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Printing

A flexographic print is made by creating a positive mirrored master of the required image as a 3D relief in a rubber or polymer material. The ink is transferred from the ink roll which is partially immersed in the ink tank. Then it transfers to the anilox roll (or meter roll) whose texture holds a specific amount of ink since it is covered with thousands of small wells or cups that enable it to meter ink to the printing plate in a uniform thickness evenly and quickly (the number of cells per linear inch can vary according to the type of print job and the quality required).

To avoid getting a final product with a smudgy or lumpy look, it must be ensured that the amount of ink on the printing plate is not excessive. This is achieved by using a scraper, called a doctor blade. The doctor blade removes excess ink from the anilox roller before inking the printing plate. The substrate is finally sandwiched between the plate and the impression cylinder to transfer the image.

Quality checks performed at this stage

  • The current ongoing job is continuously monitored for accuracy using specialised web camera for this purpose.
  • Product Quality as extrusion equipment runs best when operated on a continuous basis.
  • Before the printing is started the specific gravity of inks are checked to make sure they comply to the quality required in the print.