The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

The
Ultimate Guide To
Flexo-Printing
How to boost efficiency and save
money on label and narrow web
flexographic printing

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
1  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Introduction
Thank you for downloading our free eBook guide to flexographic printing!
Flexography is one of the most versatile and efficient print methods available.

For label printing businesses, a flexographic printing press can help you:
»»Cut down on wastage
»»Eliminate or minimise returns
»»Ensure accurate print registration each time
»»Save production costs
»»Reduce print cycle times
»»Achieve on-time production

Why We Have Written This Guide

At Focus Labels, we have been making label printing machines for more
than 35 years. Our custom-made printing presses are used by print
businesses serving a diverse range of market sectors around the world,
from print publishers, to food packaging, to bespoke label printers.

We have written this guide for

production managers to help you
make the best investment in print
technology, as it is a minefield of
different options and potential
pitfalls.

Flexographic print technology has

changed a lot, but it still has core
features that keep print businesses
coming back to these machines
time and time again. This eBook
explains why this is the case and
why flexography offers such great
value for money.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
2  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

How To Make Use Of This Guide

This eBook hasn’t been written primarily as a promotional guide. You
will find this eBook full of practical and useful information about the
print machine industry that will help you make an informed purchase
decision – whether or not you choose to buy from us. We start the
guide with a technical overview of what flexo-printing is and how the
technology works, before explaining how to get the best value for
money when investing in a flexographic press.

Before we begin, however, we would like to briefly introduce our

business; in particular, the qualities and experience that we feel make
us qualified to publish a guide such as this. If you are already familiar
with Focus Labels or would like to skip straight to the action, then
please feel free to jump to section one: How Flexo Printing Works.

You can find out more about our company any time by visiting our
website. Here you will find full details of our range of products, services
and consumables. You also might like to read our blog, which is
regularly updated with articles relevant to the print industry.

We hope you enjoy this guide and we very much look forward to
hearing from you soon.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
3  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

About Focus Labels

Focus Label Machinery Ltd was set up in 1981, so at the time of writing
(2016), we have just celebrated our 35th anniversary of continuous
operation as a business. We’ve learned a thing or two about label
printing in this time, and so feel ourselves qualified to offer some
guidance and free advice to other businesses operating in the industry.
Our background before we started Focus was in manufacturing print
machines for the narrow web label and packaging print industry, a
sector in which we had already accrued more than 30 years previous
experience.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
4  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Improving Efficiency Through Innovation

Printing technology has moved on quite a bit since 1981; and we
have become one of the world’s leading manufacturers of narrow
web printing and converting, with clients all over the world. We are
an established name in the industry, placing a strong emphasis
on innovation to continually improve the performance of our print
machines.

We try and set the high standard’s for other manufacturers to follow,
with ongoing investment in research and new product development.
In a competitive global environment, our commitment to develop &
integrate new technology and our team of highly experienced support
technicians gives our clients the edge in minimising wastage, reducing
costs and completing assignments on schedule.

It’s fair to say that we are proud of our achievements including a

number of product patents. Our latest advanced label printing
technology allows the fastest colour changes on any press on the
market today, with less downtime, less wastage, faster production,
higher output and improved quality. This is no small boast, but it is
one that is played out time and again in the efficiency savings and
improvements enjoyed by our customers. We’d be delighted to
answer any questions you might have and talk to you about how our
flexographic label printing machines can help transform your business.

Do feel free to give us a call at our UK office on 01949 836 223.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
5  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

100% UK Quality Guarantee

While outsourcing is common in the industry every machine is 100%
designed , manufactured, and assembled in our UK facility, with a full
guarantee of quality and ongoing support from our team of expert
engineers. We also partner with the leading technology companies to
integrate the latest digital & transmission& automation systems. There
are a number of good reasons why we do this, which we will go into in
more detail in the ensuing chapters.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
6  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Section One
How
Flexo-Printing
Works

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
7  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

How Flexo-Printing Works

The ideas behind modern flexography – or flexo printing – are old ones,
having their roots in the letterpress printing techniques first developed
in the 1440s by Johannes Gutenberg. Of course, a lot has changed in
the last 600 years, but print historians will be able to see the imprint of
history in even the most advanced flexographic printing machines.

