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Flexo’s Transformation—It’s All About Controlling Variables

Flexography is going through a renaissance. While it has been around since the late 19th century, it has never really had a role in “quality” printing, although that seems to be changing. This change is proving that it can fight off the increased use of digital printing for packaging production with better productivity and lower cost. In this article, David Zwang looks at one of the more significant changes facilitating that transformation.

Tuesday, November 06, 2018

(See also David Zwang's related video interview with Kodak's Chris Payne.) 

My introduction to printing was in the “pre-digital” era, and at that time it was thought of as a craft. In fact, if you consider all of the variables that needed to be controlled in the process, it was a highly skilled craft. In my initial exposure to offset printing, you had to balance ink color and formulation, water, plates, separations, screening, machine impression, environmental conditions, etc. When all these things came together in the “ideal” configuration you were able to get some pretty amazing reproductions. At that point, I learned it was all about controlling all of those inherent variables.

The highest print quality of the time was undoubtedly rotogravure, and evidence for this was its use in the production of National Geographic, often thought of as the pinnacle of printing quality. While “gravure,” as it is more widely known, is a more expensive plating process, requiring the expense and time of engraving cylinders for each color and press run, it has fewer variables making it easier to control, and therefore easier to achieve a high-quality reproduction.


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About David Zwang

David Zwang travels around the globe helping companies increase their productivity, margins and market reach. He specializes in production optimization, strategic business planning, market analysis, and related services to companies in the vertical media communications market. Clients have included printers, manufacturers, retailers, publishers, premedia and US Government agencies. He can be reached at [email protected].

Recent Articles from David Zwang

Canon: Continued Production Inkjet Development and Growth

Canon: Continued Production Inkjet Development and Growth

With more than 2,000 ColorStream units delivered worldwide, Canon has introduced the new 7000 series for mid-range production. To say that Canon has been broadening their portfolio of production printers is probably an understatement. There are new developments in the ProStream platform and the new iV7 B2+ cut sheet press is about to hit the street. Read More

Kodak Keeps on Growing!

Kodak Keeps on Growing!

Coming out of three consecutive quarters of year-over-year growth, Kodak has been delivering on their promise to rebuild and transform the company. In this Business Update video, David Zwang talks with Jim Continenza, Eastman Kodak Chairman and CEO. Read More

The Start-Up Chronicles: dappas—Next Level E-Commerce Packaging Intelligence

The Start-Up Chronicles: dappas—Next Level E-Commerce Packaging Intelligence

The ultimate goal of dappas is to help facilitate design and eliminate the entire prepress production, so all the converters who are working with them get a stream of work that is ready to go to press and converting. Read More

Labels and the Connected Supply Chain

Labels and the Connected Supply Chain

You can think of this very competitive connected supply chain landscape in four layers: material suppliers, label converters/printers, hardware OEMs, and software/platform players. The connected supply chain has changed from moving things hand-to-hand or through email to more full-featured automated systems. The good news is that, as a converter, after you decide where you would like to start, there are so many options for you to select from. Read More

Direct-to-Object: Challenging Labels and Tags or Offering New Opportunities?

Direct-to-Object: Challenging Labels and Tags or Offering New Opportunities?

Print is a very adaptive technology and direct-to-object (DTO) is another area where it can offer new opportunities for PSPs and product manufacturers. Today, most of the product and packaging decoration (i.e., labels and tags) that exists is handled by a label converter. It is a well-established process that probably won’t disappear. However, it can and will be challenged by inline DTO printing solutions, offering new opportunities. Read More