The future of flexo

The world of high definition flexo print is changing - and fast. With brand owners increasingly looking to achieve ever higher quality results, shorter production times and faster turnarounds – often for less money – the pressure on converters and printers to deliver has never been greater.

Miller Graphics Corniche (previously Corniche Fine Arts) was taken over by Miller Graphics in 2008 and now finds itself part of a multi-national prepress group which is a major player on the global scene. With a presence in nine countries, over 400 employees and strong financial backing from its parent company, Miller Graphics Corniche has been able to invest in developing what some are calling the most important development in flexo of the last decade called LiNX.

The seeds of LiNX’s development were sown in 2009, when Miller Graphics Corniche collaborated with Kodak’s European Technical Applications Group on the development of a new technology named Flexcel NX. Kodak’s Flexcel NX plates have a unique make-up of dots up to 10 microns, which potentially allow the quality of gravure print to be achieved via flexo on a wide variety of substrates.

Miller’s testing showed that the improved dot structure afforded by the Flexcel NX plates could indeed deliver printable results between 150 and 175lpi. Those results were dependent on both anilox and ink conditions, and, even more importantly, on specialist in-depth understanding of the flexo process by the prepress operator.

As a result LiNX was developed – a complete flexo process which allows an ‘unrivalled colour gamut’, ‘significant pre and on-press efficiencies’, and ‘unparalled image reproduction to be achieved’, according to Miller Graphics Corniche.

Co-operation was sought from a number of UK converting companies who shared Kodak and Miller’s aspiration to enhance flexo quality to gravure levels. LiNX was initially pioneered by Reflex Flexibles, Ultimate Packaging, TCL Packaging and Primopost.

Brand owners take notice

The potential of LiNX was recognised by several brand owners at an early stage. Young’s Seafood led the way, successfully moving production of its packaging through gravure in the Far East to the UK using LiNX flexo processes.

Simon Robertson, Graphic Communications Manager at Young’s Seafood, explains: “Getting this technology into play required close co-operation between ourselves, several of our packaging suppliers and Miller Graphics Corniche.

“We were motivated to provide a lead in this development because of the potential improvement we could see in both quality and cost reduction. At the end of the day it has proved worth the effort.”

Others soon spotted the potential of LiNX. Rosie Palmer, Marketing Manager of The Dormen Food Company, is a LiNX convert: “I am an absolute believer in this technology,” she enthuses. “You only have to look at the packaging. If I compare it with what we used to get from standard flexo it’s quite amazing and I find it very hard to differentiate from gravure.

“It’s clear, sharp and to the eye looks crystal clear. It is a step up from standard flexo. This is definitely the future as far as I am concerned and will be what I expect from our printers going forward.”

Subsequently, leading brands such as Weetabix, Peters Foods, Gardman Horticulture, Whitby Seafoods and Cémoi Confectionery have also used LiNX to both increase quality and reduce cost.

David Ettie of Miller Graphics Corniche explains: “As great a success as our development of LiNX has been, I would not want anyone to underestimate the effort put in by both ourselves and our industry partners. Together we have developed a wealth of knowledge in terms of origination, plate processing, anilox requirements and ink management.

“Those converters who have worked with us so far can be proud of the new standards we have set for the flexo process. The knowledge we have gained means we are ideally placed to support those converters seeking to achieve the levels of quality and efficiency this technology offers.

“This is the future of flexo. There’s no doubt in my mind it will be the process of choice for brand leaders worldwide,” concludes Mr Ettie.