The Rise and Impact of Flexographic Printing
Despite humble beginnings, flexographic printing has grown into a major force in the printing and packaging world. It offers a versatile, repeatable, and highly efficient method to transfer ink onto a wide variety of surfaces.
Today, the flexographic ink market exceeds $10 billion, and analysts forecast continued growth at a 4.5% compound annual growth rate through 2024. With increasing regulatory requirements, businesses using flexographic printing must prioritize compliance alongside operational efficiency.
A Brief History of Flexographic Printing
Flexographic printing was initially patented by Bibby, Baron & Sons in England in the late 19th century. Early critics mocked it as “Bibby’s Folly,” because the ink used at the time dried too slowly, often smearing on the substrate.
Early Innovations
Within a decade, the process improved with the introduction of rubber printing plates and aniline oil-based inks. Known initially as aniline printing or gummidruck (rubber printing), it gained popularity for food packaging in Germany.
Challenges and Renaissance
In the 1940s, the FDA deemed aniline dyes unsafe for food. Printers responded with food-safe inks and rebranded the process. Wider adoption followed as Mosstype Corporation and others developed the industry-standard flexographic process we recognize today.
Modern Advancements in Flexography
Until the 1990s, flexography was considered less precise and less desirable compared to other printing methods. However, improvements in ink, plates, and presses over the past 30 years have sparked a renaissance.
Today, flexography is highly effective for repeated printing on diverse surfaces, including metallic films, plastics, and paper. As flexible packaging continues to grow globally, flexographic printing remains an essential tool for packaging manufacturers.
A Wide Range of Inks for Any Substrate
Flexographic printing offers numerous advantages: low cost, scalable deployment, fast printing and drying, minimal maintenance, and reliable repetition. It works on both absorbent and non-absorbent substrates.
Ink Types and Trends:
- Water-based inks now represent 45% of the flexo ink market, driven by demand for printing on paper, newspapers, and cardboard.
- Solvent-based inks remain preferred for speed, durability, and substrate versatility.
- UV-cured inks are gaining traction due to fast curing, high color strength, sharper dots, and increased stability.
VOC Abatement in Flexographic Printing
Like many printing processes, flexographic inks contain volatile organic compounds (VOCs). For industries such as cosmetics, food & beverages, pharmaceuticals, and personal care products, regulatory compliance is crucial.
- EPA violations can harm reputation and bottom line.
- FDA violations can result in shutdowns, fines, and product recalls.
Effective VOC control starts with:
- Optimizing operations – Adjust initial process loads to reduce abatement costs.
- Identifying emissions – Understand the types and volumes of VOCs produced.
- Selecting reliable manufacturers – Choose equipment designed to meet your emissions requirements efficiently and reliably.
At The CMM Group, we specialize in designing pollution control systems for flexographic printing and packaging. Our solutions meet or exceed destruction efficiency standards while remaining efficient, reliable, and cost-effective.
See our case studies to explore successful implementations with local, regional, and global players.