When you see the pallets of vibrant, branded boxes that are being stacked high in a bustling warehouse, they all tell a story of craftsmanship, product quality, and brand identity. But do you know that behind that sharp logo and colorful print, there is something that plays a crucial role in the packaging world? Yes, we are talking about printing plates.
We at PlateCrafters offer a wide range of corrugated printing plates that help you print on any corrugated box or packaging. But printing on corrugated surfaces comes with some exceptional challenges that can impact both the print quality and production efficiency. In this blog, we explain all the challenges and the solutions to reduce them.
Uneven Substrate Surface
Challenge
The fluted structure of corrugated cardboard creates an uneven printing surface that can lead to ink pooling in the valleys between flutes, varying ink transfer, and potential print defects, resulting in a less sharp and vibrant print, which is unacceptable for most commercial applications.
Solution
In order to reduce the fluting effect, you need to use flat top dot plates. These plates also help to maintain substrate stability by ensuring consistent moisture levels in the printing environment.
Plate Swelling and Warping
Challenge
Due to fluctuations in moisture content, corrugated boards are vulnerable to warping that can affect print registration, causing misalignment, and impacting print quality negatively.
Solution
You need to maintain constant moisture levels in the environment to get rid of this challenge. Try to use perfect printing pressures and ensure proper corrugated printing plate mounting techniques to prevent warping and avoid crushing the flutes.
Ink Compatibility and Application
Challenge
Choosing the appropriate ink for corrugated materials is important to achieve the best results. The wrong ink can lead to poor adhesion, increased drying times, and inadequate scratch resistance.
Solution
Choose inks that are suitable with the particular corrugated substrate and printing conditions. In addition to this, always try to monitor the pH and viscosity of the ink to ensure consistent application and optimal drying times.
Plate Wear and Damage
Challenge
Uneven ink transfer, streaks, spotty printing, washboard effects, and image bleeding can all be caused by filthy, old, soft, uneven, or loose plates.
Solution
You need to check and maintain printing plates regularly to ensure they are in good condition and provide good print quality.
Contamination and Cleanliness
Challenge
Corrugated substrates release dirt particles that can disrupt the printing process and clog the ink cells, affecting ink transfer and leading to print defects.
Solution
By regular cleaning protocols in the printing environment, you can prevent contamination and ensure appropriate ink transfer.
If you are in the printing industry and looking to improve the quality and efficiency of corrugated printing processes, you need to address these common challenges with proactive solutions.
Apart from this, if you want to know about Flexographic Pre-Press & Design, we at PlateCrafters are here to help you.
Author: Plate Crafters
Founded in 1971 by C.J. Spering, PlateCrafters has grown from a rubber platemaker to a trusted leader in Flexographic Pre-Press & Design solutions. With over 50 years of experience and innovation, we combine craftsmanship with cutting-edge technology to serve a wide range of industries, including pharmaceutical packaging through our Para Print division.
