Flexographic printing, one of the pillars of the printing industry and a key feature at PRINT4ALL 2025, is a constantly evolving field but not without challenges. A recent survey on flexography highlights the importance of training as a fundamental issue, especially amidst challenges related to technologies and material knowledge. Let’s analyze the research highlights to understand where suppliers and printers are investing ahead of the trade show to minimize printing defects.
Suppliers' Responses
When discussing defects in flexographic printing, responses are often varied due to the broad market and the diversity of equipment and service suppliers. Customer feedback on printing errors reveals two main issues: 45.45% of responses focus on ink-related problems (such as smudging or discoloration), while 36% highlight ink adhesion issues. Other concerns include problems with plates, registration, and substrate cutting. Over 80% of supplier feedback revolves around ink-related issues, with additional specifics in the "other" category, touching on topics like color matching, viscosity, and inconsistent ink flow. These challenges have been addressed before, and in this issue, we revisit the importance of reducing color changes and ink consumption to ensure more efficient and consistent production.
Causes and Remedies for Printing Errors
A lack of operator training (over 66%) is often identified as the primary cause of flexographic printing errors. It is unclear whether this issue stems from new technologies requiring specialized training or from generational turnover, which may lead to less experienced professionals. Other significant factors include the choice of appropriate materials—inks and substrates—and machine settings. Equipment damage is only a minor cause of flexo printing errors. Precise remedies are proposed for specific causes, with operator training topping the list of solutions. Other measures include adjusting printing machine settings and changing production materials. An intriguing area of improvement is enhancing communication between clients and converters, suggesting that better information exchange could help align expectations and deliverables.
From Impact Analysis to Production Prevention
When it comes to identifying and resolving issues, suppliers believe printers are sufficiently autonomous—a positive sign. However, production delays remain a problem, with respondents reporting a high frequency of delays caused by printing errors. Not all companies have adopted systems to analyze and quantify economic impacts; fewer than 50% report knowing businesses with adequate IT systems. To prevent flexo printing errors, the respondents focus on three areas: training on services and products, adopting control systems, and improving communication between printers and suppliers. Suppliers express a strong interest in providing tailored advice to prevent flexo printing errors.
Printers' Responses
Operators' perspectives sometimes differ from those of suppliers, though they occasionally align. Printers were asked similar questions, and while some answers show consistency, others reveal contrasting experiences. Regarding the most common errors, printers' responses focus on inks and adhesion issues, with more defined percentages compared to suppliers' reports. It’s unsurprising: frequent supplier changes and ink replacements can significantly impact production if all variables aren’t considered. Delving deeper, the primary cause of flexo printing errors unanimously cited by printers is the lack of operator experience or training. This factor outweighs issues related to substrates, inks, or incorrect equipment settings. Unsurprisingly, training is viewed as the main remedy for errors, a sentiment universally echoed across this survey.
Analysis and Control Systems
In response to the question, “How often do flexo printing errors cause delays or waste in your production?” printers offered differing perspectives from suppliers, stating that production delays due to printing errors occur only occasionally. This distinction is crucial as it justifies the economic impact of such errors. For printers, the financial burden is lower, with over 60% reporting IT systems capable of analyzing and quantifying the influence of printing errors on business performance.
Printers see error prevention in flexo printing as tied to training on products and services. They also express a strong interest in receiving tailored advice for error prevention, emphasizing the importance of consistent and effective communication with suppliers.
Conclusions for Flexo Printing
The survey leaves little room for interpretation: challenges in flexography can be mitigated through proper training. Knowledge and expertise are key to preventing printing errors and addressing emergencies, which should become increasingly rare. Looking to the future and generational turnover, it is essential to ensure that company production expertise becomes a solid asset that benefits both businesses and young professionals, enabling them to learn from past mistakes and solutions. Regular maintenance of equipment, use of advanced substrates, inks, and control systems, and the transfer of expertise are critical to achieving sustainable progress in flexographic printing.
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