Differences Between Flexo Printing Machine & Offset Printing Machine

Flexo Printing Machine & Offset Printing Machine: The package printing industry is booming, and the credit goes to different types of printing methods available. With modern methods like flexographic, offset, digital, and gravure, printing is possible in various sizes, shapes, and colors. 

In the printing industry, offset and flexographic printing have gained more popularity over others. Both methods provide consistent, high-quality, and long-lasting prints. Companies involved in flexo and offset printing use a robust and technically advanced flexo printing machine and offset printing machine.

If you plan to start a printing business or expand an existing one, investing in any of the mentioned machines can be the first step towards business success. 

Although both methods use wet ink and printing plates, the printing processes are pretty different. 

In technical terms, offset printing transfers an image to an intermediate carrier using a printing plate and then onto the substrate. In contrast, flexo transfers ink from the plate directly to the substrate.

Both methods are popular but perform the printing job differently. Therefore, it is crucial to understand both the printing process and the differences they share.

This article will discuss the differences between flexo printing machines and offset printing machines.

But before step into knowing the key differences, let’s first put some light on the similarities between them:

• Both include the incorporation and use of a printing plate
• Work with wet inks
• Both methods are used to print on various substrates, like paper, plastic, magazines, books, etc.
• Both processes are ideal for long-run jobs

Offset Printing vs. Flexo Printing: Key Differences

Plates

Flexo printing, as the name says, uses flexo plates to facilitate a rotary printing process. The plates are made of photopolymer compound and possess enough flexibility to encircle a printing cylinder. The relief image is fixed on the plate using a laser image-setter. A solvent or water solution washes off the polymer from the ‘non-print areas in the processing unit. A rotating ‘anilox’ roller transfers the ink from the ink well onto the flexo plate. The use of a separate flexo plate is necessary for each color print. Now, the image is directly printed onto the substrate. The printing plates are durable and, if maintained perfectly, can be used several times before they are required to be replaced.

In offset printing, a series of rollers transfer the ink onto the printing plate. The rollers can be rotary or flat, depending on the type of offset press. The plates are usually of aluminum that effectively transfers the ink to the rollers. The complete wet image (can be a single color or multicolor) is transferred onto a blanket that is quickly turned onto the substrate to avoid drying.

Ink

In the offset printing process, mainly two types of inks are used: water-based and UV curable. The process usually consists of four ‘process’ colors: magenta, cyan, yellow, and key (black). For each color, there is a separate printing station. Every print color required in the process is made using these four colors.

In the flexo process, there is also the use of print stations for spot colors. You can purchase these colors from suppliers in a pre-mixed form or mixed in-house, whatever seems feasible to the manufacturer. Like in offset inks, flexo inks can be both water-based and UV curable. However, solvent-based ink is one more option to use. UV inks pace up the running speeds and do not demand to be empty or clean each print station at the end of the day.

On the contrary, you should remove water-based inks from the press when it is not in use. The move will prevent ink from drying in the ink trays and on the rollers.

Print On Different Materials

An offset printing machine has the capability to print on different materials, such as metal, paper, cellophane, cardboard, and vinyl. The printing surface should be smooth and flat for effective printing. The process is best for printing newspapers, magazines, books, posters, stationery, brochures, pamphlets, etc. Even the machine can print on both sides of the material by offering a second pass. Also, the machine performs different other activities like die-cutting, folding, slitting, creasing, laminating, and more as a secondary offline process.

On the other hand, a flexo printing machine prints on both absorbent and non-absorbent materials, like paper, plastic, metal, cellophane, cardboard, fabric, foil, etc. The printing machine is widely used for printing on packaging like envelopes, retail bags, sweet wrappers, labels, wallpaper, and others. The process allows printing on almost any substrate with a flexible surface. With a technically advanced machine, a manufacturer can achieve high printing speed and quality prints with only a single pass operation.

Pros And Cons Of Each Printing Process

Offset Printing

Pros:

• Ensures high print quality
• Offers a lot of flexibility with label material
• Suitable for large printing jobs
• High-speed printing

Cons:

• The complexity of the print makes the process expensive
• The set-up takes time and produces set-up waste that further increases the set-up costs
• Demands the hiring of skilled operators to keep up the quality

Flexographic Printing

Pros:

• Have short set-up times, minimum set-up wastage, and high-quality output.
• Eliminates extra work and cost by automating everyday tasks, such as die-cutting and lamination.
• A simple and more manageable printing process that requires less-trained operators to produce optimum output.

Cons:

• The printing plates are more expensive than offset printing plates.
• Difficulty in producing complex and extensive artwork.

Make The Right Choice

Both the printing methods have their pros and cons. Where flexo printing is suitable for large run jobs, offset printing helps to facilitate complex print images on different materials. 

So, which process is suitable for you? Certain things will help you pick the proper process and get starting with the production of high-quality prints. Choosing between both methods will largely depend on the work, material, and various other factors of the job you’re performing. Different manufacturers use both processes to deliver projects on time. 

We hope that the article helped you understand the differences between flexo printing machines & offset printing machines. If you have any queries, let us know in the Comments.