plate onto a cylinder or sleeve in preparation for printing. This process requires meticulous attention to detail to ensure accurate registration and consistent print quality. Initially, the printing plate is carefully cleaned to remove any residue that could affect adhesion. Next, the plate is positioned on the cylinder or sleeve, often utilizing specialized mounting equipment for precision alignment. Adhesive tapes or adhesives are then applied to securely bond the plate to the substrate, ensuring it remains firmly in place during the printing process. Throughout plate mounting, operators must maintain tight tolerances to prevent misalignment, which could lead to blurred or distorted prints. Once mounted, the plate is ready for ink application and subsequent printing, enabling high-quality, vibrant results in flexographic printing applications.

In the next and final step of the flexographic printing experience, it is time to print the design onto the desired roll of substrate using the correct and accurate inks. By mounting the cylinders into the press, prepping inks, and aligning the substrate, this thorough setup process allows for the results to be as accurate and precise as it can be. After starting up the press, the cylinder rolls into the ink tray and then impress onto the substrate creating the image. Multiple colors in the design means more inks in the press which means for precise aligning and registering the colors to give clean lines and images. Operators orchestrate the process, fine-tuning settings to maintain optimal print quality. Careful inspections occur throughout, detecting any deviations that could compromise the final product.

Connections to STS

Flexography revolutionizes packaging production, enhancing efficiency and reducing costs. With its ability to print on a wide range of substrates, including non-porous materials like plastics and foils, flexographic printing enables the creation of vibrant and durable packaging for food, pharmaceuticals, and consumer goods. This translates to safer, more visually appealing products on the shelves, contributing to consumer satisfaction and brand recognition. Moreover, the adaptability of flexographic printing technology fosters sustainability efforts. By utilizing water-based and UV-curable inks, it minimizes environmental impact compared to traditional solvent-based inks. Additionally, its efficient ink transfer and minimal waste generation during setup and production reduce resource consumption, aligning with eco-friendly practices and regulatory standards. This eco-conscious approach addresses societal concerns about environmental sustainability and fosters a more responsible manufacturing ethos.

Missing Voices

Women’s involvement in the flexographic industry is significant, but their voices can sometimes be overlooked due to various factors. One example is in leadership roles within companies. While women may be involved in various aspects of flexographic production, including design, prepress, and press operation, they may be underrepresented in higher-level management positions where key decisions are made. Additionally, in male-dominated work environments, women’s contributions and perspectives may not always be valued or given equal weight during discussions and decision-making processes. Another example is in industry events and conferences, where panels and speakers may be predominantly male, leading to a lack of diverse viewpoints and experiences being shared. Due to this lack of representation, a group of women came together to form the Women in Print Alliance. This organization advocates and promotes women in the industry and educates the broader printing industry on the benefits that would help printing companies thrive (“Women in Print Alliance”). Furthermore, implicit biases and stereotypes about gender roles can influence perceptions of women’s abilities and expertise, potentially leading to their voices being marginalized or dismissed in professional settings. To address these challenges, it’s essential for companies to promote diversity and inclusion initiatives, provide opportunities for women to advance into leadership roles, and actively seek out and amplify women’s voices in industry discussions and events.

Conclusion

In conclusion, the discussion on flexography has provided a comprehensive understanding of its rich history, intricate process, and multifaceted involvement of STS and missing voices in the industry. Flexography’s journey from its humble beginnings to its current state as a versatile and widely used printing technique showcases its adaptability and innovation over time. Through advancements in materials, equipment, and techniques, science and technology have played pivotal roles in shaping flexography into a highly efficient and sustainable printing method. Moreover, the societal impact of flexography is profound, as it facilitates the production of a vast array of printed materials that influence communication, marketing, and consumer behavior on a global scale. As we continue to explore new frontiers in flexographic printing, it’s essential to recognize the interconnectedness of history, process, and societal context, ensuring that this dynamic industry evolves in harmony with the needs and aspirations of a diverse and ever-changing world.

Citations

Gomez, Ana. (2000) “A Historical essay on the development of flexography” . Thesis. Rochester Institute of Technology. https://repository.rit.edu/cgi/viewcontent.cgi?article=4829&context=theses

OpenAI. (2023). ChatGPT (Apr 28 version) [Large language model]. https://chat.openai.com

Rees, F. (2006). Johannes Gutenberg: Inventor of the Printing Press. Google Books. https://books.google.com/books?hl=en&lr=&id=8kmsUImcv50C&oi=fnd&pg=PA9&dq=johannes%2Bgutenberg&ots=ZxdCypVyQe&sig=ZcBrtiNq9Ef-NO9bwvE9sy1g564#v=onepage&q=johannes%20gutenberg&f=false

Liu, X., Guthrie, J.T. A review of flexographic printing plate development. Surface Coatings International Part B: Coatings Transactions 86, 91–99 (2003). https://doi.org/10.1007/BF02699619