The Flexographic Plate Process: From Design to Press
At Neagle’s Flexo Inc, we combine decades of expertise with advanced technology to create high-quality flexographic plates that bring your designs to life. Here’s an inside look at how we make the plates and how they’re used in the printing press.
Step 1: Artwork Preparation
Every project starts with your digital artwork. Our prepress team reviews and optimizes each file, checking color separations, resolution, trapping, and registration to make sure it meets the specific requirements of flexographic printing. Once approved, the design moves to the platemaking stage.
Step 2: Laser Imaging
A high-resolution laser images the design onto a photopolymer plate. The laser precisely removes the mask layer, exposing the areas that will become the raised print surface. This step ensures crisp details and consistent print quality.
Step 3: Plate Exposure
The plate is then exposed to ultraviolet light. The UV light hardens the exposed areas, which become the raised parts that will transfer ink to your substrate. The unexposed areas remain soft and ready to be washed away.
Step 4: Washing and Drying
After exposure, the plate goes through a washout process that removes the unexposed photopolymer, revealing the final raised design. The plate is thoroughly dried to prepare it for the final curing stage.
Step 5: Post-Exposure and Finishing
The plate receives an additional UV exposure to fully cure and strengthen the polymer. After curing, the plate is carefully trimmed and inspected to ensure it meets our strict quality standards.
How the Plate Works in the Press
Mounting
Once the plate is complete, it is mounted onto a printing cylinder or sleeve. Using precision mounting equipment, we ensure the plate is perfectly aligned for accurate and repeatable printing.
Inking
In the press, ink is transferred from an anilox roller to the raised areas of the plate. The anilox roller uses engraved cells to deliver the right amount of ink, which is essential for achieving sharp and even prints.
Printing
As the plate rotates, the raised areas make contact with the substrate, transferring the ink to paper, film, foil, or other materials. Each color is applied in sequence, and the ink dries quickly so production can continue at high speeds.
Repeatability and Quality
The combination of precise plate production and careful press setup ensures consistent results across thousands or even millions of impressions.
