When it comes to product packaging, it’s key to ensure that your brand’s labels are high-quality, and value driven. Due to its versatility and efficiency, flexographic (flexo) label printing has become a go-to solution for many industries.
In this blog, we utilise our global expertise in the label industry to delve into the details of flexo label printing—explaining what it is, how it works, and why it’s so widely used.
Flexo Label Printing Defined
Flexo printing is a technique that uses flexible relief plates. It’s called “flexo” because the plates’ flexibility allows the printing process to adapt to a variety of substrates, including plastic, metallic films, cellophane, and paper.
The roots of flexographic printing date back to the late 19th century. Originally known as “aniline printing,” it underwent significant evolution over the decades, particularly with advancements in ink technology and printing machinery in the mid-20th century.
Today, flexo printing is a leading method for label production due to its efficiency and adaptability in producing high-quality labels, especially in large print runs.
Walkthrough of Flexo Label Printing
What sets flexo printing apart? The use of flexible plates, fast-drying inks, and the ability to print on a wide range of materials.
This method can produce simple and complex designs for brands across various industries with high-quality results.
Printing Plates
Flexo printing begins with the creation of flexible relief plates. These plates are made from photopolymer materials, which are durable and capable of transferring ink precisely onto the printing substrate.
Inking System
The inking system in flexo printing involves an anilox roll, a cylinder coated with tiny cells that hold a specific amount of ink.
As the plate cylinder rotates, it picks up ink from the anilox roll and transfers it to the printing plate.
Printing Process
- Plate Preparation: The design is etched onto the flexible plate.
- Inking: Ink is applied to the plate via the anilox roll.
- Printing: The inked plate makes contact with the substrate, transferring the design.
- Drying: The printed material passes through a drying system to quickly set the ink.
Materials Used
Flexo printing is renowned for its versatility.
The technology enables label printers to print on various substrates, including paper, plastic, metallic films, and more, making it ideal for diverse labelling applications.
Our Leeds site provides an extensive selection of substrates to meet all of your label needs, from sustainable materials that minimise your environmental impact to luxury stocks specifically tailored for the wine market.
Flexo Label Printing Advantages
Versatility
One of flexo printing’s greatest strengths is its ability to print on various materials, from specialty papers perfect for the wine market to multiple-page labels made from polypropylene (PP) tailored for brands that require more space on their labels, such as those in the chemical and healthcare markets.
Production Efficiency
Flexo printing is known for its high-speed production capabilities. It can handle large runs efficiently, making it a preferred choice for global and national brands with bulk printing needs.
Quality
To achieve high-quality results with sharp images and vibrant colours, flexo printing relies on the precision of flexible plates and the advanced inking systems. This ensures that each print is consistent and clear, meeting the high standards required in today’s market.
Flexo Label Printing Applications
Industries Served
Flexo printing is utilized across a broad range of industries due to its versatility. Some of the many industries that All4Labels globally serves include:
- Beer & Beverage: Labels for bottles, cans, and packaging
- Cosmetics: Labels for beauty products, including tubes, bottles, and boxes
- Household Goods: Labels for cleaning products, detergents, and more
- Wine & Spirits: Labels for wine bottles, including luxury embellished labels
Product Examples
Some of the innovative packaging solutions that we offer at All4Labels UK within our flexo printing site include:
- Self-adhesive labels
- Luxury embellished labels
- Wrap-around labels
- Peel and read labels
- Multipage labels
- Reverse printed labels
Innovations and Trends in Flexo Label Printing
The flexo printing market continues to grow, driven by demand for high-quality and versatile printing solutions.
Key trends include:
Sustainability
Sustainability is a growing priority in labels and packaging. Eco-consciousness is increasingly valued across the board—from consumers to retailers and regulatory agencies—making sustainability an essential focus for brands.
This is also significant in the flexo printing industry, as many printers adopt eco-friendly practices.
As a leading pioneer in sustainable packaging, All4Labels offers label solutions within the STAR Portfolio, providing sustainability gains. These include STARDIRECT™, our patented no-label look solution suitable for glass, plastic, and aluminium containers.
With STARDIRECT™ technology, the decoration is directly printed on the liner and then transferred to the container using a ‘no-label’-look substrate, minimising plastic waste and CO2 emissions.
Discover more about STARDIRECT™ and our STAR portfolio on the All4Labels global website.
Customisation
The demand for personalised and custom labels continues to grow. This marketing tool, made possible through hybrid printing, creates a unique consumer experience.
Customisation can vary in complexity, from personalised labels adorned with customer names to design variations across labels.
Smart Packaging
Another emerging and rapidly growing trend in label printing is smart packaging. This involves implementing QR codes and other interactive elements, such as augmented reality, into labels.
Integrating this technology into your labels can deliver various benefits for brands, including data collection, product traceability, and increased overall consumer engagement and loyalty.
Elevate Your Packaging with Flexo
As a versatile and efficient printing method, flexo label printing benefits a wide range of industries and applications. Its ability to produce high-quality prints on various substrates makes it a preferred choice for many brands.
The impact of flexo label printing in the packaging industry is substantial. As technology advances and sustainability becomes increasingly important, flexo printing continues to evolve, offering innovative solutions that meet the demands of the modern market.