This article has introduced a new space for the accurate application of flexographic printing by introducing the chemical composition, characteristics, and structure of the flexographic plate.
After more than ten years of development in China, flexo printing has begun to take shape and it has begun to occupy a place. The flexographic knowledge has been widely popularized, and the entry threshold for flexo printing has been greatly reduced. Together with the economic and environmental advantages of flexo printing, we have reason to believe that the development of flexo printing will usher in a better spring. However, in the actual flexo printing production, flexo printing, which is one of the main equipments for flexo printing, still has ambiguities and inappropriacies in use, operation and understanding. So how can we use the most suitable flexo model? How to determine the quality of flexographic quality? When problems occur in the printing process, are they all attributed to flexo?
Let us try to simplify the application of flexo.
1. The chemical composition of the flexographic plate: Different chemical compositions will affect flexographic ink suitability. Different ink types (aqueous inks, solvent inks, UV inks, etc.) must use the appropriate flexographic plate. Flexo, which is only applicable to water-based inks, can be printed by mistakenly using UV inks, which results in a reduction in the printing durability of the plate and the print quality may be very poor.
2. Flexographic hardness: Hardness is an important indicator of the quality of flexographic plates. Softer flexographic plates are suitable for printing rough printed substrates and simpler designs. Harder flexographic plates are suitable for designs with a rich print layer. The hardness is usually related to the thickness. The greater the thickness, the lower the hardness. Such as the printing of corrugated boxes should use softer and thicker flexographic plate, the domestic commonly used thickness is 3.94mm, the hardness is about 34 degrees in the Shore soft version. The folding carton, flexible packaging, etc. should be used correspondingly harder and thinner flexographic plate, the usual thickness of 2.30mm, 1.70mm and 1.14mm, hardness from the Shore 57 to 77 degrees.
3. The flexographic physical structure: It is divided into single layer and multi-layered plates. Nowadays, the market is mostly single-layered. Multi-layered plates are only one layer more elastic foam than single-layered plates. Network expansion. Due to the application of elastic double-sided tape, multi-layered plates are gradually being eliminated.
4. Thickness of flexographic plate: The thickness of flexographic plate is generally 3.94mm for the corrugated box printing. The thicker plate is higher than 3.94mm, and the thin plate is lower than 3.94mm. At present, most domestic corrugated box printing uses a flexographic plate with a 3.94 mm boundary thickness, and thin plates with a thickness of 3.18 mm and 2.84 mm are less used. For folding cartons, plastic bags and flexo flexo printing, of course, a thinner flexo plate is used, with a thickness of no more than 2.54 mm and a thinnest even 0.76 mm.
Compared to the thicker version, the thin-plate technology has the following advantages: vivid reproduction of patterns and colors, expanded dot reproduction range, enhanced print contrast, stable "relief" on the plate, high-speed printing become a reality, shortened plate-making time, and less consumption of washing solvents. It is more environmentally friendly, more resistant to printing, reduces the downtime of plate washing, and reduces the printing plate thickness, which helps to save the consumption of plate materials and helps to save resources.
5. Traditional flexo and digital flexo: No film is required for digital flexo plate making, and the data information (printing text) is directly transmitted to the flexographic plate by laser engraving a layer of black film on the surface of the plate, avoiding the traditional plate making process. The various unfavorable factors (such as incorrect copying of the film, the influence of dust during the main exposure, and the scattering of light, etc.) have greatly improved the quality of the plate making and the stability of the recopying plate, and it is also easier to obtain even and finer dots.
The main advantages of digital flexo are: reproducible quality is stable, dot gain is smaller, printing contrast is greater, printing gradation is more precise, high-light area printing quality is high, even if the main exposure time is longer, the anti-white part can be kept open.
6. Special application flexo: A flexo printing plate designed for white base printing inks, usually containing esters, ketones, or alcohol solvents, and has a very strong corrosive effect on flexo plates. Another special application flexo is a water-washed flexo plate, using water as a wash solvent, no chemical solvent, very environmentally friendly, and the plate making process is very fast. The whole process takes only 45 minutes, and it has very good resistance to UV ink and UV varnish. However, it is not suitable for water-based inks.
7. Polishing special edition: At present, there are basically four methods of offset printing, rubber roller coating, common flexo coating and special flexo coating. The effect of special edition soft coating is best. Gradually replaces the other three coating methods and is widely used.
8. Determine the quality of flexographic mainly from the following aspects:
(1) Flexographic ink transfer capability. Flexographic ink transfer must be two-sided, including both the ability to take ink from the anilox roll and the ability to easily release the ink onto the printed substrate. Ink transfer ability is the fundamental and premise of flexographic excellence.
(2) Is the flexographic print resistant? This is of vital importance. For flexographic printing production with a large print volume, the durability of flexographic printing is the key to reducing production costs. Flexographic prints are not tolerated. Not only do they show a lower number of prints, but they also show a large difference in the printing effect between the same batch of products, causing frequent pauses in printing production, high rejection rates, and even reaching the level at which the customer receives or claims. .
(3) Flexographic printing, especially wide-format flexo printing, requires very high flatness of the plate material, and the flatness of the plate material should reach +/- 15 μm. The poor flatness of the plate will not result in the best printing pressure, resulting in the inability to print high quality and uniform products.
(4) Exposure latitude of the flexographic plate. The exposure latitude is large, which is conducive to the reproduction of the details and the maintenance of open graphics, thus ensuring that the flexographic printing can be done without being dirty. At the same time, a large exposure latitude has lower requirements for plate-making equipment and operators, and the probability of error will decrease.
(5) Compatibility of outlets and the field. Flexo should have the ability to balance both dot and field printing. In terms of outlets, it is required that the dot enlargement rate of the printing medium is small, and the level reproduction is good. In the field, the ink transfer performance of the printing plate is required to be good, and the ink coverage rate is good.
In summary, the categories and application principles of flexo can not be summarized. In the actual flexographic production, the corresponding analysis should be made based on the actual conditions of the printing press, printing ink, printing substrate, and pattern design used. The most suitable flexographic model to achieve the best flexographic effect.
(Author: BASF)
Wen/Zheng Qihong
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