Flexographic Printing Process Explained – Step-by-Step Workflow for Flexo Machines


Flexographic printing is a high-speed, roll-to-roll printing process widely used for packaging materials such as paper, film, and labels. It is known for its efficiency, versatility, and ability to produce high-quality prints using fast-drying inks on a variety of substrates.

This article outlines the complete printing process of a flexographic printing machine, from unwinding the blank paper roll to the final rewinding after multiple color printing. The example below is based on a typical 4-color flexo printing setup.

Full Flexographic Printing Process

  1. Blank Paper Roll Loading (Unwinding)

    The process begins with loading a blank roll of substrate, typically paper, film, or foil. The roll is securely mounted onto the unwinding unit.

  2. Tension Control

    Consistent web tension is critical throughout the entire printing process. Automatic tension controllers adjust tension in real-time to avoid wrinkling or misregistration.

  3. Web Guiding / Edge Position Control (EPC)

    An EPC system ensures the substrate travels in perfect alignment, preventing lateral deviation that could affect print accuracy.

  4. Surface Treatment – Corona Discharge (Optional)

    For non-porous substrates such as plastic films, corona treatment is applied to increase surface energy, improving ink adhesion.

  5. First Color Printing Unit

    The substrate enters the first flexo unit, where the anilox roller transfers ink from the ink tray to the printing plate, which then imprints the first color onto the material.

  6. Drying System

    A hot-air or IR drying unit rapidly dries the first ink layer to prevent smudging and allow for immediate application of the next color.

  7. Second Color Printing Unit

    The substrate continues to the second station for the application of the second color.

  8. Drying System

    Each print station is followed by an independent drying system to cure the ink before the next layer is applied.

  9. Third Color Printing Unit → Drying

  10. Fourth Color Printing Unit → Final Drying

    Each additional color is printed and dried in sequence, ensuring proper ink registration and high print quality.

  11. Cooling System

    After all colors are printed and dried, a cooling unit stabilizes the web temperature, preventing material deformation before post-processing.

  12. Die Cutting (Optional)

    If label or packaging conversion is required, a rotary or flatbed die cutting unit cuts the printed substrate into the desired shapes.

  13. Slitting (Optional)

    The printed and cut web may be slit into narrower rolls, depending on the final product requirements.

  14. Rewinding

    The finished material is rewound into a roll, ready for shipment, lamination, or further converting processes.

Example: 4-Color Flexographic Printing Line

Blank Roll → Unwinding → Tension Control → EPC → Corona Treatment → 1st Color Print → Drying → 2nd Color Print → Drying → 3rd Color Print → Drying → 4th Color Print → Drying → Cooling → Die Cutting → Slitting → Rewinding

Conclusion

The flexographic printing workflow is a well-orchestrated sequence of precision-controlled stages, each playing a crucial role in achieving high-speed, high-quality multi-color printing. With technologies such as automatic tension systems, EPC, and inline drying, flexo presses offer unmatched efficiency in modern label and packaging production.

Whether you're printing on paper, plastic, or film, understanding each step in the flexographic process helps ensure optimal results and minimal downtime.