Flexo printing technology: four corrugated box printing techniques

In today’s fast-growing packaging industry, carton printing is experiencing significant growth, and customers are placing higher demands on product quality. As a result, improving the quality of carton printing has become a top priority for many companies. Below are some essential tips and techniques to help achieve high-quality, visually appealing carton prints. One important consideration when flexographic printing on low-gloss paper is the surface texture of corrugated cardboard. When using low-grit base paper, the corrugated surface may show visible flute patterns, which can make it difficult to print detailed graphics in the low areas of the flutes. To overcome this issue, it's recommended to use a flexible resin printing plate with good resilience. This helps maintain consistent ink transfer and reduces printing defects. For A-type corrugated boards made from low-grain paper, improper printing can damage the board’s flat compressive strength. Additionally, passing through the printing and embossing rollers can weaken the edge pressure strength of the cardboard. If the surface roughness of the corrugated board varies too much, it can lead to warping after production. Warped boards can cause misregistration and irregular slitting during printing, making post-processing challenging. Therefore, it's crucial to flatten warped boards before printing. If they are forced into the press without correction, it can lead to uneven printing and reduced board thickness. When dealing with color inconsistencies in the same batch of printed cartons, several factors could be at play. Even if the color registration appears accurate during the four-color printing process, inconsistent specifications across the batch can occur. One common issue is an improperly adjusted front gauge. Typically, three sheets of paper are stacked under the pre-registration mechanism to ensure proper pressure and free movement. If the gauge height is too high or too low, it can result in inaccurate paper positioning, leading to inconsistent product dimensions. Another factor is side positioning accuracy, including the height of the side pressure plate and the tension applied by the paper roll. If these settings are not properly adjusted, the paper may not be fed correctly, causing misalignment. The ideal height for the side gauge should be about three times the thickness of the printed paper, and the pulling distance should be between 5 to 8 mm to ensure accurate side registration. Adjusting the printing pressure is also critical. The pressure should be even and moderate, allowing for clear ink transfer without deforming the printing plate. Once the correct pressure is set, it should not be changed frequently during the printing process. The inking pressure—between the anilox roller and the printing plate—is equally important. It ensures even ink distribution and proper transfer to the printing plate. Too much pressure can cause ink buildup on the plate, affecting print quality and reducing the plate’s lifespan. On the other hand, too little pressure can result in insufficient ink coverage. Careful adjustment during the printing process is necessary to maintain smooth and consistent results. Finally, when printing on different types of cardboard paper with varying levels of smoothness, the ink absorption and drying time will differ. Rougher papers tend to absorb more ink and dry faster, so a higher ink application is often needed. Smooth, dense papers, such as coated whiteboard paper, have lower ink absorption and slower drying, but they provide better pattern reproduction. These papers are ideal for printing fine details and small dots due to their high resolution and consistent ink transfer. By following these techniques and paying attention to detail, printers can significantly enhance the quality and consistency of their carton printing processes.

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