Flexo Printing

Flexo printing

It's a type of printing that uses the CMYK color system and is used for printing:

• Carton boxes: for example, a TV box, a box of chips, ice cream products, and biscuits, mainly for large sizes.
• For cardboard templates: for example, pizza cartons and fast food products cartons, for small sizes.

It's divided into two phases:

1- Carton Boxes:

• Sizes are provided in unit ml.
• CMYK color scheme for all text, shapes, images and CMYK & grayscale images as well.
• Determine the color of the carton, either white or brown
• Preparing the design for the client upon completion and taking approval
• Convert texts to outline
• Embed the images in adobe illustrator.
• Then We delete the color of the cardboard in the background, so the design remains on white background, then we prepare what is called centers and registrars to help the person authorized to print in installing the color layers where each color is printed on a separate layer.
• We perform a process called compression, which is to compress the entire design in a certain longitudinal rate (detailed explanation is required).
• And we send the AI file to extract the (plates) which is the printing template, look at the bottom of the post.
• Then we take these plates to a printing press with specialized machines for printing called a Flexo machine to produce the printed and folded carton, then paste and deliver it to the customer.

2- Molds:

• It is a process very close to preparing the designs for offset printing.
• CMYK color scheme for all text, shapes, images and grayscale images as well.
• First An authorized person Designs the template in coordination as the client size and molds design.
• Second Then another technician will do the montage, which is to determine the number of molds on the size of the paper. This requires coordination with the person in charge of the design department.
• Third We prepare as a copy only for the exact printing press of the template with its montage and print guides.
• We prepare another copy, we make the design inside the template.
• Upon completion and taking the customer's approval.
• We prepare the centers and the registries.
• Repeat the mold according to the montage.
• Convert texts to outline.
• Embed images in adobe illustrator
• We perform a process called compression, which is to compress the entire design in a certain longitudinal rate (detailed explanation is required).
• And we send the two copies for printing.

Flexo Plate:

After the client accepts the designs we send it to a company specializing to print the design it on a plate and print it to the carton.

The topic needs a more detailed explanation in a practical and not theoretical way, but the goal here is to explain the printing process in general. Later on, I will be making a video describe to the process from design to montage production and cartoon templates.

For designers, It requires less time to learn than offset printing.