The first flexographic printing presses were developed in the 1890s in

Liverpool and have undergone many incarnations since. What makes
flexo printing so versatile and popular is its ability to print on almost
any flexible substrate material. This includes paper, cellophane, metallic
films and plastics – thus making it ideal for printing food packaging and
product labels.

Flexographic printing presses are also extremely efficient and cost-

effective. A modern press can print at a rate of up to 400m per minute,
a phenomenal speed compared with some of the alternatives, such
as lithographic presses or digital printing. It also has the advantage
of using a variety of Ink types such as Water based, Solvent & UV
Inks which makes it ideal for almost every application including
those having a high level of health & safety obligations such as food
packaging.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
8  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

The Flexo-Printing Process

There are thousands of different types of flexographic printers available,
with the best ones currently being made in the UK, Europe and the
USA. Each machine shares a common printing process, so if you are
familiar with one flexo machine you will be able to understand them all.
The key parts of the process are explained below:
Platemaking

The most important element of flexography is the printing plate, which

contains the images and text to be printed in negative as a mirror
image. A separate plate needs to be made for each colour used in the
print run.

Platemaking is an art and science all of its own. There are three main
methods that have been used historically:

1) Metallic plate etching/Rubber Plates: The print image is first etched

in negative onto a metal plate made of zinc or magnesium, which is
then washed in an acid bath. The image will appear in bas relief on the
plate. A second stage creates a plastic mould, which is then utilised to
fashion the final printing plates out of a flexible, thermoplastic polymer.
This is an expensive and time-consuming method which is rarely used
these days.

2) Photo etching/ Photopolymer Plates: The print image is etched

through a photo negative directly onto a light-sensitive polymer plate
by means of ultraviolet light. When the polymer hardens, it is then
washed out in a bath of water or solvent, at a temperature of about
40°C. This is still the most common system of flexo plate production
today.

3) Digital platemaking/Digital Plates: This most modern method uses

a digital image to direct a computer operated laser to etch the printing
plate. This eliminates the need of a photo negative and is now the
fastest growing technique for platemaking applications.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
9  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

The Flexo-Printing Process

Printing

To begin the print process itself, the printing plate is loaded into the
printing press on Plate cylinders. As each colour needs a separate plate,
it is essential that the plates are mounted correctly on the press, so
that the images are transferred to the substrate accurately. Most print
presses use specialist video assisted mounting machines to make sure
every plate is aligned & positioned appropriately.

When the run is due to begin, Ink is transferred from the ink tank
through a fountain or metering roller, and then on to an anilox or
ceramic roller. This regulates the deposit of ink onto the printing plates
and ensures an even coverage of Ink. The anilox roller is a fascinating
piece of kit. Its surface is covered with thousands of tiny, cell -like
impressions that act like tiny ink cups.

To avoid ink flooding or patchiness, a doctor blade, or scraping tool is

used to clear the anilox roller of excess ink. This prevents smudging
when the plate is driven through the impression cylinder to make
contact with the substrate. The result is a positive print image (from the
negative print plate).

When the printed image is transferred to the substrate, the Ink needs
to dry as quickly as possible. This can be affected through fan powered
Infra red dryers, or by ultraviolet (UV or LED) curing, depending on the
Ink type used.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
10  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Understanding The Key Flexographic

Label Printing Press Components
As well as following a broadly similar process, all flexographic printing
presses have a similar suite of components. These are:

Feed & Unwind Station: Control of the

substrate is essential, feeding it into the
press at a pre-defined tension , constantly
even as the diameter of the roll changes .
The unwind system should have automatic
web guides and options for web cleaning
and Corona treaters for synthetic substrates.

Printing station: The print station needs to

provide a smooth & stable drive to ensure
the printed image is clean & vibration free.
The basic Flexo systems includes an Ink
storage tank , one or more fountain/metering
rolls , Anilox Roll & Plate Cylinder . As we saw
above, The ink is picked up from the tank by
the metering roll which wets the anilox Roll
and then ink transferred to the plate cylinder
which holds the printing plates, and then
onto the impression cylinder which carries
they substrate, the image is transferred from
the plate to the substrate before repeating
the continuous process. Together, the two
cylinders are sometimes known as the print
anvil.

