Flexography
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2008-07-09T20:04:12Z
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{{unreferenced|date=July 2008}}
{{Redirect|Flexo|the robot character in [[Futurama]]|List of recurring robot characters from Futurama}}
[[Image:Flexography-Platecloseup.JPG|thumb|250px|A flexographic printing plate.]]
{{History of printing}}
'''Flexography''' (also called '''surface printing'''), often abbreviated to '''flexo''', is a method of [[printing]] most commonly used for packaging (labels, tape, bags, boxes, banners, etc.).
A flexographic print is made by creating a positive mirrored master of the required image as a [[Three-dimensional space|3D]] [[relief]] in a [[rubber]] or [[polymer]] material. A measured amount of [[ink]] is deposited upon the surface of the printing plate (or printing cylinder) using an engraved [[anilox]] roll whose texture holds a specific amount of ink. The print surface then rotates, contacting the print material which transfers the ink.
One method of plate development uses light-sensitive polymer. A film negative is placed over the plate, which is exposed to ultra-violet light. The polymer hardens where light passes through the film. The remaining polymer has the consistency of chewed gum. It is washed away in a tank of either water or solvent. Brushes scrub the plate to facilitate the "washout" process. This method is considered "old-fashioned," but is still widely used in smaller operations, and is still taught in most high school and college flexo programs.
Originally flexographic printing was basic in quality. Labels requiring high quality have generally been printed using the [[offset printing|offset]] process until recently. In the last few years great advances have been made to the quality of flexographic printing presses.
The greatest advances in flexographic printing have been in the area of [[photopolymer]] printing plates, including improvements to the plate material and the method of plate creation, usually [[photography|photographic]] exposure followed by chemical etching, though also by direct [[laser engraving]].
Digital [[direct to plate]] systems have dominated the industry recently with their better resolution and the ability to print four color process (or more) as well as offset. Companies like Dupont in DE and PlateCrafters in Colmar, PA have pioneered the latest technologies with advances in FAST washout and the latest screening technology, even companies who make plates in house are going to trade shops to get these high quality plates.
Laser-etched [[anilox]] rolls also play a part in the improvement of print quality. Full color picture printing is now possible, and some of the finer presses available today, in combination with a skilled operator, allow quality that rivals the [[lithography|lithographic]] process. One ongoing improvement has been the increasing ability to reproduce highlight tonal values, thereby providing a workaround for the very high [[dot gain]] associated with flexographic printing.
Flexo has an advantage over lithography in that it can use a wider range of inks, water based rather than oil based inks, and is good at printing on a variety of different materials. Flexographic inks, like those used in [[gravure]] and unlike those used in lithography, generally have a low [[viscosity]]. This enables faster drying and, as a result, faster production, which results in lower costs. Printing press speeds of up to 800 meters (2,625 feet) per minute are achieveable now with modern technology high-end printers, like TRESU [http://www.tresu.com].
==History==
The process of flexography was originally called “aniline printing,” named for the [[aniline]] oil used in the [[ink]].
In 1890, the first patented press was built in [[England]] by Bibby, Baron and Sons. The water-based ink smeared easily, leading the device to be known as “Bibby’s Folly”.
In the early 1900’s, other European presses were developed using rubber printing plates. But by the 1920s, most presses were made in [[Germany]], where the
process was called “gummidruck”.
During the early part of the 20th century, the technique was used extensively in food packaging in the [[United States]]. However, in the 1940’s, the [[Food and Drug Administration]] classified aniline dyes as unsuitable for food packaging.
Printing sales plummeted. Individual firms tried using new names for the process, such as “Lustro Printing” and “Transglo Printing,” but met with limited success. Even after the government approved
the aniline process, sales continued to decline.
Intent on re-popularizing aniline printing by changing its name, [[Franklin Moss]], president of [[Mosstype Corporation]], surveyed the industry in 1951 and received over 200 different name suggestions. In October of 1952, the
new name was announced; “flexography.”<ref>The Pressman</ref>
==Products==
Typical products printed using flexography include brown corrugated boxes, flexible packaging including retail and shopping bags, food and hygiene bags and sacks, flexible plastics, self adhesive labels, and wallpaper. A number of newspapers now eschew the more common offset lithography process in favour of flexo.
==In education==
The Flexo in Education Program, formerly The Flexo in High School Program, was started at South Mecklenburg High School in [[Charlotte, North Carolina]] by the Flexographic Technical Association in 1993. Since its inception many other high school programs have been started. For example Asheville High School in [[Asheville, NC]], The Applied Technology Center in [[Rock Hill, SC]], Fort Mill High School in [[Fort Mill, SC]], and others. The program has even gone international with the inclusion of Gordon Graydon Memorial Secondary School in Missasauga, Ontario Canada. The program was re-named to become The Flexo in Education Program because [[post-secondary]] [[institutions]] began to participate in the program. Many technical colleges and universities incorporate flexography into their curriculum. For example [http://graphics.clemson.edu The Department of Graphic Communications] and [http://www.clemson.edu/centers-institutes/printcon the Clemson University Printing and Converting Research Center] at [http://www.clemson.edu Clemson University], [http://www.cpcc.edu Central Piedmont Community College], [http://www.chowan.edu Chowan University], [http://www.appstate.edu Appalachian State University], the [[Heidelberg Centre - School of Graphic Communications Management|Graphic Communications Management]] program at [[Ryerson University]], and others include flexography in their curriculum.
Sadly, Charlotte-Mecklenburg Schools, the school district where Flexo in Education got its start, announced in 2008 that the first ever Flexo in High School program at South Mecklenburg High School would be discontinued. The building where their flexography lab was located was demolished Monday, July 7, 2008, to make way for a new 3-story building to house the school's science and technology department. The school district determined that it would be too difficult and expensive to move, store, and re-install press and equipment in the old lab. It was, instead, donated to another school in North Carolina to start a new flexo program.
== Flexographic printing inks ==
The nature and demands of the printing process and the application of the printed
product determine the fundamental properties required of flexographic inks.
Measuring the physical properties of inks and understanding how these are
affected by the choice of ingredients is a large part of ink technology. Formulation
of inks requires a detailed knowledge of the physical and chemical properties of
the raw materials composing the inks, and how these ingredients affect or react
with each other as well as with the environment. Flexographic printing inks are
primarily formulated to remain compatible with the wide variety of substrates used
in the process. Each formulation component individually fulfils a special function
and the proportion and composition will vary according to the substrate.
==References==
<references/>
1.http://www.thepressman.com/Pressman%20April%202003.pdf
[[Category:Printing]]
[[Category:Packaging]]
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[[it:Flessografia]]
[[pl:Fleksografia]]
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[[tr:Fleksografi]]
[[zh:柔性版印刷]]