Flexo printing house.Production of labels

Label printing

Label printing with flexographic technology is constantly being modernized and improved. This method currently dominates in printing, thus reducing the frequency of using classic printing techniques. The advantages of flexographic label printing include:

  • easy adaptation of work effects to customer expectations,
  • simple structure of the printing system,
  • the possibility of printing at a relatively high speed (50-150m/min),
  • printing on both absorbent and non-absorbent printing substrates (papers and foils),
  • use of a wide range of inks (any Pantone color).

Compared to offset printing, flexographic printing is characterized by the lack of a dampening solution, a simpler printing process and much less waste. Low costs of making forms and prints (for runs below 1 million copies) distinguish flexographic technology from intaglio printing. One of the most important advantages of flexo printing is the relatively quick preparation of the machine for printing. Flexographic printing is most commonly used on the market and has the best price-to-quality ratio. One of the most important advantages is REPEATABILITY OF WORKS.

 

BART flexographic printing house is able to execute any project using the flexographic method. We offer printing in various shades of metallic inks. We can increase the attractiveness of the color label by using silver printing (silvering or P877 silver ink) or gold printing (gilding or printing with Pantone 871 gold ink). BART flexo printing house has the most modern machine park that allows us to achieve the highest quality production. The print on labels is checked using special automatic AVT Inspection devices (read more). By using AVT and X-Rite Spectrophotometer color measurement devices, label content and colors are repeatable and consistent with customer requirements. The effects of the flexographic process often depend on the operator/printer’s ability and commitment to achieving the highest quality results. Although high-quality machine tools are important, people operate them and the quality of the final product depends on them.

 

FLEXOGRAPHIC INKS.

The main advantages of flexographic inks include very fast drying time and reduced degree of evaporation. Immediate attainment of a dry surface allows printing with a thinner layer of ink on the printing form. Such action limits the growth of halftone dots during printing and improves print quality. UV flexographic inks are suitable for printing on absorbent and non-absorbent materials. Modern UV inks are produced in accordance with environmental protection requirements - their composition consists of renewable raw materials such as vegetable oils (not mineral). Water is also increasingly used in ink production, replacing solvents. Thanks to the continuous improvement of ink compositions, they are becoming increasingly durable while being environmentally friendly, with high standards for food contact (read more).

UV flexo inks are cured by UV rays on paper, synthetic labels, hangers and plastic loops. They are characterized by excellent printability and excellent adhesion to various types of substrates.

Modern flexographic machines print at a resolution similar to offset printing, with an ink layer thickness approaching screen printing, at the most favorable price.

Completely cured UV ink achieves optimal resistance 24 hours after the end of printing.

 

Labels with weather-resistant printing. Labels achieve a durable color print that is resistant to weather conditions - the Sun, thanks to special inks “with increased resistance to weather conditions”. These inks are made to special customer requirements. The customer should provide information on how resistant the print should be, what durability and lifespan it should have. Should it be resistant to: solvents, soap, fats, alkalis? In the case of high light resistance required, we recommend using special high-resistant HR (High Resistant) inks.

The durability of the print can be further increased by covering the label with a protective layer of varnish or laminate. If you have any questions, please contact our sales representative.

 

 

VARNISH - FLEXOGRAPHY.

The purpose of varnishing (applying varnish) is to give prints a high gloss or matte finish and protect the printed image from surface damage, thereby extending its durability and improving quality. Varnishing increases the level of gloss, color saturation, sharpness of the drawing and total range. UV varnishes create coatings characterized by very high resistance to various chemical influences, temperature and mechanical forces. With sufficient thickness and optimal technology, UV varnish coating is a guarantee of achieving a similar effect as in lamination. UV varnishes do not contain any solvents (100% dry matter), so they are considered environmentally friendly. UV curing is performed immediately after applying the varnish and lasts a fraction of a second. In the printing industry, it is believed that UV varnishes have properties similar to UV printing inks. Adherence to technological discipline is a guarantee of safe varnishing. The cured layer is chemically inactive and physiologically neutral, which means that UV varnishes can also be used when working with materials from which food packaging is to be produced.

Lacquered labels on which thermal transfer printing can be done. At the customer’s request, labels can be covered with a special varnish that protects the print while allowing it to be printed (with a label printer). Such varnish does not contain silicone - TTR varnish. A standard varnish can also be selectively applied to the label - Varnish with selection.

 

Like any flexographic printing technique, it has its advantages that distinguish it. Fixing prints on outer materials is not a problem. UV printing traditionally or with LED diodes allows for fast printing and the print dries properly. There are no such problems as the SMUDGING EFFECT - i.e. soiling of the lower part. A well-fixed print does not cause such a transfer of ink, mirror reflection on adjacent layers of material. A big advantage is the repeatability of work prints, thanks to Automatic Vision Print Inspection (read more) and X-Rite Spectrophotometer devices. Images printed with screens by applying CMYK images provide constant color. Single-color apple colors can be changed.

 

 

DISADVANTAGES - PROBLEMS.

Unfortunately, the flexographic printing technique also has its dark sides, flaws that printing houses try to eliminate during implementation. In the case of Pantone inks, slight color deviations may appear when the customer does not specify exactly what color he is interested in. Improper matching can cause color distortion in illustrations and images. Poorly matched label cutting relative to the print can also have a negative impact on label quality. These problems are detected and eliminated during production thanks to special AVT Print Vision Inspection (read more) unless the customer made a mistake at the design stage. Quality control can detect customer errors (substantive, content with spelling errors, addresses, barcodes) or polymer preparation (moire effect, insufficient drying of matrices - too short a fixation time), but the time to correct and change a bad matrix is time-consuming and in practice usually extends the order fulfillment by 1-2 days. The printing of self-adhesive labels depends on many stages, parameters and people, so if it is not perfectly conducted, it is exposed to mistakes. That is why the experience of the printing house is extremely important.

 

 

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Thermal transfer printing service is used when labels are to contain variable data such as consecutive batch numbers, consecutive barcodes (serially). TTR - thermal transfer printing can be performed on white and/or color labels prepared accordingly for this purpose. The most popular color printed with a dye ribbon is black. Text prints, address data, barcodes, numbering, pictograms, images and technical diagrams are most often printed. Nowadays, the best solution for customers is to have their own label printer with which they can print white labels. With an adequate supply of white labels, you can always label your products with the necessary data to place the product on the market. It is better to prevent and have a fully flexible solution that will provide us with delivery security.

BART TTR printing is performed at BART printing house when the customer does not have their own device or in a situation when they need a small amount of monochromatic printed products. The print can be made on almost all materials/labels available at BART. These are both ordinary and specialist materials/labels.

To make labels with variable serial print, you need to send materials for printing with data placed in Excel files.

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