Talking flexo

Talking flexo

Converting Today speaks with Paul Hesketh, print development manager at FFP Packaging Solutions, to gain insight into how flexo has developed across the industry, and how digital is impacting on the packaging sector.

From a packaging perspective, is flexo holding its own against digital?

Paul Hesketh: As a supplier of flexible packaging to several large brands and all the major retailers, we are keeping a close eye on developments within digital, and assessing if the process is becoming a viable option. Improvements in speeds and applications have certainly been made in recent years and we are in regular contact with HP [to keep track of] their new innovations. However, at FFP, within the food sector of flexible packaging, flexo is still the dominant process in our area. For added-value products such as ovenable, microwaveable packaging, there are technical aspects of the flexo ink systems that are ahead of their digital counterparts. Flexo is also still more viable for print runs over 5000mts due to higher machine running speeds.

Can you point to any innovations with flexo in the packaging sector that illustrate how this process still has value to brands?

Brand image is very important, and quality and consistency on shelf is crucial for maintaining a strong brand image. New developments in colour management and plate technology, plus the latest printing press developments, have kept flexo ahead of the other processes in flexible packaging.

In terms of consistency, as on-shelf colour is key, we are using the latest software developed by X-Rite ColorCert in conjunction with PantoneLIVE, as this allows brands to choose a colour from a dedicated flexo colour library via the cloud that we can formulate and match accurately. We can then measure the colour on press using spectrophotometers and upload colour data to the cloud for the brand owner to view. This gives the customer visual confirmation in real time that every printed reel of film coming off the press is consistent.

In recent years, plate technology in flexo has improved massively. Among others, we are using Asahi AWP, a digitally imaged and water-processed plate produced at our in-house plate making facility at 4000dpi and 150lpi. We are printing strong vibrant solids with the use of microcell technology and printed highlights down to 5%, which is comparable to gravure, litho and digital.

Are there any trends in the flexo printing sector that will shape the industry in the near future?

All of the suppliers to the flexo industry such as anilox, plates, inks, mounting tapes and press manufacturers have been developing their products. This has seen huge improvements in quality and efficiency. These improvements have allowed us and other flexo printers to use four-process colours as a fixed colour palette to produce designs for retailers and brands. It is now possible to achieve a high percentage of the Pantone library from CMYK. Combined with this, flexo press manufacturers have developed high tech machines that run much more efficiently with little waste; there are automatic wash-up systems, automated setting and register systems on our W&H Miraflex and, with faster running speeds, we have significantly improved output.

How is flexo reacting to the developments of more interactive packaging designs (NFC-enhanced labels, for instance) that offer consumers more engaging on-shelf experiences?

Ink manufacturers within the flexo sector offer various coatings and special inks, such as fluorescents that glow in the dark. We have used these in the past for brands in promotions for Halloween. We also use other coatings to recreate the paper feel on film using matt and tactile lacquers. Achieving this is a huge saving to our customers as this would normally need a film laminated to paper; using a paper-feel coating saves a substrate and a process.

Are there any particular flexo innovations coming up at drupa that you are particularly excited about?

There are new innovations from EFI and GMG on the proofing side of things. We are always confident in providing accurate predictions of our CMYK print to proof. However, when predicting tonal values of Pantone colours and Pantone overprints, this is an area that needs improving. GMG and EFI have made some strides in these areas and we are keen to see these developments. The latest in digital from the major machine manufactures will also be interesting, as will new innovations from the flexo machine manufacturers and suppliers to the flexo industry in general.