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Conventional Printing

Conventional UV Flexo Printing:

Used in the packaging and label industries. It merges the traditional principles of flexographic printing with the advanced technology of ultraviolet (UV) curing, resulting in a process known for its efficiency, durability, and versatility.

At its core, flexography is a form of rotary printing that utilizes a flexible photopolymer printing plate. This plate, which carries a raised image of the desired content, picks up ink and transfers it directly onto a moving substrate. The “UV” aspect refers to the specialized inks that are dried, or “cured,” almost instantly by exposure to intense UV light.

The Step-by-Step UV Flexo Process

The conventional UV flexo printing process is a continuous, high-speed operation involving several key stages:
1

Plate Mounting

A flexible printing plate with the raised design is mounted onto a rotating cylinder inside the printing press. A separate plate is required for each color being printed.

2

Ink Transfer

An enclosed chamber, known as a chambered doctor blade system, holds the UV-curable ink. A rotating roller, called an anilox roll, sits partially submerged in this ink. The surface of the anilox roll is engraved with thousands of microscopic cells that pick up a precisely controlled amount of ink.

3

Doctoring the Anilox Roll

As the anilox roll rotates, a doctor blade scrapes off any excess ink from its surface, ensuring only the ink held within the engraved cells remains. This precise ink metering is crucial for achieving consistent color and quality.
4

Inking the Plate

The anilox roll then transfers its ink onto the raised portions of the flexible printing plate as it rotates.
5

Image Transfer to Substrate

The substrate, which can be paper, film, or foil, is fed through the press and pressed against the inked plate by an impression cylinder. This transfers the image from the plate directly onto the substrate.
6

UV Curing

Immediately after the ink is applied, the printed substrate passes under a powerful UV lamp. The UV light triggers a photochemical reaction in the ink, causing it to harden and cure instantly. This process is repeated for each color station until the full design is printed.
7

Finishing

Because the inks are instantly cured, the printed web can be immediately sent for finishing processes like die-cutting, laminating, embossing, or slitting without the risk of smudging.+

Key Advantages of Conventional UV Flexo Printing

This method is a popular choice for many applications due to its significant benefits:

High-Speed Production

UV flexo presses can run at very high speeds, making the process extremely efficient and cost-effective for medium to long print runs.

Exceptional Durability

The UV curing process creates a hard, resilient ink film that is highly resistant to abrasion, chemicals, moisture, and fading from sunlight.

Superior Print Quality

The process delivers vibrant colors, sharp text, and crisp, high-resolution graphics. The instant curing prevents ink dots from spreading, leading to a higher quality image.

Substrate Versatility

UV flexo can print on a vast range of materials, including non-absorbent substrates like plastics (PP, PE, PET), foils, and films, as well as traditional paper and board.

Environmental and Safety Benefits

UV inks are typically free of solvents, which means they release minimal volatile organic compounds (VOCs). This makes them a more environmentally friendly option compared to solvent-based inks.

Immediate Finishing

The instant cure allows for in-line finishing, streamlining the entire production workflow and reducing turnaround times.

Limitations to Consider

Despite its advantages, there are some limitations to conventional UV flexo printing:
  • Setup Costs: The process requires the creation of physical printing plates for each color in a design. This initial setup cost makes it less economical for very short print runs compared to digital printing.
  • Not Ideal for Prototypes: The plate costs and setup time make it inefficient for one-off prototypes or very small quantity jobs.

Common Applications

The combination of speed, quality, and durability makes UV flexo printing ideal for a wide array of products, particularly in the packaging sector:

  • Product Labels: For food, beverages, cosmetics, pharmaceuticals, and household chemicals.
  • Flexible Packaging: Such as pouches, sachets, and wrappers.
  • Shrink Sleeves: Full-body labels that conform to the shape of a container.
  • Cartons and Folding Cartons: For consumer goods and retail packaging.
  • Tags and Tickets: Including industrial tags and event tickets.