Combination printing creates a new future for printing

When two or more entities come together or work together, they form a hybrid, meaning that results change, often for improvement, not necessarily for replacement. New, different results do emerge. Of course, this is what is expected when deploying combinatorial (hybrid) printing. With the increasing popularity, falling costs, and ease of use of digital printing, the understanding of hybrid printing in the narrow web industry has become synonymous with the combination of traditional flexo and digital printing. The advantages of flexo and digital printing in a true hybrid system are obvious. Waste and time savings can be achieved by combining the best techniques and adding processing processes.

However, combinatorial or hybrid printing has been around for many years - whether in-line, or a separate process. It can sometimes look very different from today's assumed digital models. So let's focus on other combinatorial or hybrid technologies. The move from a single printing technology to combinatorial or hybrid printing is driven by factors that most of us are aware of - more product customization, smaller batches, more SKUs for a single design, and more efficient and sustainable production.https://www.risedongsheng.com/

We do see that combo printing has stabilized and maintained its position in the market. By combining the unique capabilities of a particular printing technology and leveraging multiple technologies, printers can create highly attractive products that enable brand owners to stand out from the crowd.

Flexo + Offset Printing

In the past few decades, we have seen flexo printing swallow up traditional offset printing operations. However, offset printing still has a place in the modern narrow web label and flexible packaging market. It is true that flexo printing has evolved from a relatively low-cost, low-quality, high-volume technology to a very high-quality technology, which has largely helped it replace traditional high-quality technologies such as offset printing.

Despite this, the combination of flexo and offset printing will continue to exist. At the same time, there will always be certain applications that require the use of unique technologies, such as sealing, coating, and laminating, for functional reasons. Unlike in the past, modern presses eliminate multiple process steps by combining them into a single machine and processing them in-line, thus making the process more efficient.https://www.risedongsheng.com/

No matter whether the base machine is based on offset or flexo printing, other technologies such as silk screen printing, coating or laminating, decoration can be easily integrated. Offset printing and flexo printing are the ideal combination for high-quality special labels. When talking about anti-counterfeiting printing, specific security offset printing technologies can be easily combined with flexo printing technologies for special glazing, spot colors, silk screen printing to add another security step. Hot stamping for special effects, digital solutions such as adding decorative barcodes or variable data printing can also be easily integrated.

Flexo + silk screen printing

Flexo printing and silk screen printing are well-known combinations of label and film work. The high opacity of white that silk screen printing has, and the possible extreme ink layers to be able to print text/tactile, make this combination widely accepted.

Flexo + Gravure 

In the case of narrow web, gravure as a separate technology seems to be being phased out, but it can still be beneficial when applied to flexo or offset production lines. All mainframe manufacturers offer gravure stations tailored to specific applications. Adding gravure units to narrow web rotary presses allows printers to perform more process steps online, making it more cost-effective.

Printing special metals instead of using cold or hot stamping, special coatings and opaque whites are just examples. Modern gravure units are integrated into narrow web presses and are often also hybrid, meaning they can handle both water-based and solvent-based inks and coatings. Today, narrow web UV presses can be configured, partially equipped with solvent-based printing units (flexo or gravure) for special applications that used to be difficult to combine with industry standard UV ink technologies. Depending on the size of the job, adding water-based or solvent-based white inks to most UV-printed products can be very beneficial and cost-effective.

interconnection

One can also look at the mix in terms of data and information. Traditional machine builders used to focus on developing and optimizing the actual press, while other companies focused on data related to the workflow. In the narrow field, no machine data is collected other than that provided and entered by the operator or other employees on the production floor. This data is used to create an overall view of the printer's performance and is often integrated into the plant MIS, which are separate and separate streams of information.

As the Internet of Things (IoT) matures, features integrated into the latest generation of printing presses allow us to see these streams converge, ruling out human input and interpretation. Combination printing is here to stay. With the development of the aforementioned modern flexo press, coupled with increased knowledge of prepress technology, flexo printing may push offset printing to a dead end. However, it will not replace it.https://www.risedongsheng.com/

At the same time, expectations of ever-evolving digitalization and ever-decreasing costs pose challenges for flexo printing. Combination printing will bring additional functionality and attractive trim for the foreseeable future. As with all other decisions, it all depends on the mathematical calculations before the investment. Knowing the product portfolio and the customer and calculating the return on investment in detail is only the first step. Fully understanding and maintaining the total cost of ownership (TCO) for combination printing is as valuable as the initial return on investment, if not more so. Work with the press manufacturer to determine the tools and time required to determine the best approach for the specific situation.