5 Tips for Optimizing Your Corrugated Flexo Printing Machine

Introduction

Flexographic printing on corrugated packaging is an art as much as a science.

A well-tuned flexo printing machine can produce vibrant, high-quality prints that help your brand stand out. However, maximizing your machine’s potential requires more than just a basic understanding of its operation. Here are five tips to ensure you’re getting the best performance out of your corrugated flexo printing setup.

Use the Right Anilox Roller

The anilox roller is one of the most important components in flexo printing machine. It controls the amount of ink transferred to the printing plate, directly affecting print quality. Selecting the correct cell count and volume for your specific substrate and design is key. For finer, detailed graphics, choose an anilox roller with higher line screen (LPI). However, for solid, bold prints, a lower LPI roller can deliver the ink coverage needed.

Optimize Ink Viscosity of Flexo Printing Machine

Ink viscosity plays a key role in achieving the right print quality. Too thin, and the ink may bleed, causing blurring and color inconsistencies. Too thick, and it may not flow smoothly, resulting in an uneven application. Use a viscometer to monitor and adjust ink viscosity regularly. Maintaining the right temperature and humidity in the printing environment can also help in stabilizing ink performance.

Tip: Test the ink before running large batches to avoid waste and ensure consistent results.

Maintain Consistent Tension Control

For precise registration and sharp images, controlling the tension of the corrugated board is essential. Inconsistent tension can lead to misalignment and distorted prints. Ensure that tension throughout the machine is constant from the unwind section to the rewind. Regularly inspect tension settings and adjust them based on board type and flexo printing machine speed.

Tip: Use automatic tension control systems to minimize manual errors and improve overall productivity.

Ensure Proper Plate Mounting and Care

Flexo plates must be mounted precisely on the cylinder for accurate print registration. Even the smallest misalignment can lead to image distortion or poor registration, especially when dealing with multi-color jobs. Use mounting tapes that provide sufficient cushioning without compromising the image quality. After printing, clean and store your plates properly to prolong their lifespan.

Tip: Periodically check for plate wear or damage, and replace plates as needed to maintain print quality.

Implement Regular Machine Maintenance

Consistent flexo printing machine maintenance is crucial to preventing breakdowns and ensuring optimal performance. Set up a preventive maintenance schedule that includes checking the inking system, doctor blades, gears, and bearings. Lubricate moving parts regularly and ensure that filters are clean. Downtime for repairs can be costly, but routine maintenance helps avoid unexpected issues.

Tip: Keep a log of maintenance activities and machine performance to identify patterns and potential problems before they escalate.

Conclusion

Corrugated flexo printing is a complex process, but by optimizing key elements of flexo printing machine such as anilox rollers, ink viscosity, tension control, plate mounting, and machine maintenance, you can achieve consistent, high-quality results. Implementing these tips will not only improve your print quality but also boost your production efficiency, ensuring that your corrugated packaging stands out in the competitive market.