Elimination of the Solid Graininess Issue with Different Micro-Pattern Structures at Flexo Printing

Flexo printing is a relief printing system, and ink transfers on the solid areas are not transferring well during the printing. That is why graininess is increasing and pinholes are occurring on the solid areas. This is a well-known issue in the flexo printing system. Micro-patterns usually eliminate these pinholes. Using correct micro-patterns allows homogeneous ink laydown and increases solid ink density. Micro-pattern holes behave like gravure cylinders on plate surfaces, and this makes for better ink transfer to the substrate. In this study, a more successful micro-pattern structure than the ones currently used was found by examining the solid ink density (SID) values and ink laydown obtained from the structure by producing eight different micro-pattern structures of 1000 LPI and 1500 LPI (line per inch) pattern screen frequencies with the same polymer structure and type. Densitometric values of solid prints made with the developed micro-patterns were measured. By eliminating the pinholes formed in solid prints and at the screen dot shapes, the ink is distributed more homogeneously without graininess. It has been determined that this results in a more stable measurement of ink density and eliminates the measurement of excess ink and low density.