Anilox technology provider Apex International, in collaboration with Ahmedabad-based packaging printer and converter Flexure Print N Pack and pre-press house Pinmark, has successfully executed a project aimed at showcasing the potential of flexographic (flexo) printing to match and even surpass rotogravure and digital print quality.
The collaboration focused on demonstrating outstanding print quality, superior tonal range, flexo printing process capability, and flexibility by using a limited set of anilox sleeves on the company’s 8-color servo driven gearless Flexosmart Echaar CI flexo press. Using its automatic plate mounting machine with Smart Plate Positioning technology the press runs at 300 meters a minute.
The rationale behind the collaboration
Apex International sought partners whose expertise aligned with its objective to highlight the capabilities of flexo printing. Flexure Print N Pack was chosen for its proven ability to deliver exceptional print quality with precision and expertise. Pinmark, a leading prepress house in India, was selected for its extensive experience in processing photopolymer plates and color separations for high-quality packaging designs. The synergy between these three flexo printing industry leaders ensured a well-rounded approach to pushing the boundaries of flexo printing.
Technical insights into the project
The project comprised two key trials to evaluate the performance and consistency of Apex’s GTT (Genetic Transfer Technology) anilox technology.
Trial 1: Traditional Screening — Printing with various screen rulings
The first trial focused on assessing the consistency of GTT technology across different plate resolutions. Print trials were conducted using plate screens at 150, 179, 193, and 208 LPI on 12-micron polyester film. The results were impressive and demonstrated:
- Exceptional print quality with high edge definition, sharp and fine details, with clean highlights and shadows.
- No anilox adjustments were required when switching between various LPIs, concurrently offering superior ink transfer, contributing to better ink densities and quicker ink management control.
Trial 2: Hybrid Screening – Surpassing rotogravure quality
A second trial was conducted to evaluate hybrid screening capabilities, using the same GTT anilox to achieve a print quality equivalent to 350 LPI—far exceeding the average rotogravure print range of 155–195 LPI. The results demonstrated:
- Smooth linear vignettes with perfect gradients resulted in photorealistic printing.
- Improved color vibrancy, improved grey balance using CMY and wider color gamut were achieved.
- Consistent print results right through print runs, leading to fewer unscheduled press stops.
With the correct human intelligence on the flexo press and proper prepress expertise, Flexure Print N Pack and Pinmark Block played a crucial role in taking a big leap in flexographic print quality.
Anilox: The heart of precision in CI flexo printing
At the core of this collaboration lies Apex International’s advanced GTT anilox technology, which played a pivotal role in achieving print consistency and quality. Anilox are the key to ink transfer in flexographic printing, and this project exemplified how a limited set of anilox sleeves can deliver exceptional tonal range, fine details, and seamless ink transfer.
“Our print samples are a testament to how a limited anilox set can still achieve high-quality, exceptional tonal range, fine details, and seamless ink transfer. These samples are tailored for both wide web and narrow web markets to demonstrate how flexographic printing can cater to rival the quality of rotogravure while maintaining the simplicity of flexo,” says Mangesh Bhise of Apex International.
Sample of printWith the demand for higher-quality, cost-effective, and sustainable printing solutions, this collaboration demonstrates that GTT anilox technology is not just an innovation—it is a game-changer for the future of CI flexo printing.
Prepress House — behind-the-scenes performer
Through precise plate processing and advanced hybrid screening techniques, Pinmark engineered flexo plates capable of reproducing ultra-fine details, smooth gradients, and vibrant colors — achieving a print quality equivalent to 350 LPI. By optimizing dot structure, ensuring accurate color separations, and implementing cutting-edge screening technology, Pinmark enabled gravure-like quality prints while enhancing tonal range and consistency.
“This expertise not only matched gravure’s precision but also demonstrated flexo’s superior flexibility and efficiency, proving that with the right prepress advancements, flexo printing can outperform rotogravure in both quality and production efficiency,” says Rutul Zaveri, director at PinMark.
Pressroom — the magic room
In the pressroom, the printing engineers identify, measure and control multiple variables that impact the efficiency and stability of a process, aiming to optimize print outcomes.
“Given that multiple variables co-exist with the respective tolerances and to print the job exactly the way it had started till the end is a testament of print consistency at Flexure Print N Pack, which reflects in the samples printed for this project and is accomplished with the team of highly skilled professionals,” says Jainam Shah, director of technology at Flexure Print N Pack.
He says the flexible packaging industry in light of flexographic printing typically works in bottom-up approach in its well defined value chain model where pressroom engineers generally up skill and provide the pre-media, prepress and other suppliers with accurate and precise information regarding process capabilities to translate the consumer product company’s requirements into an superior end product and the “magic happens” when pressroom people’s ideas are successfully translated by the value chain partners and executed by the skilled pressroom professionals.
One exemplar at Flexure Print N Pack of this is pushing print resolutions from standard 110-120 LPI to ultra-high resolutions such as in the range of 193-208 LPI and beyond enabling flexo as a game changer in the flexible packaging industry.
Implications for the CI Flexo industry in India
The evolving market demands quicker turnaround times and exceptional print quality, and this project underscores the advantages of flexo over traditional rotogravure and digital printing. Gravure cylinder processing typically takes longer than flexo plate processing, and with advancements in trade shops, flexo plates can now achieve minimum dots as small as 1% with precise color correction.
Flexo printing companies are increasingly focused on process stability and efficiency, minimizing changeover times and ensuring consistency. Apex’s GTT anilox technology allows printers to use the same set of anilox rollers for resolutions ranging from 120 to 208 LPI, making it a game-changer in the industry. In comparison, traditional rotogravure printing averages between 155 and 195 LPI, meaning flexo can now rival or even surpass gravure quality.
This shift presents significant market opportunities. If flexo printing continues to prove its ability to match or exceed rotogravure print quality, more players in the industry may consider transitioning from rotogravure to flexo, reshaping the printing landscape in India.
Note – this article has been slightly edited on 21 April to include the configuration of Flexure’s CI flexo press in this quality exercise. — editor