Drying Station: each colour should be dry

before the next is applied to the substrate.
The drying section might include a
combination of Infrared & Air drying or UV /
LED curing or both systems. Better machines
will ensure the drying intensity is matched to
the press speed which can be variable with
different applications.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
11  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Understanding The Key Flexographic

Label Printing Press Components
Chilling Rollers: with a growing use of
ever thinner synthetic and unsupported
films there is a need to control the web
temperature to ensure the substrate remains
stable through the press. This is even more
critical where using UV drying system which
inherently create a lot of heat . The addition
of chill rollers provide that control.

Die Cutting & Converting: these are more

commonly found on narrow web presses
for production of labels, tickets & cartons.
Products can be cut, creased, Foiled,
Stamped, Embossed, perforated all in line
in the same operation as printing. Therefore
producing the finished product or label in
roll or sheet form. Die cutting modules need
to be built with heavy duty components for
the high levels of pressure/force required to
convert flexible webs up to 300gsm.

Outfeed and Rewind: The output section

maintains tension as the substrate leaves the
printing press, by means of tension control
sensors. Waste products are rewound out
of the system and the final products are
rewound into large rolls for later inspection.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
12  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Types of Flexographic Label Press

With these core processes and components in mind, it is time to
introduce you to the three main types of flexographic label press. The
right choice for you will depend on your print requirements.

1) In-Line Press
Suitable for narrow web and mid-web printing, the sturdy in-line press is
a popular choice for printing on a range of substrates. Individual colour
stations are stacked in line horizontally from front to back. In –Line
presses are very versatile and can integrate new technology with greater
ease than the other systems we will look at. In-line presses are great
for wider width printing. Reverse-side printing is made easy in some
machines by turning bars that rotate the substrate without having to
change the print cylinder. A variety of additional processes can be added
in combination with flexo to add value to a printed product such as Foil
blocking, Cold foil, Laminating.

2) Central Impression Press

Central Impression Presses are suitable for narrow web printing and are
the most commonly used flexographic print machine for unsupported
substrates . Typically 4 to 10 colour stations are possible , but instead of
arranging them in line, each colour is positioned as a satellite around
the main Central Impression cylinder. The Central cylinder can be over a
metre in diameter. These types of machine have an advantage of being
compact if space is an issue. They also provide very stable register on all
types substrates. They are not as efficient as in-line presses or as operator
friendly. Printing on both sides of the substrate may involve reducing the
available printing width by 50% .

3) Stack Press
Stack presses provide the advantage of a compact footprint like the CI
press . They are however the black sheep of the flexographic printing
family being difficult to operate a stack of four to eight vertical colour
stations and requiring a ladder to get to the upper print stations. The
substrate follows on a snake like journey through the stack; the colours
being imprinted on the substrate as it is passes through each station.
This makes it difficult to monitor production quality during a long print
run .Stack presses can comfortably handle most supported webs but are
not suitable for unsupported materials.
Focus Label Machinery Ltd
 [email protected]
 01949 836 223
13  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Is Flexo Printing Suitable For Your Business?

Now we have gone through the main processes and technologies used
in flexographic printing, it is time to explore whether or not it is the best
option for your print business. Before we look at the different options
available to you – both with flexo print and its alternatives – we will
spend the next section exploring realistic budgeting, and how much
you should expect to pay.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
14  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Section Two
Setting A
Realistic Budget

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
15  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Setting A Realistic Budget

