Quality Control in Flexographic Printing

Packaging production requires applying logos and other information for customers on wrappers. Although the modern industry offers several printing technologies, flexography comes as the most popular method. Its wide popularity is determined by the high quality of applied images, versatility in terms of applicable materials, high resistance to abrasion, and speed of processing.

Yet, to achieve the satisfactory quality of applied images and information, it is necessary to know that all parts perform properly and comply with the requirements set in the industry. This is why quality control stands as one of the essential stages of flexo technology.

Below, we’re going to consider the method of quality control in printing and packaging, outline the main steps, and point out other important features.

Understanding the Importance of Quality Control

Poor-quality wrappers result in such problems as brand damage and increased costs. Since covers will be unattractive, consumer loyalty will be lower. More funds will be spent on repeated packaging production. The following aspects affect the quality of applied information:

1. Colour accuracy. The success of wrapper appeal lies in the corresponding choice of colors and their combinations. When printing logos and info, it is vital to ensure that the printing machine applies corresponding accurate colors to materials.
2. Density. To ensure durability and resistance to abrasion, it is necessary to apply inks densely. The denser the layer is, the more vivid and attractive the cover will be. Moreover, low-density images will be semi-transparent and poorly visible.
3. Resolution. It is important to pick the right resolution to avoid multiple visible defects, such as enlarged pixels, blurred lines, etc.

If you need to apply info on wrappers using the flexographic printing method, visit Uniflex. The company is an expert in packaging manufacturing and the application of marketing information. It guarantees the perfect operation of all machines and excellent results for all clients.

Machine Parts that Affect Quality

The proper application of images on materials is achieved when all components work correctly. The result of the applied images depends on the following components:

1. Anilox rollers. This part comes as the main one in the machine, which is why it is called its “heart”. Due to this part, the ink is distributed over the target printing form, ensuring the proper density to guarantee stable and even ink application.
2. Plate cylinders. These parts are essential in pressure-sensitive printing; they are enrolled in the process of image application to the substrate. By attaching printing plates to these cylinders and pressing them to the material, inked images are transferred.
3. Printing plates. Printing itself occurs due to the use of these parts. The evolution of printing plates from natural rubber to photopolymers led to an increase in the quality and accuracy of image transfer. By designing proper plates, half-tones, layouts, and solid tones are achieved. If plates are designed incorrectly, images and info are applied improperly.
4. Inks. When dealing with printing, the speed of ink drying comes as one of the key factors. Flexography allows for the use of low-viscosity inks, which means that images dry quickly. Besides, ink consumption is lower if compared to other printing technologies, which allows for making the technique more cost-effective.
5. Materials. Note that various materials require different configurations when setting the machine. For instance, different temperatures, heat levels, speeds, and other parameters are adjusted, depending on the physical properties of materials.

Flexible technology is the leading method of applying images to flexible wrappers. Due to its automatic functioning and wide adjusting opportunities, it allows for processing different types of materials and guarantees durable high-quality images.

Step-by-Step Guide to Quality Control

1. The procedure implies scanning and comparing a printed image with a master image. Thus, it is necessary to print an image. A sample is sent for processing and printing. Once the result is ready, it is redirected to the system for scanning.
2. Next, comparing starts. The utility detects and maps visible defects. These can be blurred lines, visible pixels, low image density, white spots, etc.
3. Visible defects are documented and sent to the staff. An operator studies documentation to adjust the machine and re-configure settings to eliminate problems. Most errors are detected by the system, so the human participation is minimised.
4. Then, the process is done once again. The image is printed again to check whether all defects are eliminated. The procedure repeats until the printed image is marked as “100% acceptable”. In this case, the machine passes quality control and can process orders.

This process helps identify the existing shortcomings of the system, evaluate their severity, document hazards, find ways to correct them, and proceed to produce high-quality covers. Fortunately, nowadays, the process is automated and allows for detecting and eliminating defects quickly and easily.

Flexography is a convenient and cost-effective way to apply images on wrappers and guarantee their serviceability provided that the system works smoothly and steadily. Thus, make sure to perform examinations and quality control. Maintenance and evaluation take little time if the procedure is done timely.