Regardless of the printing method used, pre-press production plays a crucial role in determining the final print quality. In particular, flexographic plate making is often referred to as the "foundation" of the entire process. If the plate is not made properly, it can result in a complete waste of time and resources. Unlike other printing methods, once a flexo plate is produced, any issues cannot be easily corrected or compensated for—making it one of the biggest challenges in flexo printing. To avoid complications in the subsequent printing stages, it's essential to follow strict quality standards:
1. The printing plate must have the appropriate hardness depending on the material being printed. For corrugated cardboard boxes, the Shore hardness of the flexographic surface should be around 30–35 degrees. For plastic films and paper, the hardness should be approximately 50–55 degrees. This ensures good ink transfer and durability during the printing process.
2. The four corners of the printing plate should be even and the thickness consistent throughout. The embossing depth of the design should be about half the thickness of the plate. Small text and fine gaps must also have sufficient depth to prevent ink smearing or loss of detail.
3. The edges of text and lines should have a slight slope to prevent ink buildup and ensure clean separation. The layout should be non-sticky, meaning that no areas are too close together, which could lead to unwanted ink transfer.
4. All elements—text, lines, and background images—must be complete with no missing strokes, broken lines, or imperfections such as dirt spots or trachoma (a term used for small, irregular dots). Any flaw at this stage will be visible in the final print.
5. The dimensions and specifications of the printing plate must be precise. Color separation must be accurate, and the concave areas should be flat and free from unevenness, ensuring uniform ink distribution across the entire plate.
6. For halftone or screen-printed plates, the dot structure must be consistent. High and low key dots should not be missing, and the dots should appear smooth and well-defined. Some low-key dots may have a slight depth to maintain visual contrast and clarity.
By adhering to these standards, printers can significantly reduce errors, improve efficiency, and ensure high-quality output. Flexo printing is a delicate process, and the success of the final product starts with the quality of the plate itself.
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