However, combined printing or mixed printing has existed for many years – whether online or as a separate process. It can sometimes look very different from the digital models assumed today. So let’s focus on other combined printing or mixed technologies. The move from a single printing process to combined printing or mixed printing is driven by factors that most of us are aware of – more product customization, smaller lot sizes, more SKUs of a single design, and more efficient and sustainable production.
We do see that combined printing has stabilised and maintained its position in the market. By combining the unique features of specific printing technologies and making the most of a variety of technologies, printers can create highly attractive products that allow brand owners to stand out.
Flexography + Gravure
In the last few decades we have seen flexo printing eating away at traditional offset work, however, offset still has a place in the modern narrow web label and flexible packaging market. Indeed, flexo has evolved from a relatively low cost, low quality, high volume technology to a very high quality technology, which has helped it replace more traditional high quality technologies such as offset.
While this is the case, the combination of flexographic and rotogravure printing will continue to exist. Meanwhile, there will always be applications that require the use of unique technologies, such as coating, sealing, and lamination, for functional reasons. Unlike in the past, modern printing machines eliminate multiple process steps by combining them into one machine and performing them in-line, making the process more efficient.
Whether the underlying machine is based on offset or flexo, other technologies such as screen printing, coating, or lamination can be easily integrated, and offset and flexo are an ideal combination for high-quality special labeling. When talking about security printing, specific security intaglio technologies can be easily combined with flexo technologies used for special coating, spot colors, and screen printing to add an additional security step. Thermal箔 for special effects and digital solutions such as decorative条形码 or variable data printing can also be easily integrated.
Soft printing + screen printing
Combination of flexo and screen printing is a well-known match for label and film work. The high whiteness and opaqueness of screen printing, as well as the possibility of having an extreme ink film to be able to print brush/tactile, makes this combination widely accepted.
Flexographic + intaglio
For narrow web卷筒 paper, rotogravure as a stand-alone technology appears to be gradually being phased out, but when applied to flexo or offset web lines, it is still beneficial. All major machine manufacturers offer gravure units that are suitable for specific applications. The addition of a gravure unit to a narrow web sheetfed press allows the印 house to perform more process steps in-line, making it more cost-effective.
Printing with special metals, rather than using cold or hot stamping, special coatings and non-white whites are just examples. Modern intaglio units integrated into narrow web sheetfed printing machines are also mixed, meaning that they can handle both water-based and solvent-based inks and coatings. Nowadays, narrow web sheetfed UV printing machines can be configured with solvent-based printing units ( flexo or intaglio), for special applications that in the past were difficult to combine with industry standard UV ink technology. Depending on job size, adding a water-based or solvent-based white ink to most UV printed products can be very beneficial and cost effective.
Interconnection
People can also look at hybridization from a data and information perspective. Traditional machine manufacturers used to focus on developing and optimizing actual printing machines, while other companies focused on data related to workflows. In the narrow web sector, no machine data is collected other than what is provided and entered by operators or other employees in the production department. This data is used to create a overall view of the printer’s performance and is often integrated into the factory’s MIS, these are separate information streams.
As the Internet of Things (IoT) matures, the capabilities integrated into the latest generation of printing presses allow us to see these data streams converging, eliminating the need for manual data entry and interpretation. Combined printing will continue to exist. With the development of modern flexographic machines mentioned earlier, coupled with the increased knowledge of prepress technology, flexography may push offset to the brink of extinction. However, it will not replace it.
Meanwhile, people expect continuous development of digitalization and falling costs, which brings challenges for flexo. In the foreseeable future, combined printing will bring additional features and attractive decoration. As with all other decisions, all this depends on the mathematics before the investment. Understanding the portfolio and the customer, detailed calculation of the return on investment is only the first step. A full understanding and maintenance of the total cost of ownership (TCO) of combined printing is as valuable as the initial investment return, if not more. Work with your printing machine manufacturer to determine the necessary tools and time to determine the best method for your specific situation.