The strain on our environment cannot be denied, nor can the fact that resources are becoming scarce. That's why, as specialists in sustainable packaging and optimum packaging solutions, we've given some thought to which printing process is considered particularly resource-friendly.
We see it as our responsibility to expand the selection of sustainable materials and thus contribute to relieving the burden on the environment.
For us, this also includes educating our customers about the complexity of this topic. We would therefore like to give you an understanding of the advantages of our sustainable and resource-saving products and processing techniques.
Flexographic printing: High quality and resource-saving at the same time
With a focus on sustainability, we took a closer look at common printing processes. We were most impressed by flexographic printing, a printing process that sets standards in terms of quality and careful use of resources.
This printing method is not a new invention, however, and it existed long before the "trend" towards sustainable business management developed. As early as 1907, the German printer Carl Holweg applied for a patent on the printing method, which emerged as a form of letterpress printing.
More precisely, it is a direct letterpress printing process: The ink is applied to the mirror-inverted printing plate, which is raised in relief. In this way, the ink reaches the printing stock directly.
At that time, however, solvent-based, UV-curing or water-soluble aniline inks were used. This is why this type of printing was initially called aniline printing.
The following years were devoted to the development of inks and the optimization of the machines in order to further increase efficiency. Among other technical innovations, the anilox roller was added to the machines in the 1930s. This ultimately resulted in an improvement in ink distribution.
It was not until 1952 that aniline printing was renamed flexographic printing. Due to the fact that various low-viscosity printing inks are used nowadays, this printing method is considered to be particularly environmentally friendly and is used in a wide variety of areas.
In addition to paper and cardboard packaging, non-absorbent plastic films made of polypropylene (PP), polyethylene terephthalate (PET), adhesive films and other products can also be printed using this process, for example.
The secret to resource-efficient printing: It all depends on the ink!
Surely you are aware that there are numerous varnishes and paints that are considered very toxic and harmful to the environment due to their ingredients.
The same was true of the aniline inks originally used. One of the reasons for this was that these inks contained a high proportion of solvent. This is no longer the case today. This is because the inks used in the flexographic printing process are water-based, food-safe and, above all, particularly environmentally friendly.
According to a study by the Federal Environment Agency , several tons of solvents from paints and varnishes enter the environment every day and have real consequences for flora and fauna. Not only the environment suffers from this pollution, but also the health of humans and animals.
In addition, binders, pigments and additives are used in the manufacture of numerous paints in industry, which also contain environmentally harmful ingredients.
In our production, we therefore pay attention to environmentally friendly and resource-saving alternatives.
The special properties of flexographic printing meet precisely these criteria, because it is
- environmentally friendly due to its ingredients,
- water-based and therefore easy and quick to apply; as well as abrasion-resistant,
- food safe and therefore non-toxic.
 For us as packaging professionals, the advantages of this type of printing are obvious, and the fact is that the use of low-pollutant printing ink helps to reduce the burden on the environment. |
What possibilities does this way of printing products offer?
You are probably wondering how the flexographic printing process works in detail and in which areas it can be used. We have compiled all the information for you below.
This type of direct letterpress process is not infrequently used in the packaging industry. This is due not least to the very good print quality and the fact that different materials can be printed with it.
But there are other positive properties that make flexographic printing so popular: Numerous materials that are not easy to print on - these include, for example, cellulose, elastic or stretchable films, various plastics, aluminum, glass, ceramics - can be handled without any problems using this technique. This printing method is therefore considered particularly suitable for printing soft cardboard with a coarse-pored surface.
Another advantage is that very large print runs can be processed in an environmentally friendly and precise manner. Even printing on food packaging paper is harmless using these water-based, food-safe inks.
The versatility of flexographic printing has been clearly demonstrated to date.
Here are some examples of the many products that are printed with it today:
- Advertising materials of all kinds, e.g. carrier bags, cardboard boxes, etc.
- Beverage packaging, transport cartons, sales packaging
- Wallpapers
- Carbonless copy sets
- Latex balloons
- Corrugated cardboard
The range of products that can be printed using this method in a resource-saving manner can be expanded at will.
The printing principle simply explained
Flexographic printing is a direct letterpress process. Flexible clichés (printing plates) made of rubber or photopolymer are used here. As these materials are very flexible, they are particularly suitable for use with equally soft and flexible materials, as they conform to the fabric to be printed during the printing process.
As the name "flexographic printing" suggests, its special characteristic lies in the highly pronounced flexibility of the printing plates and the resulting ability to print on soft, stretchable and elastic materials.
From a direct
This means that the printing ink is simply applied to a relief-type, mirror-inverted printing for me and printed directly onto the substrate, which lies between the printing forme and the impression cylinder. The ink is transferred to the printing forme cylinder by an anilox roller.
In the opposite direction, the impression cylinder requests the substrate and the printing forme cylinder applies the ink at the point of contact. Depending on the desired number of colors, a typical flexographic press has four to ten anilox rollers.
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It is therefore a simple and at the same time very efficient way of printing on a variety of materials quickly and in high volumes - and without any loss of quality or speed. |
What else speaks for this direct high pressure type?
The water-soluble inks used in flexographic printing can be regarded as environmentally friendly and resource-saving not only because of their ingredients, but also because the ink is applied very thinly to the printing plates. This in turn has an effect on abrasion, because it is correspondingly low.
That's why this process is also very popular for newspaper printing. You're sure to be familiar with the situation when your fingers get black ink while you're leafing through the newspaper - that's exactly what you're spared with flexographic printing.
However, this printing method has another strength. It is possible to print very long runs in a very short time while maintaining consistent quality. Even reprinting a run is possible without any problems because the printing forms can be reused at any time.
Above all, this means that the manufacturing costs of the printing plates can be put into perspective. The possibility of reuse creates yet another advantage - namely less waste, which in turn has a positive effect on our environment. This is particularly important in the production of packaging and other mass-produced goods.
Conclusion: Flexographic printing - a resource-saving printing process
The flexographic printing process offers numerous possible applications - various industries can use it for their own benefit and at the same time protect the environment
This is due not least to the inks used: they are considered to be of particularly high quality and harmless, as they are both water-soluble and food-safe. In addition, the paint is applied only thinly, is abrasion-resistant and easily degradable by nature.
The packaging industry in particular makes use of this type of printing because all materials can be printed with it without any problems and in consistent quality.
The positive aspect of the reusability of the molds also reduces costs and at the same time waste production is reduced. However, this is not the only environmentally friendly aspect: the prints on the packaging are thinly applied, which means that they do not represent a burden on nature.
Whether in terms of printing or other manufacturing processes: We always keep an eye on the latest developments - so we always opt for resource-saving alternatives in our production that do not come at the expense of our environment.
 As packaging specialists at Palamo, we therefore rely on flexographic printing for its environmentally friendly properties to print on diverse materials quickly and efficiently. |
FAQ
Question: Is the flexographic printing process expensive?
Answer: No, measured in terms of efficiency and the reusability of the printing plates, it is fair value for money.
Question: For which run lengths is it particularly suitable?
Answer: It is particularly efficient and cost-effective as the height of the printed materials increases.
Question: Can flexographic printing also be used to print on packaging that comes into direct contact with food?
Answer: Yes, the ink can also come into contact with food. It is neither toxic nor does it leave any traces on the product, as it is particularly abrasion-resistant.