Because flexographic label printing presses are reasonably complex
and large machines, they inevitably involve a considerable investment.
This is understandable when you consider all the variables that go
into flexo printing, such as the precise mounting of print cylinders.
Any inefficiencies in the process or defective components can have
a negative effect on the quality of the print run. These can result in
increased wastage, increased returns, inaccurate print replication and
overall reductions in quality.
So when planning an investment in new flexographic equipment, what
sort of budget should you be working towards? This is an open question
with lots of variability, so first we will look at factors that affect the
market value of flexographic label presses.
Factors Affecting The Price Of A New Narrow Web Flexographic Label Press
Number of colours: The more colour Type of drying system: As discussed
options, the more expensive the press earlier, print can be dried through
will be. high-pressured air , Infrared or ultraviolet
curing. Some presses also use LEDs to
Web width: To print wider labels, a fix the ink to the substrate. LED & UV
larger impression drum is required, thus systems are more expensive than IR and
adding to the unit cost. fan powered systems, although LED may
have lower energy requirements and
Type of drive system: The more thus cost less to run.
technologically advanced the print
drive system, the more it will cost. Your Level of automation: Modern printing
options relate the level of technology & presses can be very sophisticated, with
components are involved in the drive. A high levels of automation. For print
non-servo drive will operate manually on businesses this cuts back on manpower
an open loop system with some simple requirements and can make your
automated components, whereas a full production line more efficient, but it will
servo drive is a closed-loop system with involve a larger initial investment.
more extensive technology options. It
will monitor feedback signals from the Optional equipment: additional
press and make automatic adjustments equipment, such as Web Cleaners,
to maintain tension, register, and print Corona Treaters, Video inspection
speed. A partial servo drive has some, systems , conveyor systems, will increase
more limited feedback options, but not the amount of money you need to
as many as a full servo drive. spend on the press. Have a clear idea
of essential features you need. Don’t
overload your specification with options
you may never use.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
16  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Average Price Ranges For New Machines

The prices for new machines vary considerably, depending on their
size and features, so these estimates should only be taken as very
loose averages. Nevertheless, they do give an indication of how much
you should expect to pay for a new flexographic print machine. If you
receive a quote that is significantly lower or higher
than these figures then it is wise to treat it with
some scepticism. Find out from the manufacturer
what additional features or cost savings justify the
price.

Six colour presses: Price range varies from

£100,000 up to £450,000 for large machines. An
average investment would be £150,000-
£295,000.

Additional colours and specialist

applications: Investment price starts to rise
as more colours and specialist applications
are added. A non-standard or high level
specification press could cost in excess of
£600,000.

Is there a cheaper alternative?

In the two sections that follow we will look at two money-saving
alternatives to buying a new, British-made press. However, we cannot
emphasise enough that simply looking for the lowest quote is a false
economy.

Instead of looking at the cash figure of your initial investment – which

in most cases can be attained through credit – it is more realistic to
view your purchase in terms of ROI. So long as you purchase a print
press that closely matches the requirements of your business, then the
resulting increase in productivity and sales output will soon make your
investment worthwhile.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
17  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Section Three
Second Hand
or Refurbished
Machines: The
Pros and Cons

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
18  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Second Hand or Refurbished Machines:

The Pros and Cons
While new printing presses are now the industry standard, there are
plenty of second-hand machines available for those who look. As
print technologies have advanced rapidly over the past few years
(especially in terms of digital platemaking and print Servo automation),
the market has become flooded with second-hand and refurbished
machines. Do these offer true value for money?

Advances In Print Technology & Credit Availability

There was a time when print technology didn’t change all that much
from one year to the next, so that buying a 10-year-old, second-
hand press wasn’t much of a risk. This isn’t the case anymore, now
that emerging print technologies can give businesses a significant
technological advantage over their competitors.

Additionally, it wasn’t always easy to get credit to purchase new

machines, whereas finance is now easily available. New machines are
therefore more widely accessible to a greater number of businesses
than they were previously. This has resulted in a decline in the number
of businesses buying second hand machines.

In the interest of balance, we have to say that if initial investment is

your only consideration, then you probably will save money by buying
a second-hand machine. However, there is a strong chance that your
second-hand press will be technologically obsolete before it is even
installed. New equipment offers the benefit of the latest technology;
with better print quality, quicker set-up & job changes, greater energy-
efficiency, higher productivity, less wastage, less downtime and less
operator stress.

With this caveat, here are the advantages and disadvantages of buying
second-hand…

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
19  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Disadvantages
»»Obsolete technology: Second-hand printing presses are unlikely to
have the same richness of automation options and energy efficient
drivers that new presses do.

»»Underlying technical issues: A risk you take when buying second-hand

are the underlying technical issues that many old machines have.
These may not be apparent at first but may suddenly appear after only
a few print runs.

