What Materials Can Flexo Printing Machines Print On? | Flexo Substrate Guide
What Materials Can Flexo Printing Machines Handle?
Flexographic printing machines (flexo presses) are renowned for their ability to print on a diverse range of substrates, from paper to plastic films. However, not all materials perform equally well on basic configurations. To achieve optimal print quality, some materials require additional components such as corona treatment, reverse-side printing units, or drying upgrades. In this article, we’ll explore the types of materials flexo machines can handle, and what optional configurations are recommended for the best results.
1. Paper-Based Materials: Widely Compatible
Paper substrates are the most straightforward to print on with flexo machines.
Common Types:
- Coated paper (art paper, glossy/matte)
- Uncoated paper
- Kraft paper
- PE-coated paper (used for cups, bowls)
Configuration Tips:
- Standard flexo machines handle these materials with excellent results using water-based ink and standard drying systems.
- For PE-coated paper, consider a stronger hot-air dryer or UV curing unit to ensure full ink curing, especially in high-speed production.
2. Plastic Films: Require Additional Treatment
Printing on plastic films such as BOPP, PET, and PE can be challenging due to their low surface energy.
Common Film Materials:
- BOPP (Biaxially Oriented Polypropylene)
- PET (Polyester)
- PE (Polyethylene)
- PVC (Polyvinyl Chloride)
Recommended Configurations:
- Corona Treatment Unit: Enhances surface tension of films, improving ink adhesion and print sharpness.
- Dual-Sided Printing (Turn Bar): Enables double-sided printing on films, essential for flexible packaging.
- Closed-Loop Tension Control System: Ensures smooth material feeding and consistent register during high-speed runs.
- UV Drying System: Preferred for films, especially with UV inks, for fast curing without damaging the substrate.
- Web Guide System: Keeps film aligned to prevent misregistration and print defects.
3. Self-Adhesive Label Materials
These include multi-layer constructions used for product labeling and barcoding.
Types:
- Face Stock (paper or film)
- Adhesive layer
- Release liner
Recommended Configurations:
- Precise Tension Control to avoid label curling or misalignment.
- Die Cutting Unit: Allows inline cutting of labels into specific shapes after printing.
- Laminating Station: For protective or functional top layers (optional).
4. Specialty Substrates
Certain high-value or niche applications require special handling.
Examples:
- Aluminum Foil: Used in pharmaceutical or food pouches.
- Tyvek and Synthetic Paper: Tear-resistant, used in medical or industrial tags.
- Thermal Paper: Direct thermal label stock for receipts.
Recommended Add-Ons:
- Precision Drying Unit: For aluminum or foil, to prevent heat deformation.
- Anti-Static Device: Especially helpful for synthetic or lightweight materials.
- Chilling Roller: Prevents heat-sensitive materials from warping after UV curing.
5. Optional Converting Functions for a Complete Production Line
To enhance production efficiency and reduce the need for secondary processing, modern flexographic printing machines can be configured with additional inline modules:
✅ Die Cutting Unit
- Enables inline label or packaging cutting, reducing setup time and costs.
- Supports rotary or flatbed die cutting depending on material and speed.
✅ Slitting Unit
- Allows printed material to be slit into narrower rolls for various downstream uses.
✅ Rewinding & Waste Rewinding Systems
- Dual rewinding systems support both finished roll collection and waste matrix removal.
- Optional tension-adjustable rewinding shafts ensure tight and even winding.
✅ Cold Foil or Lamination Unit (Optional)
- Adds branding effects and protective layers directly in-line.
Conclusion: Match the Right Configuration to the Right Material
Flexographic printing machines can handle a wide range of substrates, but achieving optimal print quality depends on choosing the right machine configurations for each material type. From corona treaters for plastic films to die cutting for adhesive labels, the flexibility of a well-designed flexo machine allows manufacturers to meet diverse production needs.
At Wenzhou Henghao Machinery Co., Ltd., we specialize in customizing flexo printing machines to match your materials, product specifications, and production goals. We also provide on-site installation and operator training to help your team get started quickly and confidently.
Contact us today for a tailored flexo printing solution with optional die cutting, slitting, rewinding, or corona treatment systems – all designed to meet your unique printing challenges.
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