When you want to print on cardboard, plastic, metallic film or even fabric — at scale and with consistency — you need flexographic printing.
Flexographic printing (or flexo, as it’s often called), is the modern version of “letterpress printing”. From cereal boxes and plastic shampoo bottles to medical packaging and print media, using this process, colours and designs can be applied to almost any kind of substrate.
Despite having been around for over a century, flexographic printing remains the premier and go-to solution for many brands and businesses: it has extremely high press speeds, it’s suitable for long print runs, it can be used on almost any kind of substrate and requires little configuration.
However, the future of flexographic printing is an interesting one. New digital solutions, such as laser and inkjet printers, provide brands and businesses with an alternative to the now “traditional” flexographic printing method. These plate-free technologies require almost no set-up time, making them ideal for small- to mid-sized print runs.
Sustainability and flexibility are also key concerns to the future of flexographic printing. With brands and businesses across the globe under pressure to deliver products in eco-friendly packaging, are they equipped with the right flexographic printing solutions and prepared for what the future holds?
Let’s take a look at some of the technologies and changes that will define the future of flexographic printing.
According to Smithers, an industry-leading, multinational provider of market research, testing, consulting and compliance services, the global value of flexographic printing will rise from $167.7 billion in 2020 to $181.1 billion in 2025.
This increase can be attributed to the fact that flexographic printing continues to advance. Digital printing solutions offer cost-effective alternatives for small to mid-sized print runs, certainly, but flexographic printing remains the best choice for high-volume, high-accuracy printing.
For example, we’ve seen developments in plate mounting technology, sustainable inks (i.e. water-based), press accuracy, automatic register control, digital screens for plates, adhesives and many more components of flexographic printing. It’s not as simple as choosing one (flexo) or the other (digital).
The future of flexographic printing will combine both traditional (flexo) and digital solutions. This gives brands and businesses the flexibility they need to print in specific ways, meeting the diverse needs of today’s market, while keeping costs down. But more on that later.
One of the great things about the future of flexographic printing is that modern solutions — i.e. self-adhesive plate mounting — are sustainable by design.
Firstly, flexographic printing plates are designed to be used for high-volume print runs. This makes the process much more sustainable, adaptable (which is increasingly important given the push for eco-friendly packaging) and cost-effective where repeat orders are common.
Secondly, modern flexographic printers use far less energy. Newer devices feature regenerative drives that allow the printers to use the equipment’s own inertia to regenerate energy at a later time. For example, as you stop and slow down the machine, the energy is absorbed, stored in capacitors and then used when the machine returns to operation.
Thirdly, high-performance drying systems will become more prominent throughout the flexographic printing process. Businesses will use them to reduce time, cost and energy waste — all while delivering an excellent printing result. These thermal drying systems will eliminate the need for solvent in the plate making process, which is safer and provides a cleaner environment.
Finally, the future of flexographic printing will likely include reusable, high-quality self-adhesive mounting plate sleeves.
Take our tesa® Twinlock solution, for example. The first of its kind, tesa® Twinlock provides a high-quality, self-adhesive compressible sleeve that ensures consistent, high-quality printing.
It starts with adding a polyurethane (PU) foam layer to the top of the base sleeve (from the customer’s preferred supplier). The PU foam is then coated with a unique polymer that is permanently tacky.
The benefits? Fast printing speeds, lasting print quality without adjustments, excellent registration, lower running costs, reduced carbon footprint, faster ROI when reusing for repeats and more precise estimates for production costs. What more could you ask for?
For more on how sustainability will influence the future of flexographic printing, read this article.
The flexographic process has traditionally relied on the skill of the operator, but OEMs are increasingly involved at every stage.
With this tight-knit partnership, in the future, OEMs will be able to develop for-purpose solutions, aiding with process, plate preparation, and planning. The end result will be shorter turnaround times for print runs and turnovers.
Automation will address the shortage of skilled labour in the flexographic printing industry, but also allow existing operators to focus on the quality of produce and sustainability initiatives.
The future of flexographic printing is hybrid: a blend of digital technologies and what are now “traditional” flexographic printing practices.
The reasons for this are simple: a dual operation provides brands and businesses with the flexibility they need to drive sustainable package printing in the future. Whether they need to accommodate short or medium print runs with highly specific (or specialised) labelling through digital technology — or need a robust, high-speed and environmentally friendly option in the form of flexographic printing and plate mounting.
The two are complementary technologies that can position your print business for future success.
Preparing for the future of flexographic printing now will enable your brand or business to seize new opportunities later. Plate mounted solutions, automation and digital print provide new features and functions that will keep your business flexible, adaptable and ready for any customer requirements, both now and in the future.
At tesa, we’re committed to helping print businesses future-proof their operations and seize new opportunities through sustainable, high-quality, and efficient processes and technology.
To help you navigate that future, we’ve put together a detailed guide outlining the latest trends and developments in the industry — as well as what they mean for your brand or business. Click the button below to download your free copy.