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At Multifilm, we print using flexo presses. Flexographic printing works much like a rubber stamp: Printing ink is transferred from a "pad" and is "stamped" on to the substrate using a rubber plate or cylinder. Ink is contained in a pan and is transfered to an engraved steel cylinder, called an anilox roll, using a rubber cylinder.
The ink is transferred from the anilox roller to rubber plates that are mounted on steel cylinders. The plates have a raised surface that transfers the ink to the substrate in the desired design. The amount of ink that is laid down on the substrate is controlled by the anilox roll, which is engraved with small "pockets" that carry the ink. The smaller the "pockets", the less ink is transferred, and the finer the print quality.
Most flexo presses are equipped with a large razor blade, called a doctor blade, that scrapes off excess ink from the anilox roller.
The main advantage of flexo printing is inexpensive plates, making the upfront investment smaller. In addition, modern flexo presses have come very close to matching the print quality of roto. Most plate makers today use digital technology, and turnaround is very quick.
Flexographic printing is the most widely used printing process in North America today. Other printing processes include rotogravure and off-set.
Rotogravure printing uses an engraved metal cylinder, which contains the desired design, which is rotated in an ink pan. A doctorblade removes excess ink, and the ink contained in the engraved area is transferred directly to the substrate.
The main advantage of roto is the excellent image reproduction. In addition, printing cylinders typically do not wear out, which makes this process well-suited for long runs. Unfortunately, the cost of the cylinders is very high and lead time tends to be measured in weeks, not days.
By contrast, flexo plates are inexpensive, making the upfront investment smaller. In addition, modern flexo presses have come very close to matching the print quality of roto. Most plate makers today use digital technology, and turnaround is very quick.
Offset printing is mostly used to print cardboard and paper, where the inked image is transferred, or "offset", from a printing plate to a rubber blanket, then to the substrate. Offset, or lithographic, printing produces a high-quality image, low cost plates, and is well suited for small runs and narrow webs. However, repeat lengths are often limited.
