While digital printing has become one of the hottest topics in label and package printing, flexographic technology still accounts for the lion’s share of production in our industry. On the second day of FTA Forum, numerous industry experts from the label and flexible packaging industries delved into what the future holds for flexo.

The session, chaired by Esko’s Rory Marsoun and Clemson’s Kenny Tucker, delved into key considerations for converters – from training and attracting the next-generation workforce to utilizing the newest flexographic technology to make packaging pop on the shelf.

Marsoun addressed the latest trends in flexo, including the quest for consistency. “Print quality means different things to different people,” he explained. “Depending on where you live in the industry – whether you’re a printer, brand or supplier – that will change your view of print quality. I would say beautiful dots and screening technology. Among attendees, you’re saying consistency, and that’s been something we’re hearing from everybody. Consistency is really what matters.

“In the US, it’s all about whatever I print today, I need to be able to reprint tomorrow and six months from now, creating brand integrity,” added Marsoun.

Marsoun conducted a study with 43 print converters to gain insight into the perception of the modern flexographic industry. The average self-rating of print quality among respondents was 8/10, and 73% stated their print quality was better than other flexo printers.

“We have this perception that we’re doing better than we are,” noted Marsoun. “Most of the printers I visit I would not rate 8/10, so I feel like we’re overestimating how we’re printing in many cases.”

The newest technologies, many of which were highlighted at FTA’s INFOFLEX from May 6-7, 2024, in Kansas City, MO, USA, have been engineered to improve print quality throughout the label and packaging industries.

“Flexo has definitely come a long way, but we can do a lot more,” Marsoun commented.

Marsoun cited the average LPI, which measures the screen definition and how small the dots are, to illustrate quality growth over the past two decades. However, while flexible packaging continues to make strong strides, flexographic label quality has remained stagnant over the past 10 years.

“We have seen a progression in quality,” said Marsoun. “In 2000, labels measured at a 133 LPI. In 2010, that increased to 150. Now we see the label space really hasn’t continued to increase while flexible packaging has continued to increase to 2024. Why? A lot of label printers have switched their focus to digital printing. I’m not saying they’re not trying to optimize their flexo printing, but the quality of flexo has not really increased.”

According to Marsoun, there are numerous factors that can drive quality and cause LPI to surge in the future. For example, high resolution imaging, combined with advanced surface screening, will allow printers to transfer more ink with lower volume aniloxes. Meanwhile, new technologies, such as inks, aniloxes, plates, presses, and imaging technology, can also improve print quality.

“We can do more with screening, and that screening has made some pretty strong improvements with half-tone dots and LPI,” said Marsoun. “Among other benefits, lower volume aniloxes allow printers to print higher LPIs. Surface screening dots also greatly reduce dot bridging, which often allows printers to increase LPI.”

There are numerous advancements in use at converting shops today, including flat-top dot technology, high resolution imaging technology, advanced highlight screening technology, expanded color gamut, LED plate exposure, and more.”

“The quality improvement could be big, and more than you think,” added Marsoun. “This is an opportunity to drive quality forward.”

Training and recruitment will also help the industry advance. Currently, label converters and suppliers are working tirelessly to attract the next-generation workforce. For example, Kenny Tucker, assistant director at the Sonoco Institute of Packaging Design and Graphics at Clemson University, cited several popular courses that are promoting flexo education. Introduction to Flexography is available both online and in the classroom, along with Flexo Foundations and Advanced Techniques in Flexography.

“We also have online training, and we’ve had 142 people take advantage of that,” stated Tucker. “This started during Covid. That shows that there are people looking to learn about flexo and get involved in our industry.”

Inclusivity will play a big role, too. FTA’s Women of Flexo has expanded significantly since its inception in 2020, and Tucker noted that 71% of his graduates in 2023 were female.

“We need to have opportunities for females in this industry,” said Tucker. “I’ve recommended several of my female students to go into a student mentorship program. The industry is changing, and we need to react to that. The FTA has done that, which is really great.”