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Print 101: Flexography

Print 101: Flexography

Print 101: Flexography – Episode Summary

In this hands-on episode of The Print University, Ryan McAbee and Pat McGrew explore flexography—also known as “flexo”—a versatile analog printing technology central to packaging production. Commonly featured in printing industry training programs for new employees and bindery equipment training courses, flexo is ideal for printing on plastic films, labels, flexible pouches, and corrugated containers.

Flexo operates like a high-speed, industrial rubber stamp. It uses flexible printing plates, anilox rollers with microcells, and quick-drying inks to produce sharp, durable output on a wide variety of substrates—including materials too delicate for heat-based processes. Listeners learn how flexo stands apart with its heat-free operation, making it compatible with thin plastics and laminated films, perfect for food-safe packaging and CPG products.

The episode breaks down press configurations such as inline vs. central impression units and narrow vs. wide web formats. Hybrid flexo platforms—combining analog with inkjet—are discussed as cost-effective solutions for short-run, versioned, or personalized packaging jobs. Pat and Ryan also touch on the increasing role of digital toner-based systems entering flexo territory, giving printers more flexibility with small batch or seasonal runs.

The discussion also explores recyclability, sustainability considerations, and brand color fidelity—critical in packaging environments. Flexo may require skilled operators, but it delivers unmatched reliability and print durability across a wide substrate range, making it a staple in modern packaging workflows.

You Will Learn:

  • How flexographic printing works: plates, anilox rollers, and ink transfer

  • Applications across packaging: labels, bags, pouches, cartons, and more

  • Differences in press types: narrow web, wide web, inline, central impression

  • Hybrid configurations combining flexo with digital inkjet

  • Sustainability and recyclability factors based on substrate and ink choice

Who This Course Is For:

Packaging converters, press operators, production managers, and brand-focused printers exploring outsourced training for print production staff or lean manufacturing training printing industry

Time to Watch:

Approx. 20 minutes