It is also used to a limited extent for newspaper printing. Flexo print quality has gone through major improvements in quality with flexo CtP that provided better more controllable plates, and these plates have had a significant impact on the type of work being printed.

I have recently received input on two major ongoing developments in flexo platemaking and workflow that are likely to further enhance the flexo printing markets. Flexo printing has many benefits over other printing processes in that it is almost a digital process. Once the plate has been made and the press made ready there are not constant variations in set-up, as with offset, to keep the presses running at high quality.

In that approach it is similar to gravure, however gravure, because of its high prepress costs and high press costs, is mainly seen as a long run color printing process. Flexo is much more suited to short runs because of much simpler presses and lower prepress costs. Gravure also runs at higher speeds.

In packaging flexo is more the smaller format short run approach whereas gravure is for very long runs. Both gravure and flexo can print on a wider variety of substrates than offset and because of these are the only technologies for flexible packaging. (No doubt Agfa with its Dotrix and HP Indigo with their new HP Indigo 7200 press will dispute this).

The two new developments in digital flexo workflow and CtP come from EskoArtwork and Kodak. I’ll cover Kodak first as they are the newcomer to this area.

At drupa last year Kodak introduced its new Flexcel NX system for flexo platemaking. Kodak Flexo NX system comprises the new Kodak Flexel NX digital flexo plates, the Kodak Approval digital color imaging system for accurate color proofing, the Kodak Prinergy PowerPack Workflow System, and the Kodak Cutting and Creasing Table. The Kodak Flexcel NX plates are imaged in the Kodak Flexcel NX Digital Flexographic System that is based upon a Kodak Trendsetter CtP system.

This images the special Flexcel NX material that is then laminated to the Flexcel NX plate prior to imaging. The Kodak claim is that these plates can produce achievable print quality up to 300 lpi, with dots as small as 10 micron.

Kodak has recently sent me an impressive package called Kodak Power of Packaging. This shows three samples produced both on the Kodak Approval digital color imaging system for proofing using the printing substrates, and with printing using the Kodak Flexcel NX plates on both Gallus and Arpeco flexo presses on PVC, folded carton stock, and adhesive Opticite substrates by Ginzler Graphic Inc. and York Label. I have to say I have difficulty in assessing which product is a proof and which is the printed product. All the items contained the packaged products; in this case a Kodak Funsaver Single Use Camera. The comments from the printers were exceptional including the following. “I’ve never seen flexo printing of this quality and consistency across such a wide range of substrates.”

Kodak is obviously looking with the new Flexcel NX system at expanding its role in traditional flexo markets, but also because of the achievable quality in opening new markets, perhaps including magazines as it challenges gravure and offset. The benefits in this case would be lower printing costs on low cost substrates, lower set up costs than gravure, and consistent quality. It will be interesting to see how this develops.

I stated earlier I had received input on two new flexo developments. The other came from the established market leader in digital flexo, this being EskoArtwork. The development is HD Flexo. In order for the quality of flexo printing to rival offset, the flexo platemaker needs to use the combination of high-resolution optics along with an exceptional screening technology.

EskoArtwork, the world leader in digital imaging of flexo plates and sleeves is revolutionizing flexo platemaking with the introduction of HD Flexo, a system that combines 4000 dpi HD optics along with unique screening technologies to take advantage of sharper and more accurate imaging. This technology will be available on new Cyrel Digital Imagers (CDI) and can be upgraded on all existing CDI systems.

HD Flexo combines high resolution, 4000 dpi optics, with proven screening technology used by many printers as the ideal solution for highlights and exceptional flexo print quality. The high-resolution optics are claimed to deliver more accurate, sharper imaging of text and line art. With the higher resolution, the optics also deliver more clearly defined, better-shaped screen dots, because the dots are made of more pixels.

The rounder dot shape means that they are more stable on press, resulting in longer print runs with the same printing plate. HD Screening places both large and small dots in the highlight areas to extend the tonal range to a much smaller percentage value than was previously possible with digital flexo. This effect can only be achieved through the combination of higher resolution optics and smart screening. The HD Flexo system can use flexo plates from a number of vendors.

According to EskoArtwork the ‘holy grail’ for flexo has always been the promise of developing a system that matches the quality and ease of use of offset CTP. With HD Flexo, EskoArtwork closes that gap by offering consistent color and print quality, once more raising the industry standard for flexo quality.

At drupa I reported on four new developments in flexo platemaking, and the above are two of these. The others are due to come from McDermid and Fujifilm. What the above indicate is that flexo is not standing still and is reacting to the challenge that is coming from digital systems like the new HP Indigo 7200 press. The Kodak and EskoArtwork technologies that have been announced and are in the market show that flexo is likely to move forward and continue growing. While flexo may be losing much of the label market to digital it looks likely to expand its role in packaging and even move into new areas, possibly magazines.

Comment below to have your say on this story.

If you have a news story or tip-off, get in touch at editorial@sprinter.com.au.  

Sign up to the Sprinter newsletter