Manufacturer · Fashion & Home Accessories
Flexo printing of labels is a rotary method in which ink is transferred onto the textile tape by flexible photopolymer plates mounted on cylinders. The machine prints continuously on a roll of tape at high speed, so the method is the most economical for large runs with the same design – for example a brand label or a standard care label that is ordered repeatedly.
Flexo printing of labels – how it works
A flexo press has a few main elements: an ink reservoir, an anilox roller that meters a precise amount of ink, a plate cylinder and an impression cylinder. The anilox roller applies a thin, even layer of ink to the raised parts of the plate, which transfers it to the tape passing between the cylinders. After printing, the ink is dried, and the tape is rewound onto a roll or goes directly to cutting.
For multi-colour printing the press has several print stations, one for each colour. The tape passes through them in sequence, and the operator sets the exact registration of the colours.
What matters for quality
- Precise ink metering – gives an even colour from the first to the last label in the run.
- A quality plate – determines the sharpness of lines and the minimum text size.
- The right tape – smooth synthetic tapes give the sharpest print.
- Curing – textile inks must be properly dried to withstand washing.
When flexo printing is the best choice
Flexo printing makes sense when most of the following conditions are met:
- The design is the same or has few variants.
- The quantity is large or the label is ordered regularly.
- An even colour is needed throughout the run.
- Unit price is more important than flexibility for changes.
Typical examples are the main brand label, the “Made in…” label, a standard care instruction label common to a whole product line, and labels for home textiles with fixed text.
Comparison with thermal transfer and screen printing
| Criterion | Flexo printing | Thermal transfer | Screen printing |
|---|---|---|---|
| Printing forms | Plates | None | Screens |
| Speed | High | Medium | Lower |
| Cost-effective for | Large runs | Small runs, many variants | Medium runs, rich colour |
| Variable data | Limited | Excellent | Limited |
| Light print on dark tape | Limited | Limited | Very good |
Tapes and inks for flexo printing
For flexo printing, polyester satin tapes, nylon taffeta and coated polyester tapes are used most often. They have a smooth surface that takes the thin layer of ink evenly. Cotton tape can also be printed, but because of its rougher structure the details are softer and a sample check is needed.
Inks for textile labels are designed to stay flexible after drying, so that they do not crack when folded, and to withstand detergents. The ink is chosen according to the tape and the expected washing conditions.
How to prepare an order for flexo printing
- Final design. Since the plate is made from the file, any change afterwards means a new plate. Check the texts, especially compositions and translations, before approving.
- Vector file with text in outlines and colours separated by Pantone.
- Minimum sizes. Very thin lines and small letters can “fill in” with ink. Ask about the minimum font size for the specific tape.
- Repeatability. State whether the label will be reordered – this affects the decision to invest in a plate.
- Finishing. A roll for automatic cutting in the factory, or cut and folded labels.
Colour and consistency between orders
One of the great advantages of flexo printing is consistency. When the plate and the ink recipe are fixed, labels from the next order look like those from the previous one. For a brand that sells in several shops or online this matters – customers notice if the logo on the label is a different shade in two styles from the same collection.
To keep the colour consistent, it helps to:
- give a Pantone reference, not just “navy” or “burgundy”;
- keep the approved sample as a reference and attach it to each new order;
- use the same tape – changing the base changes how the colour is perceived;
- give advance notice if you plan a design change, so that a new plate can be made in time.
Factors that affect the price
The price of flexo labels depends on the number of colours and plates, the type and width of the tape, the length of the label, the quantity and the finishing method. Quantity has the greatest effect: the larger the run, the less set-up weighs in the unit price. A specific amount can only be given after a request for a quote.
Flexo printing combined with other labels
Many brands use flexo printing for the fixed part of their labelling and supplement it with other solutions. The brand label can be woven or flexo printed, while variable data – size, batch and barcode – is on a separate thermal transfer label. You will find an overview of all types in the labels category, and for care instructions see care and composition labels.
Printed labels from Polkom
Polkom is a manufacturer of accessories for fashion, furniture, footwear and bags, based in Sofia, with over 30 years of experience. We make custom printed labels with flexo printing, thermal transfer and screen printing, produce samples quickly and deliver across the EU. Minimum quantities depend on the item. Send the design and expected quantities via Contact to receive a quote.
