Asahi Kasei Brand

What is Flexography Printing and What Types of Packaging is it Used For?

When it comes to packaging printing technologies, there are several methods such as Screen, Offset, and Digital Printing. However, if we talk about a printing process that can print on a wide range of substrates, offers high printing speed, involves less complex processes, and supports various types of inks—Flexography (Flexo Printing) is the answer.

As Press Systems Group (PSG), we are an expert in printing solutions, offering UV & UV LED curing systems, UV lamps, printing inks, printing equipment, technical support, and flexo plates (photopolymer printing plates).—we will explain what Flexography is, its advantages, which packaging it is commonly used for, the main components and equipment involved, the printing steps, and why photopolymer plates are crucial.

What is Flexography Printing?

Flexography is a relief printing process that uses flexible photopolymer plates in combination with a rotary printing system to continuously transfer ink onto different substrates. The image area on the plate is raised higher than the non-image area, allowing ink to be picked up and transferred directly to the substrate.
This technology is highly popular in the packaging industry because it can print on diverse materials at high speed, making it ideal for packaging production—including food packaging.

Key Advantages of Flexography Printing

Flexography is commonly used in the packaging industry because it offers several advantages, such as:
Wide range of substrates – Can print on foil, corrugated board, paper, coated paper, plastic films, stickers, shrink sleeves, and more. Suitable for both absorbent and non-absorbent surfaces.

  • Versatile inks – Compatible with water-based, UV ink, and solvent-based inks.
  • High speed & cost efficiency – Suitable for mass production, reducing both production time and costs.
  • Durable plates – Photopolymer plates are highly durable and can handle long print runs.

What Types of Packaging Use Flexography?

Flexography is widely used in the packaging industry and is suitable for a broad range of applications, including:

  • Flexible Packaging: Snack bags, plastic pouches, shrink sleeves
  • Corrugated Boxes: Direct printing of logos and product details on cartons
  • Labels & Stickers: Paper or film-based product labels
  • Paper Packaging: Paper bags, paper cups, milk cartons, juice boxes

Flexo Printing Press Sizes

1. Narrow Web Flexo (8–20 inches / 200–500 mm)

  • Commonly used for labels, stickers, and small packaging
  • Typically uses for UV Flexo inks cured with Mercury or UV LED systems

2. Mid Web Flexo (20–40 inches / 500–1000 mm)

  • Suitable for flexible packaging such as snack bags or mid-size food packaging
  • Supports UV, solvent-based, and water-based inks

3. Wide Web Flexo (40 inches+ / 1000 mm+)

  • Designed for large-scale jobs like multi-layer industrial packaging films
  • Uses mainly solvent-based or water-based inks with drying systems (hot air, IR)

Key Components of Flexography Printing

While flexography is not overly complex, it consists of essential components:

  1. Ink Roller – Transfers ink from the ink pan to the anilox roller
  2. Anilox Roller – The heart of the system, with thousands of microscopic cells that precisely meter and transfer ink to the plate for consistent, high-quality prints
  3. Doctor Blade – Removes excess ink from the surface of the anilox roller
  4. Impression Roller – Provides pressure, ensuring proper ink transfer from the plate to the substrate

The flexographic printing process

The flexographic printing process consists of the following steps:

  1. Ink Supply: Ink is delivered to the anilox roller either through a chambered doctor blade system or a fountain roller system, depending on the press design.
  2. Ink Metering: The ink is transferred onto the anilox roller, where the doctor blade removes excess ink, leaving only the precise amount of ink within the engraved cells of the anilox roller.
  3. Ink Transfer to the Plate: The anilox roller then makes contact with the photopolymer printing plate mounted on the plate cylinder, transferring ink to the raised image areas of the plate.
  4. Printing on the Substrate: The substrate passes between the plate cylinder and the impression roller. The plate cylinder applies pressure, transferring the inked image onto the substrate with clarity and accuracy.
  5. Drying: After printing, the substrate passes through the drying system to ensure the ink is completely dried before being rewound or sent to the next production stage.

What are Photopolymer Plates and Why are They Important?

Photopolymer plates are a key element in flexography. They create the raised surface (relief) that carries ink and transfers it onto substrates. These plates are durable, reusable, and deliver excellent ink transfer and print quality. Compared to other plate-making systems, they are also faster to produce.

Why Choose AsahiKASEI Photopolymer Plates?

AsahiKASEI has over 50 years of expertise in developing sustainable photopolymer plates. Their eco-friendly solutions reduce the use of solvent-based cleaning agents (VOCs), supporting a safer and greener future.
Solvent ZERO – The Path Toward Reducing Solvent Usage for the Safety of People and the Planet

1. AFP™ (Standard Solvent-Washable Plate)

  • Uses solvent-based washout
  • Equipped with CleanPrint Technology for superior ink transfer, reduced ink build-up, less frequent plate cleaning, extended plate life, and reduced waste
STEP 02 - AFP™-R

2. AFP™-R (Reduced Solvent)

  • Continues to utilize the existing solvent-based plate processor
  • Reduces solvent consumption and shortens plate production time. AFP plates require only 12 minutes for washing and 1 hour for drying, compared to conventional plates which take 16 minutes for washing and 2 hours for drying
  • No additional investment required—simply switch to AFP plates
STEP 03 - AWP™

3. AWP™ (Water-Washable Plate)

  • Completely eliminates hydrocarbon solvents
  • Compatible with automatic plate processors like CrystalCleanConnect
  • Reduces plate swelling and provides sharp, accurate print quality
  • Represents Asahi’s cutting-edge technology for a sustainable future

CleanPrint Technology Product Range

  • Water Washable Plates (AWP)
    • AWP-DEW (Round Top) – For labels, flexible films, paper, etc.
    • AWP-CleanFlat (Flat Top) – For films, paper, corrugated board, etc.
Solvent Washable Plate (AFP)
  • Solvent Washable Plates (AFP)
    • AEPR (Round Top) – Ideal for labels, films, preprint, and high-quality paper jobs
    • AEPF (Flat Top) – Suitable for labels, films, preprint, and high-quality paper jobs

Contact Press Systems Group

Let PSG help you find the right flexographic printing solution for your business, whether it’s premium labels, high-quality packaging, or sustainable photopolymer plates. Our team provides consultation and problem-solving support backed by AsahiKASEI’s global expertise.

Address: 3030 Moo 10, Samrong Nuea, Muang Samutprakan, Samutprakan, Thailand 10270
Phone: +66 (0) 2 118 3852
Mobile: +66 (0) 61 789 4744
Email: info@presssystems.co.th
LINE: @presssystemsgroup