Labels play a crucial role in product identification, branding, and information dissemination. The process of creating labels involves precision, efficiency, and attention to detail. Flexographic printing, with its versatility and speed, is a widely used method for label production. In this blog post, we will explore how labels are made on a flexo press, highlighting the key steps involved in the process.
Design and Prepress:
The label creation process begins with the design phase. Graphic designers create the artwork, considering the brand elements, product information, and any regulatory requirements. Once the label design is finalized, it is prepared for printing using prepress software. This involves separating colors, optimizing images, and creating the printing plates necessary for the flexo press.
Plate Preparation:
Flexographic printing utilizes printing plates to transfer ink onto the label substrate. In the plate preparation stage, the chosen printing plates, typically made of photopolymer or rubber, are mounted onto the plate cylinders of the flexo press. The plates are securely fixed and aligned to ensure accurate printing registration.
Ink Preparation and Mixing:
Before printing, the ink needs to be prepared and mixed to achieve the desired colors and consistency. Ink technicians follow specific formulations and Pantone color references to ensure accurate color matching. Ink viscosity is adjusted to suit the requirements of the label and the printing press.
Printing Setup:
Once the press is ready, the operator sets up the parameters for the specific label job. This includes adjusting the tension of the label material, setting the printing speed, and fine-tuning other press settings. The printing press is equipped with various components, such as anilox rolls, doctor blades, and ink chambers, which control ink transfer and ensure precise printing.
Printing:
With all the preparations in place, the flexo press begins the label printing process. As the label material passes through the press, the ink is transferred from the printing plates to the substrate. Flexographic presses use a combination of printing stations, each dedicated to a specific color or varnish. The plates on each station rotate against an impression cylinder, transferring the ink onto the labels.
Drying and Finishing:
After printing, the labels go through a drying process to ensure the ink is fully cured and ready for further processing. Drying can be achieved through various methods, such as hot air, UV curing, or infrared drying, depending on the ink and label material used. Once dried, the labels may undergo additional finishing processes, such as die-cutting, laminating, varnishing, or embossing, to enhance their appearance and functionality.
Inspection and Quality Control:
Before the labels are deemed ready for use, a thorough inspection and quality control process takes place. This involves checking for color accuracy, print registration, and any defects or imperfections. Labels that meet the quality standards are prepared for packaging and shipment.
Conclusion:
The production of labels on a flexo press is a multi-step process that combines design, prepress, plate preparation, ink mixing, printing setup, actual printing, drying, and finishing. Flexographic printing offers excellent versatility, speed, and print quality, making it a preferred method for label production. From product identification to branding, labels created through the art of flexographic printing play a vital role in communicating information and captivating consumers.