Prepress production of flexographic printing plates

With the development of social economy and the improvement of people's living standards, they began to pay attention to the aspects related to their own health, and concerned about the health effects of daily necessities, food, and packaging products used in life. As a kind of environmental protection printing, flexographic printing is used more and more in packaging products in European and American countries, with a larger share. Especially used are products related to people's lives such as napkins and disposable paper cups.

Paper cups are one of the daily necessities commonly used by people. When drinking from disposable paper cups before, when the cup is raised to the mouth, you will smell a little pungent odor. Do you know why? Because paper cups used to be printed by offset printing before, the smell is the smell of offset printing ink; offset printing ink itself contains harmful ingredients to the human body. Previously, domestic packaging products printed with offset printing were exported to foreign countries, and the whole batch of goods was returned because they did not meet the foreign environmental protection requirements.
Now you can't smell the pungent smell of paper cups when you drink in KFC, it is because it uses flexographic printing. Flexo printing uses environmentally friendly water-based inks, which have passed the EU environmental certification.

Of course, flexographic printing has its own shortcomings. Because it is web printing, it is a bit worse than offset printing in terms of registration. Offset printing is usually done in Y, M, C, and K. Many small texts are printed in two or three colors. If flexo printing also uses multiple colors to overprint small text, the effect is definitely not good, so at this time flexo color can be made into spot color for printing. This not only reduces the problem of overprinting, but also the hue of the text is stable.

Figure 1 is a small text stacked in two colors. We can see that due to the problem of overprinting, the text has two color edges.

Comparison between flexo printing and gravure printing: gravure printing can be made of a solid version of the ground and the screen line on a single plate. When engraving the plate, the depth of the printing plate is engraved, so that both the ground and the screen line get better results when printing. Flexo printing can't take care of both if a large-area field and a large-scale network cable are used in one plate when making a plate: the screen printing needs to use light pressure, and the printing field needs a little more pressure. If the screen printing is done, then The part on the ground is false (not thick enough); if it is solidly printed, the dots are deformed too much, as shown in Figure 2.

We recommend that if you encounter a situation where there are both color patterns and a solid field, you can divide it into two plates when making a plate, and separate the plate from the color network cable. [next]

Flexographic printing is a kind of printing between offset printing and gravure printing. Its ink layer is thicker than offset printing. In addition, it has the following characteristics:
· Environmental protection printing;
· High color saturation;
· Stable printing quality;
· Flexible combination printing;
· Can be connected with screen printing, offset printing and gravure printing;
· Bronzing, die-cutting unit in-line processing to finished products and other advantages.

The quality of a packaging and printing product depends on what kind of printing its design is suitable for. Design according to the characteristics of the flexographic printing method, give full play to the characteristics of flexo printing, you can print flexo quality; for example, you can design multi-color spot colors, because flexo printing is by anilox roller ink, only one net Quantitative ink transfer of the pattern roller, the amount of ink transferred to the printing plate during the printing process is basically the same. Compared with the ink transfer method of offset printing and gravure printing, its ink color is more stable and the characteristics of stable printing quality are brought into play.

Here are a few things to note about flexo pre-press design.

The following points should be avoided:
· Excessively small text and thin lines;
· Lines or text that are overprinted in two or more colors;
· Small reverse text or reverse lines;
· The picture is off with high light, or 1% small outlet;
· Make lines and text in Photoshop software;
· Design wide and long bars and ground along the horizontal direction of the printing cylinder;
· Avoid long and wide gradient design in the printing direction;
· Large-area field is on the same page with the outlets and small text;
· Inconsistent operating software, etc.

The aspects to be noted in the design artwork format are:
· Due to the fact that design companies often need to operate in Photoshop in design, however, because flexo needs to be adjusted on the image according to the characteristics of flexo before making a plate, it is best to save it if there are layered files psd format;
· Do not put the final layout output program of the entire design draft, pictures and text in Photoshop software at the same time (see Figure 3);

· Picture accuracy is not less than 300dpi;
· Graphic design operation can use Illustrator, Freehand professional typesetting software. [next]

Use Photoshop software to make the text come out, the edges are jagged.
Take a look at the effect of printing the small reversed text, some strokes of the text are pasted together, as shown in Figure 4.

Designing a long and wide gradation along the printing direction is prone to ink stick phenomenon, as shown in Figure 5.

Above we have listed some designs that are not suitable for flexo printing. You can take a look at some more suitable designs for flexo printing.

The background color in Figure 6 is a spot color field. The dark document above is directly imprinted on the background color, and there is no overprint problem. The edge of the flower is lighter in color, and there will not be a darker color due to overlapping colors with the background color buckle.

The overall design of Figure 7 uses four colors + spot colors, there are not many opposite colors, because it is suitable for flexo printing, so the overall printing effect is very good. A reasonable process also has a great impact on printing. Since more flexo products are now transferred from the original offset or gravure printing, we also need to change the process. For example, as shown in Figure 7, the original design was designed according to offset printing. In the process, we separated colors according to the characteristics of flexo printing. The base image was completed in four colors, and the red color blocks and text were printed in spot colors. For flexographic printing, the quality of color separation also plays a key role in the printing effect. [next]

Color separation principle:
· Whether it is close to the original;
· According to different printing characteristics;
· Image contrast;
· Image contrast;
· Image authenticity;
· Meet the requirements of plate making.

Although the flexographic plate making is not to be screened as much as possible, some products can also be screened. Of course, we are required to perform some technical processing on the image so that the opposite color of the printed product will not change due to the 3% dots. It's dark, and it's not like a hard cut like a normal broken network. Figure 7 is made by us using absolute network technology.

At present, 175 lines can achieve 1% to 97% of plate making, but we generally do not recommend customers to make too high anilox number. On the one hand, the number of plate making lines should be determined according to the anilox rolls configured by the printing factory. From the author's experience, the difference in the number of network lines is within 20 lines, usually there will not be too much visual difference, but there is a big difference in the printing plate durability, such as the 175 line printing plate durability It is 40% less than the 150-line printing plate; it is also higher in terms of cost. On the other hand, in terms of the yield of printing, the phenomenon of blocking ink at 150 dots will be less than that at 175 lines, so the yield will be higher invisible.

Although Figure 8 is a 150-line product, the printing effect is very delicate.

The above are some of the author's technical experience, share with you readers. The above products are all printed by traditional flexographic printing, and the printing effect is close to that produced by using laser printing. At present, through some technical adjustments, our company can allow users to use traditional flexographic printing to achieve an effect close to that of laser printing.

In order to better serve customers, the company has set up a technical department, and employees have more than ten years of flexographic platemaking / printing experience, which can meet the technical requirements of customers' offset printing and gravure printing to flexographic printing, making products more suitable for flexographic printing. . At present, the largest plate-making format that our company can provide is 200cm × 130cm, and the maximum number of lines is 175 lines.

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