»»Spare parts rare or unavailable: It can be difficult to obtain spares &

replacement parts for older, used equipment – especially electronic
components, which can be expensive if original versions have become
obsolete.

»»No capacity for upgrades: Similarly, it may not be possible to expand

the capabilities of an older press, exacerbating the problem of
obsolete technology.

»»Specification: if you have any special requirement it is unlikely you will

find a used machine in the exact specification & condition you need.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
20  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Advantages
The only significant advantage we can think of with second-hand
machines is the lower upfront cost. Depending on the manufacturer,
the age of the machine and the availability of spare parts, you could
pick up a flexographic printing press at a fraction of the going rate for a
new machine. For small businesses this can be an attractive option.

If you already have a similar machine purchasing another may be seen

as a good case for a back-up, and you will already know the limitations
or problems associated with that model of machine.

Second hand machines are also popular (or used to be) with businesses
who wanted to make an outright capital investment without taking on
additional debt.

New machines often have long lead times, if time is critical the only
option may be to find a used machine. However you will need to be
flexible with regards to specification.

The Best Investment Decision

The decision is yours, but on balance most print businesses find that a
new machine is a better investment. They work better, are cheaper to
maintain and are subject to fewer faults and defects than older models.
Second hand presses have a shorter working life than new models –
and may ironically end up costing you more throughout their lifecycle
than a new press.

If you do choose to purchase a second hand press, it is vital you

make sure that spare parts are abundantly available and you have
a good service plan in place. Will the dealer take care of transport
& commissioning. Is there any warranty ..? who do you contact if it
goes wrong…? Dealers are often merely just a broker and simply
middle men linking buyer & seller. Finally don’t simply hand over your
money without guarantees in place. Always contact the original
manufacturer, they will often have the machines service record and
may be able to offer technical support. Ask about spare parts and
recent service work if any..?

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
21  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Section Four
UK, USA
or Far-East
Manufacturer:
Getting the
Best Value

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
22  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Getting The Best Value

If it is no longer feasible or cost effective to save money on a second-
hand printing press, what about cheaper new machines? A lot of
businesses now turn to cheap manufacturers based in China, South
Korea or Taiwan. You can save money by going down this route, at least
in the short term. But in order to explain why this is not always the best
idea, we’d like to give a brief overview of the label printing machine
industry as it stands.

British, American and European Presses

The heartland of innovative flexo printing has

always been the UK , Europe and America. It
was British companies who first developed the
modern flexo printing process and American
businesses who pioneered the printing of
food packaging in the 1940s. US giants such
as Kodak and AV Flexologic continue to lead
the way in the field of digital platemaking
technologies, while on our side of the pond,
Focus and companies like us work on designing
faster, more versatile and energy efficient printing hardware.
Germany, Italy and the Netherlands also have an advanced print
machinery industry.

Far East Presses

The Far East industries produce a lot of

flexo presses. Many of them are attractively
marketed and available at low prices.
However, they all seem to be copies of
American and European designs; reverse
engineered from design brochures. They
vary widely in quality. Some are better than
others, but there isn’t any real way of verifying this before you purchase.
Build standards and component quality are lower than British,
American or European equivalents. After sales service and technical
support is usually non-existent.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
23  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Getting The Best Value

The dangers of subcontracting

The risk of purchasing a cheap press from the far east comes from the
common practice of subcontracting all aspects of the manufacturing
process to a variety of different businesses in Asia. From the perspective
of the end-user, it is impossible to verify quality or keep check on all
these sources. This explains the inconsistent quality experienced by
customers of these manufacturers, even for ones with a reasonable
reputation. You may be lucky and get a press that works well, or on the
other hand you may not.

