When two or more entities come together or work together, they form a hybrid, meaning outcomes change – generally for improvement; not necessarily for replacement. New and different results do occur. Of course, that’s what is expected when deploying combination (hybrid) printing.

With the growing popularity, specifically around cost decreases and the ease of use of digital printing, the understanding of hybrid printing in the narrow web industry has become a synonym to the combination of conventional flexo and digital printing. The true benefits of flexo and digital printing in a hybrid system are clear. Waste, and time savings can be achieved by combining the best of the technologies and adding converting.

However, combination printing, or hybrid printing, has been around for years – whether inline or in separate process steps. It can and does sometimes look very different than today’s assumed digital model. So, let’s focus on other combination printing or hybrid technologies.

Shifting from a single printing technology to combination, or hybrid printing, is driven by factors that most of us are aware of; more customization of products, smaller run sizes, more SKUs on a single design and more effective and sustainable production.

We do see that combination printing has settled down and kept its place in the market. Combining features that are unique to a certain print technology and getting the best out of multiple worlds, printers can create highly appealing products with which brand owners can distinguish themselves.

Flexo and Offset
In the last few decades, we saw flexo eating up traditional offset jobs, however, offset still has its place in the modern narrow web labels and flexible packaging market. True, the evolution of flexo from a relatively low cost, low quality, large volume technology to a very high quality technology, helped it to replace traditionally higher quality technologies like offset, to a large extent. What used to be printed in offset due to the technology of printing finer lines and more gradient screens can now be printed in flexo.

Still, the combination of flexo and offset is here to stay. Where offset is used for the process colors and very subtle screens and color tones; flexo in the same job is used for consistent non process colors, high ink volumes, and embellishment options, like cold foil or inline lamination.

At the same time, there will always be certain applications required that demand using unique technologies because of functionality, like sealants, coatings and laminations. Unlike the older days, modern presses give the opportunity to make the processes more efficient by combining it into one machine and processing inline, eliminating several process steps.
Whether the base machine is based on offset or flexo, other technologies like screen, coating or laminating, embellishments can be easily integrated. Offset and flexo are an ideal combination for high-quality special labels.

When talking about security printing, specific security offset technologies can easily be combined with flexo technologies for special varnishes, spot colors, screen for adding another security step, lamination for special effects, hot foil for adding embellishments. Digital solutions like barcode or variable data printing can easily be integrated as well.

Flexo and Screen
Flexo and screen is a well-known combination for both labels and filmic jobs. The high opacity of a screen white, together with the possibility to have extreme ink layers to be able to print braille/tactile inline, makes this is very widely accepted combination.

Flexo and Gravure
Looking at narrow web, gravure as an individual technology seems to be phasing out, however applied in a flexo or offset line, it can still be beneficial. All main machine manufacturers offer gravure stations for specific applications. Adding a gravure station to a narrow web press enables printers to do more process steps inline and therefore be more cost effective.

Printing special metallics, instead of using cold or hot foiling, special coatings and opaque white are mere examples. Modern gravure stations, integrated into narrow web presses, usually are “hybrid” as well, meaning they can process both wa- ter-based and solvent-based inks and coatings.

Nowadays, it is possible to configure a narrow web UV press, partially with solvent-based print stations (either flexo or gravure) for special applications that were difficult to combine in the past with industry standard UV ink technology. Depending on job sizes, adding water- or solvent-based white inks to a largely UV printed product, can be very beneficial and cost effective.

Connect and expect
As a last teaser, one can also have a view on hybridization from a data and information perspective. Where traditional machine manufacturers used to focus on developing and optimizing the actual printing press, other companies focused on the data related to the workflow.

In narrow web, there was no machine data collected, other than the data that was provided, and entered, by the operator or other staff at the production floor. That data was used to create overviews of the print shop performance and often integrated into the factory MIS. These were individual and separated information streams.

With the maturation of the Internet of Things (IoT), features that are integrated into the latest generation printing presses, are allowing us to see those streams come together, excluding the human input and interpretation and making the classic 1+1 = 3 cliché come really close.

Combination printing is here to stay. With the previously mentioned development of modern day flexo presses, in combination with the increased knowledge of prepress technologies, flexo might push offset a bit more into a corner; however, it will not replace it.

At the same time, the expectation is that digital keeps developing and costs come down, presenting flexo with a challenge. For the foreseeable future, combination printing brings extra capabilities and attractive embellishments into the equation.

Like all other decisions to be made, it all comes down to doing the math before investing. Knowing your product portfolio and customers. Having a detailed calculation on the return of your investment is only the first step. Having a good understanding of, and maintaining your Total Cost of Ownership (TCO) of combination printing, is as valuable, if not more valuable, than the initial ROI. Work with your press manufacturer to identify the tools and the time necessary to determine the best way forward for your specific situation.