Why is a flexo printing machine suitable for large volume production?

Why is a flexo printing machine suitable for large volume production? Every business regarding the production volume in consideration packaging, label printing, and flexible material printing, and production volume, requires tools and machines that help produce in speed, and also help save on the costs. Flexo printing machines also flexographic printing machines, are one of the machines that are used for these purposes. Unlike other technologies used in printing which focus on high volume tasks, flexo machines are designed to perform seamless and uninterrupted printing for large batches. This article explains the key reasons why flexo printing machines excel in large volume production and become a reliable tool for businesses.

The most obvious advantage of flexo printing machines for large volume production is their high printing speed.These machines are web fed and can print fast on a large roll of materials like polyethylene films, plastic, paper and non woven materials without a stop. For instance, a basic flexo printing machine works at a speed of 150 - 300 meters a minute and some even exceed those limits. This is way faster than any sheet fed printing machine which works by distributing pages and stopping every time. For companies and businesses that print large orders of seamless packaging rolls for a beverage brand or advertising materials for a product like roll printed product labels for a company. There is no reason to worry about the deadlines. It is fast and time efficient.

Wide Material Scope Improves Flexibility

Most production activities involve the use of diverse materials, the versatility of flexo printing machines comes in handy for accomplishing this. They can accept flexible materials such as plastic films, aluminum foils, and fabrics and on rigid materials such as cardboard, corrugated papers, and paperboards. This versatility facilitates the use of a single machine to accomplish different tasks which comes in handy during mass production. For example, a flexo machine can print on plastic wraps food packaging, and paper labels for cosmetics, at once and without production line adjustments. This also goes for other machines. The time and operational costs saved as a result of the inability to complete the tasks using individual machines confirms the low investment of flexo printing machines for large print requirements.

Less Downtime Keeps Everything Running Smoothly

Flexo printing machines are built to maximize continuity and greatly ease maintenance. Unlike, say, heavily complicated digital or offset printers, flexo machines are easier to work on, and repair. The crucial pieces, Anilox Rolls, flexo plates, and blades, are simple to swap and replace. Changing flexo plates takes mere minutes, but other types of plates might take hours. The most advanced digital printers expect hours of adjustment to replace the flexo plates. All machines are prone to issues. Devices with self-diagnostic systems are capable of running adjustments to re-align rollers and correct other estimated issues like ‘ink leaks’ before large problems develop. Less breakdown time on the machines means unlimited and continuous printing and production. The set number of hours and large batches needed can be easily piled up and printed within tight deadlines.

Consistent Print Quality Across Large Batches  

Keeping the same quality on thousands or millions on printed copies is something that is very hard to achieve in large volume production. However, flexo printing machines do this in the best way possible. The flexo printing process in the anilox printing system uses anilox rolls to distribute the desired amount of ink onto the printing plate. This process guarantees that every single print receives sufficient, if not uniform, ink coverage. This precision eliminates the risk of any color or sharpness drift that commonly occurs in other techniques, especially in large volume prints. A classic example of this is when printing brand logos on a packaging roll. A flexo machine achieves the same color intensity and crystal clear detail on the first roll, and the same on the thousandth. This is very crucial for businesses that want to successfully maintain brand identity, and satisfy customer quality standards. The same rule applies when there are changes, in huge quantities, the product is likely to be rejected, which will result in huge financial loss.

Cost Efficiency for Long-Term Large Production  

The cost of large volumes of production is an important concern, and flexo printing machines have been proven efficient at managing these expenses over time. First, the consumables for flexo printing, such as flexo plates and ink, are much more cost-efficient than for digital or offset printing. Flexo plates can also endure multiple prints, and are therefore, more economical as the cost per unit is less. Second, the flexo machine’s high-speed printing capability coupled with the reduced need for operators results in lower labor expenditures per print. Third, flexo machine energy consumption is more efficient than some high-temperature printing machines which lowers overall utility costs. Large volume print service providers such as label printers for retailers can realize these savings, and maintain profit margins while boosting competitiveness.

Flexo Printing Integration with Post-Printing Processes

In high volume production, finishing steps like cutting, laminating, or die-cutting must be performed, and flexo printing machines integrate effortlessly with these steps. The majority of flexo machines today can be outfitted with inline finishing units, enabling printing and finishing to be performed in a seamless, uninterrupted operation. A good example of this is a flexo machine that prints packaging labels and upon finishing printing, cuts the web into individual labels, all with no setup needed to transfer the materials to a different machine. This type of integration streamlines the entire production process, augmenting operational efficiency and eliminating the requirement for manual batch handling, the material damage risk, and production hold-ups. In turn, businesses experience operational acceleration, which leads to improved overall customer satisfaction, allowing maintaining a strong position in a market where speed these days, is a critical requirement.