Long term ROI

Once again, with affordable finance available to suit most budgets,

upfront cost isn’t the most important factor at stake. Instead of
thinking about how much money could be saved by purchasing
from Asia, it is better to look at how much additional value you
could get by buying from a known manufacturer. Firstly, with a
UK manufacturer you will have direct access to the manufacturing
workshop. Secondly you have a support team at the ready, within
your time zone, if you need advice, troubleshooting or training. Finally,
you have peace of
mind that your press
is manufactured to
high international
standards with the best
components available
on the market – and
assembled by trained,
professional engineers.
This is why you will get
the best long-term
return on investment
by buying British, even
if it might cost you a bit
more to begin with.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
24  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Section Five
Alternatives to
Flexo-Printing

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
25  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Alternatives to Flexo-Printing
When reviewing your options, you may like to examine alternatives to
flexo printing. Some magazine, book and newspaper publishers still
use lithographic printing presses, but for label printers the only real
alternative is digital printing. In this section we will give a brief overview
of digital printing and how it compares to flexographic printing.

Digital Printing
Digital printing was first put to commercial use in 1991, but has still not
been widely adopted by the industry. Putting Convenience aside this
is because, compared with flexo print, digital is still relatively expensive
and not economical for medium to high volume production. Although
digital printing technologies are improving all the time and there are
some advantages, for large-scale, commercial printing businesses,
flexographic printing is hands down still the most cost-effective option.
Cost comparison print runs of 2,000 labels or less you will
Some label printing businesses are save time compared with flexo. However,
attracted to digital equipment for when processing medium & large print
initial cost reasons. Indeed some Digital runs, the time required to set up a
printers can to be less expensive than flexographic press is insignificant. Once
flexographic machine. A digital printing up and running, flexo print machines will
press does not have to contend with run far more quickly and efficiently than
all the rollers, print plates, cylinders, their digital cousins.
mechanical drivers and dryers that
constitute a flexographic printer. So you Ink and substrate
will pay less upfront for a digital machine. Flexographic printing gives you far more
However, this is where the savings end. colour options and choices of ink than
Unit per unit, digital printing is far more digital printing. You can use water-based,
expensive than flexo. If you are doing solvent or UV based inks in flexo, giving
large print runs it is more cost-effective to you enormous versatility. Flexo Ink tends
go flexographic. are much cheaper to purchase too.
Similarly, you have far more flexibility
Print cycle when it comes to substrate. Digital
On the surface, digital printing has the presses often require specially prepared
advantage in terms of print turnaround substrates which are more expensive
time. To use a digital printer, it is than standard materials. Digital
essentially a matter of selecting some printing lacks the capacity for printing
files and pressing go, whereas flexo in continuous runs, making it unsuitable
printing involves filling inkwells, resetting for wallpaper, food packaging and most
drivers and creating print plates. For small commercial labels.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
26  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Section Six
Common
Mistakes and
How to Avoid
Them

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
27  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Common Mistakes & How To Avoid Them

After examining the options, you may have decided that buying a new,
British made flexographic printing press is the best option for your business,
and if so we would like to congratulate you on making a great choice!

However, before you choose a manufacturer you should be aware of four

common mistakes that businesses make when buying a printing press.

1) Not prioritising the important features

New printing presses come with so many ‘bells and whistles’ that it can be
difficult to prioritise the features you actually need. A big mistake people
make is to over specify the features, to include lots of optional extras which
end up hardly being used. This bumps up the price of the press. Worse
still, these extra features are often selected at the expense of important
features, such as a higher number of colours or wider web width.

2) Choosing the cheapest option

Even when choosing a new machine there is the natural temptation
to favour the cheapest option. This isn’t always the best decision, as
cheaper machines often come with fewer features, reduced energy
efficiency and longer set up times & lower production speeds.

3) Insufficient product testing

Before you buy a printing press you should be fully aware of how it’s
going to be used and the materials it is intended to work with. Choose
a machine to match your output, rather than trying to adjust your
requirements to match the machine. Importantly, the machine needs
to work with the substrate you will be printing on, whether this is paper,
cellophane or wallpaper. A big mistake companies make is to not fully
test the press for suitability before purchase.

4) Skimping on training
Flexographic equipment are complex pieces of kit and involve a
learning curve. Operators should be given enough time to be fully
conversant with the machine before it is put into active use. Not
allowing enough time for proper training after installation increases the
risk of product wastage and damage to the press through human error.
This is why at Focus we put such a strong emphasis on training and
technical support – both before and after installation.
Focus Label Machinery Ltd
 [email protected]
 01949 836 223
28  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Section Seven
Benefits of
Buying From
Focus

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
29  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Benefits of Buying From Focus

Investing in a high quality flexographic press, with the right consumables
and strong technical support, is the best way of guaranteeing on-time
production and consistent quality across your print runs.

