Flexography, also known as flexo printing, has undergone a remarkable transformation since its inception. This printing technique has evolved significantly over the past century, becoming a cornerstone of the packaging industry…roughly 60% of the entire packaging industry uses flexography in the construction of their packaging! Let’s take a journey through the history and advancements of flexographic printing.
The roots of flexography can be traced back to the mid-19th century. In 1853, an English paper bag printer developed a unique rotary press, marking the early stages of what would become flexographic printing. However, it wasn’t until the early 1900s that significant progress was made. A French businessman named Charles Holweg developed a press that used synthetic aniline dye ink, chosen for its fast-drying properties. Synthetic aniline dye inks were colorants derived from coal tar or benzine derivatives.
The 1920s and 1930s were pivotal decades for flexography. It was determined that early aniline inks were of poor quality; they weren’t durable and would fade over time, the inks often bled or smudged when exposed to moisture, and there were health concerns associated with their use, as their ingredients were toxic. A breakthrough came in 1927 with the development of an ink that used Triarylmethane dye dissolved in cellosolve, which was chemically fixed to prevent bleeding when wet. This innovation significantly improved the quality and reliability of flexographic printing.
in 1941, the introduction of the anilox roll revolutionized ink transfer and consistency. This is a hard cylinder coated with a ceramic material (often chromium oxide). The surface of the roll is engraved with millions of tiny dimples which are designed to hold a precise amount of ink, which is then transferred to the printing plate. The term “flexography” was officially adopted in 1952, replacing the earlier term “aniline printing” due to the negative connotations associated with aniline dyes.
Since the 1960s, flexographic printing has continued to evolve, incorporating new materials and technologies. The introduction of photopolymer printing plates and digital direct-to-plate systems has significantly enhanced print quality and efficiency. In recent years, the industry has made strides towards sustainability with the development of water- and vegetable-based and UV-curable inks. Additionally, advancements in recycling and waste management have further solidified flexography’s role in sustainable packaging solutions.
Today, flexographic printing is a versatile and efficient printing method. Flexography’s journey from rudimentary rubber plates to sophisticated digital systems is a testament to the industry’s commitment to innovation and quality, two values we hold at think4D.
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