Flexo Technology
Why plate quality matters beyond cost in modern flexo
By Les Jones, technical director at Contact Originators
tolerances. But maintaining that advantage requires continuous investment in both technology and the skilled team who understand how to optimise it for diff erent applications.
What frustrates our team about the current market dynamic is that too many print issues are misdiagnosed as press problems when they actually originate in plate specifi cation or production quality. Press operators can waste valuable time troubleshooting symptoms rather than addressing root causes. In an industry where effi ciency is increasingly critical, particularly given the pressure we’re all under, this represents a real bottom line impact.
The market trends we’re seeing reinforce why the expertise around the plate matters.
Digital integration and automation are transforming
he print industry is facing some uncomfortable realities right now. Margins are tight, demand is volatile and overcapacity is putting pressure on pricing across the board. In this environment, it’s entirely understandable that converters and printers are scrutinising every line item on their cost sheets, and fl exo plates inevitably come under that microscope. The temptation, particularly when budgets are squeezed, is to view plates purely as consumables where price is the primary consideration. After all, that’s a logical response to market pressures. But at Contact, what we’ve observed over three decades in this business is that the plate itself is only part of what determines print performance. The knowledge, technical support and expertise surrounding that plate often matters just as much, and sometimes more.
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When printers choose a platemaking partner, they’re never simply buying polymer. Instead, they’re investing in a relationship that directly impacts production effi ciency, print quality, waste levels and ultimately their ability to compete eff ectively. The diff erence between a functional plate and one that delivers exceptional press performance comes down to factors that aren’t immediately visible on a purchase order.
The platemaking market has evolved considerably, and we’re now seeing a fairly clear division emerging across three broad categories of supplier. There are volume-focused operations where the business model is built around scale and cost, typically with
limited technical support infrastructure. These businesses serve a purpose in the market ecosystem; they’re quick and comparatively cheap, but typically come at the cost of quality and support. Then we have suppliers who invest heavily in marketing and branding, often repackaging existing technologies under proprietary names to create diff erentiation. Again, there’s a place for this approach, though the substance behind the messaging can vary considerably.
The third category, and this is where we position ourselves at Contact, centres on treating platemaking as both craft and science. It’s an approach where innovation, comprehensive technical expertise and attention to detail aren’t optional extras, they’re built into what we do. This approach recognises that diff erent substrates, press conditions and print applications genuinely demand tailored solutions. The idea that one plate specifi cation optimally serves every printing scenario doesn’t hold up in practice. What’s often invisible to customers is the infrastructure required for consistent, high-quality plate production. Precision matters at every stage, from maintaining exact exposure parameters to ensuring processing conditions remain stable with minimal variability. This demands ongoing investment in equipment maintenance, calibration and validation protocols that, frankly, not every supplier prioritises to the same degree. Our investment in LED exposure technology over 15 years ago, for instance, represented a genuine step change in achievable screening capabilities and
workfl ows, and substrate diversity is expanding constantly – from novel textures to compostable materials that behave entirely diff erently on press. We also see smart labels incorporating RFID and NFC technology adding complexity to the design process. Each of these developments places new demands on plate specifi cation and production. It’s not enough to simply manufacture plates anymore; suppliers need to understand how their products perform across increasingly diverse applications and be able to provide genuine technical guidance.
So, what should converters reasonably expect from a platemaking partner today? I’d suggest four fundamentals. First, genuine accountability for results, not just timely delivery. Second, accessible technical support when print challenges arise – ideally someone who can visit your facility and troubleshoot on press if needed. Third, proactive recommendations for optimising plate specifi cations based on your specifi c substrates, applications and press conditions. And fourth, transparent quality control measures that give you confi dence in consistency batch to batch. When evaluating plate suppliers, particularly in the current economic climate where every decision is scrutinised, it’s worth looking beyond the price per square metre. Consider the complete package. Do they have the technical depth to optimise plates for specifi c requirements? Can they provide meaningful on-press support? Are they investing in technology and training that translates into better performance?
The plate is essential, obviously. But in my experience, it’s the expertise, support and commitment behind that plate that often determines whether you’re simply functional, or genuinely competitive.
28
February 2026
www.convertermag.com
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