At Focus, we believe we have the right combination of expertise,

professionalism and creativity to provide you with the flexographic
solutions you need. With every build we combine cutting-edge design, high
engineering standards and after sales support to help you get the best
return from your investment.

These are what we feel are the five main strengths of our business model
that set us apart from our competitors, both in the UK and abroad.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
30  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Benefits of Buying From Focus

1) Engineering and build quality
All our printing presses are designed, engineered and
assembled at our facility here in the UK. We don’t
outsource any part of the process, so when you visit our
workshop – which you are very welcome to do – the
engineers you meet are the same people who will be
working on your machine. This is how we combine
cutting-edge technology with personal service, and
is one of the main benefits of buying from a UK
manufacturer. We are always available to answer your questions and field
your calls throughout the process.

Our presses have a professional reputation for extreme reliability while

also being versatile and cost-effective. As technologies change, we will be
able to update your press with upgraded modules, so you can maintain
your competitive edge. All our designs are future proof in this way, to guard
against obsolescence and give you greater long-term value for money.
Every press comes with full build quality assurance and product warranty.

2) Reliable components
We sometimes use third-party suppliers to provide
electrical components, such a servo drives, control
systems, gearboxes and UV systems. We are
completely transparent in this and only ever use
reputable UK and European supply partners. We
never try to cut corners by sourcing electrical
components from the Far East.

3) Innovative R&D Department

A print business that fails to innovate rapidly falls
behind its competitors. We are therefore always
working to give our customers a technological edge
by innovating new products and components to
improve the performance of our printing presses. We
never simply replicate what other companies are
doing, but instead try to lead the field ourselves by
approaching problems in a new way.

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
31  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Benefits of Buying From Focus

4) Custom solutions
We manufacture a range of market leading
printing presses that can be ordered,
manufactured and installed within a short
turnaround time. However, we are not in the
business of selling ‘off-the-shelf’ presses. Every one
of our products can be customised and upgraded
to suit your unique requirements. We can also
provide tailored & bespoke solutions for non-
standard applications. Simply get in touch with
one of our team to discuss your requirements and
find out more.

5) Excellent technical and after-sales support

We pride ourselves on our excellent technical
support and after sales customer service. Wherever
in the world you are based, we can offer you
fast, expert support through our global network
of representatives and distributors. Our rapid
response service gives you access to spare parts
and engineering services whenever you need
them.
Our support begins even before installation, with
our comprehensive training package. We want
to ensure that all your team are completely
confident in operating your new press so you
can start running at full efficiency straight away.
We therefore offer full training as an inclusive
service. We have a showroom at our Nottingham
headquarters that features working models of all
of our presses, so if it is convenient for you we can
host your team here for a full demonstration.

Alternatively, we can carry out your training at

your location. Simply let us know what works
best for you. You can drop into our showroom at
any time for top up training or to speak to one
of our engineers. It is always good to meet our
customers face-to-face! Focus Label Machinery Ltd
 [email protected]
 01949 836 223
32  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Find Out More

Many thanks for taking the time to download and read this guide. We hope
you have found out a few new things about flexo-printing and will give
serious consideration to ordering a new press from Focus.

If you would like to discuss any of the issues raised, or have questions about
our products or services, please do not hesitate to get in touch with a
member of our experienced customer service team.

We would be delighted to meet you in person and show you around our
manufacturing facility.

For a quote to suit your budget, please give us a call on 01949 836 223 or
send us an email to [email protected]

Focus Label Machinery Ltd

 [email protected]
 01949 836 223
33  @FocusLabel  Focus-label
The Ultimate Guide to Flexo-Printing A Free Guide From Focus Labels

Get In Touch
 [email protected]
 01949 836 223
Our Address
Kendryl Park
Chapel Lane
Bingham
Nottingham
NG13 8GF

Follow Us
@FocusLabel  Focus-label
34
 focus-label-machinery-limited
 Focuslabel
 01949 836 223
 @FocusLabel  Focus-label