Flexo Technology Flexo environmental By Tom Kerchiss, chairman of RK Print Coat Instruments P
rinting press and web fed converting machinery manufacturers are driven by the needs of their customers to develop equipment and systems that are able to provide higher specific output without compromising on core values: product quality, the ability to innovate and also stay relevant in highly competitive and environmentally aware times. Technological advances have enabled package and label converting machine developers to provide higher levels of automation that have made for faster make- ready and run times in processes that include flexography. Advances in microprocessors, servo driven technology; embedded communication and AI are of note. Improved pre-press support and in narrow and medium web width a continuing move towards convergent platform technology is extending processing possibilities for products associated with flexible packaging, electronics and even folding carton. Predictive fault finding, diagnostics and maintenance scheduling: all areas that demand close operator involvement and are time consuming are viewed as areas benefitting from AI involvement. Modularity or open architecture for inline narrow/medium web width machines for applications such as labels simplifies access to flexo print units and other components seems a general trend. Mention must be made of the value added possibilities afforded by hybrid flexo plus digital and/or LED UV inkjet and other platform technologies. Traditionally considered competing technologies, hybrid single pass systems streamlines workflow practices, eliminating secondary conversion or finishing steps while enabling processors to add QR and barcodes and other data rich and last minute information, without sacrificing the rich embellishment advantages of flexography. Hybrid fl exo presses used, where and when appropriate, speeds production, enabling companies to bid for and obtain jobs away from familiar areas of expertise. New application possibilities may include those that require a mix of digitised variable data and accurately rendered graphics such as the conversion of material for small portion fl exible sachets/pouches. These products are favoured by marketers for regionalised direct marketing campaigns or try outs prior to commitment to full-scale production.
Many of the materials and chemistries developed as replacements are certainly less harmful than previous products used to support converting processes. Dig deeper though and there are additives and components even in those flexographic consumables such as water based inks, coatings and even in some paper based materials, that may or may not equate too well with the ethos of sustainability and carbon neutral concepts. Even so, progress has been made and will continue to be made in 2026 and onwards. Product development tools, pilot coating and printing systems and colour communication devices for flexography that are capable of determining printability and highlighting colour and other issues associated with inks and substrates are available. These enable users of many descriptions to investigate alternative chemistries and materials or engage in material reduction strategies.
RK Print Coat Instruments have designed, manufactured and delivered the VCML pilot coater for the application of barrier coatings, especially for the application of barrier coatings onto films and papers. Short run capability together with selectable print and coating applicator technology, the VCML pilot coater speeds the bringing of products to market and is widely used for the development of sustainable materials and environmentally acceptable alternative chemistries. Will it process? Probably the most often question voiced by converters and others engaged in the production process. There are a number of product monitoring, product development systems and equipment available to resolve the process conundrum and much more besides.
The FlexiProof family of colour
communication and proofing devices enable users and producers of flexo inks to ensure consistency of performance determine printability, trial unfamiliar materials/ consumables, colour match and assess how inks and components interact with substrates over time. Additive, resins and producers of various chemistries are amongst the users. The FlexiProof LED UV is the most recent addition to the range with lamps typically designed for outputting at the all-important 385nm or 395 nm.
Low odour and low migratory inks are
available, particularly for flexible packaging, pharmaceuticals, medical and electronics. A significant benefit of the LED UV lamps is the minimal heat/energy transfer. Especially important given that many filmic materials are often heat sensitive.
RK Print Coat Instruments have provided FlexiProof colour communication devices in variants such as the FlexiProof 100 and FlexiProof UV. Perhaps one of the most curious flexographic applications was the supply of a FlexiProof to an international banking group for the UV curing of an unspecified material under a nitrogen blanket purportedly to optimise the sense of touch.
The servo driven VCML pilot coater with a working web width of up to 300mm, off ers short run capability and enables users to print, coat and laminate on all types of fl exible substrates.
The FlexiProof LED UV enables users and producers of LED UV fl exographic inks and other consumables and materials to achieve quality objectives in areas such as colour control and printability for label, fl exible packaging and other products.
www.convertermag.com
February 2026
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