Flexible Packaging
Achieving consistent colour in flexible packaging – why anilox tolerances matter
By Stuart Mitchell, technical director, print, Sandon Global I
n fl exible packaging, colour is everything. For brand owners, colour signals product quality on the shelf. For printers, it is the benchmark: hitting the right shade, matching it across substrates, and reproducing it repeatedly. At the heart of this challenge sits the anilox, often described as the ‘heart of the press’ as the metering device that governs how much ink reaches the plate and, ultimately, the substrate. Its condition and tolerances are directly linked to whether a job can achieve target colour reliably.
THE IMPACT OF VOLUME CONTROL Every cell engraved into the anilox has a purpose: to hold and deliver a precise volume of ink. Even the slightest deviation in cell volume can shift Delta E values and take colour out of tolerance.
In fl exible packaging, this is particularly acute. Short runs, rapid turnarounds and complex designs leave no margin for error. A change in ink density of just a few percentage points can aff ect brand colours, compromise opacity, or force longer makeready as operators chase target shades.
WHY VOLUME, NOT LINE COUNT, MATTERS Higher line counts do not automatically deliver better print. While line count has its place in specifi cation, it should never be the sole focus. What really matters is volume: the precise amount of ink an anilox can hold and release. This is what creates the optical density in print.
Even a fractional change in volume, caused by wear, manufacturing inaccuracy, or inconsistent coating, can produce a visible colour shift. In
modern fl exible packaging, where Delta E tolerances are often set below two, such shifts are unacceptable. This is why tight volume control is necessary for repeatable, high-quality colour reproduction.
For brand-critical packaging, colour consistency translates directly into reduced waste, fewer press stops and improved fi rst-time-right colour.
THE CUMULATIVE EFFECT ON CONSISTENCY
Even the most advanced colour management systems cannot compensate for unstable ink delivery. The anilox is the foundation. Consider the cumulative eff ect across a multi-station press: if one or two stations deliver slightly inconsistent ink fi lms, the imbalance can cause knock-on eff ects in trapping, density and overprints. The result is colour drift that no amount of operator adjustment can fully correct. By contrast, Sandon Global’s anilox, produced to the tightest tolerances, let printers start from a position of control. Colour management software can work as intended, ICC profi les remain accurate, and operators can focus on effi ciency rather than fi refi ghting.
BUILDING COLOUR CONFIDENCE INTO THE PROCESS
Achieving consistent colour is an ongoing discipline. Regular inspection, cleaning and anilox maintenance ensure that tolerances are preserved throughout their service life. Printers who treat the anilox as a consumable rather than a long-term asset often face higher hidden costs in colour correction, ink usage and waste.
CONCLUSION
In the competitive and dynamic world of fl exible packaging, colour is key. Press speeds are increasing, design complexity is rising, and substrates are more varied than ever. Brand owners want packaging produced faster, leaner and more sustainably, without compromising colour integrity or shelf impact. While inks, substrates and workfl ows all play their part, the anilox remains the critical factor in controlling ink delivery. In fl exo, colour consistency is key to brand success. And it starts with the anilox.
20 September 2025
www.convertermag.com
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