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Thermal-Transfer Printers Challenge Flexographic Printers
Flexography printing is also referred to as surface printing and for a long time
was the preferred method of printing for packaging. With flexography, a mirrored
3D master plate is created of the image out of a rubber or polymer material. Using
an anilox roll, ink is then dispensed in measured amount onto the surface of the
printing cylinder. The print surface rotates, and transfers the ink as it comes
in contact with the print material. Flexography was named due to its originally uses as a method for printing the uneven
surface of corrugated cardboard. The flexible printing plate remains in contact
with the surface during the entire print process, producing a smooth and even finish.
When this process was first used, it had a very low print quality. However, great
advancements have been made in the last few decades in improving the plate material
and the method of which the plate is created. Today, photographic exposure is used
which is then followed by chemical etch. However, some manufactures also use direct
laser engraving. Because of these advancements, full color printing is now possible. Flexographic printing is still the most widely used printing method for flexible
packaging. However, with the major advancements of thermal-transfer printing an
increasing number of companies are switching from flexographic printing to thermal
transfer printing. One reason for this is the growing global market and the increasing
number of languages and internationally understood symbols, which are required on
packages. In addition, in order to comply with European and United States market
and FDA regulations, packages must clearly display lot codes/ numbers and expiration
dates. This had made the use of flexographic printing plates, which now require
constant updating very expensive. In order to comply with packaging regulations an increasing number of manufactures
have turned to thermal-transfer printing. This simple programmable technology is
not bound by the limitations of having to physically create a printing plate, but
instead can program the needed information directly into the a database, which the
microprocessor translates and makes the needed changes to the graphic image. However, flexographic printing does have its loyal followers. With new and improved
inks and plate materials being developed, flexography is still an appealing option.
This is especially true for companies who are requested by, their clients to print
unvarying information and provide preprinted packaging materials. Therefore, what
we are seen in the in-house packaging printing market is a union between flexography
and thermal-transfer printing. Flexography VS Thermal Transfer Printing Approximately 70% of the films used for packaging are printed on using flexography
due to its versatility and its inexpensive operating cost. Another reason why flexographic
printing is still used is that it is more suitable for printing on foil, films,
and DuPont's Tyvek brand spunbonded olefin than thermal transfer printing is is.
In addition, flexographic technology also produces excellent print quality at high
speeds, with flexographic printers having the ability to print hundreds of feet
per minute. This makes it even more appealing and economical for large volume print
jobs. Flexography ability to print on much wider webs at faster speeds does not
harm print quality in fact; many supporters of flexography find it produces finer
lines and logos. However, the main disadvantage of flexography is its inability to compare to the
ease of thermal-transfer printing when it comes changing text content. With flexographic
printing when any part of the text or codes requires updating the users must change
printing plates. Many times this means creating new print plates that can cost
as much as $500 each. However, with thermal transfer printing, the user simply
enters the changes into the system with a few keystrokes and the change have been
made and sent to the printer, costing the company only the time needed to enter
the new data. Packagers routinely faced the problem of frequently having to make print changes
due to the market demand for bar codes, lot numbers, and expiration dates as well
as the need to print in multiple languages. This need for frequent changes can
cost a company an estimated $150,000 to $250,000 per year on printing plates for
multiple languages as well as ever changing expiration dates and lot numbers. Still, many manufactures feel the over all cost of thermal transfer printing is
too expensive when compared to flexographic printing despite the drawback of having
to create new print plates.
Small business guides: , Thermal Transfer Labels Guide.com |
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