Digital + Flexographic combination labels

Digital label printing is a modern printing technique that utilises digital technology to transfer a digital image directly onto the printing surface. Unlike traditional methods that require printing plates, digital printing applies toner directly to the substrate, allowing for a clean and precise image in a single pass. This method is particularly advantageous for short to medium-sized runs, as it offers quick turnaround times and the flexibility to easily change designs without the need for new plates.

At Labelservice, we have harnessed the power of digital printing to revolutionise the way we handle short and medium-sized orders. Our state-of-the-art digital presses enable us to offer unique label solutions, such as just-in-time ordering, multiple sort runs, and the ability to accommodate design changes with ease.

Flexographic label printing, commonly known as flexo printing, is a traditional printing method that employs the use of flexible polymer plates to transfer ink onto a substrate. These plates carry a raised image of the design, which is inked and then pressed against the material to be printed on. The process is highly efficient and can operate at speeds exceeding 100 metres per minute, making it ideal for high-volume, long-run printing projects.

Flexo printing offers a high degree of versatility, allowing for the use of a wide range of substrates and the incorporation of various embellishments such as cold foil, hot foil, embossing, and lamination. Furthermore, it provides the capability to match very specific Pantone colours, making it the go-to choice for businesses that require exact colour matching for elements like corporate logos.

At Labelservice, we have honed our expertise in flexographic printing over 15 years, providing cost-effective and high-quality solutions for long-run projects across various industry sectors.

Determining the most cost-efficient printing method between digital and flexographic printing involves a multi-faceted analysis that takes into account several key factors:

Run Length: Digital printing is generally more cost-effective for short to medium-sized runs due to the absence of setup costs like printing plates. Flexographic printing, on the other hand, becomes more economical as the volume increases, offsetting the initial setup costs over a larger number of units.

Material Compatibility: Flexo printing offers greater versatility in substrate options, including specialised materials that may not be compatible with digital printing. If your project requires a specific material, flexo might be the more cost-efficient choice.

Colour Specificity: If your project demands exact Pantone colour matching, flexo printing is the superior option. While digital printing can approximate Pantone colours, it may not achieve the exact shade, which could be a crucial factor for brand consistency.

Design Complexity: Digital printing allows for easy design changes without additional costs, making it ideal for projects that require personalisation or multiple versions. Flexo printing would require new plates for each design change, adding to the cost.

Turnaround Time: Digital printing usually offers quicker turnaround times, which could result in cost savings if time is a critical factor for your project.

At Labelservice, we offer a unique hybrid solution that combines the best of both digital and flexographic printing technologies. Our latest hybrid presses enable us to deliver combination labels that meet the specific needs of our clients, whether it’s achieving a particular price point for longer runs or enjoying the benefits of digital printing for shorter, more personalised projects.

The amalgamation of flexographic and digital printing technologies into digital flexo label printing presents a pioneering hybrid solution that leverages the distinct advantages of both methods. This innovative approach offers several key benefits:

Optimised Cost Structure: Digital flexo label printing enables businesses to capitalise on the cost-effectiveness of flexographic printing for large-volume runs, while also utilising the benefits of digital printing for shorter, more customised projects. This results in a cost structure that can be finely tuned to meet the specific requirements of each assignment.

Enhanced Colour Matching: The hybrid model of digital flexo label printing allows for the precise Pantone colour matching capabilities of flexographic printing to be combined with the rapid setup times of digital printing. This dual advantage ensures both brand consistency and operational speed, even for intricate designs that necessitate specific colours.

Material Versatility: Digital flexo label printing expands the gamut of substrates that can be employed, ranging from specialised materials to conventional label stocks. This provides businesses with greater latitude in their choice of materials.

Design Flexibility: The combined approach facilitates effortless design alterations and customisation without the need for new flexographic plates. This makes it particularly suitable for projects that demand multiple versions or frequent updates.

Streamlined Production: The integration of both printing methods into a single press optimises the production process, reducing lead times and boosting operational efficiency.

Quality and Speed: Digital flexo label printing ensures the high-quality output associated with flexographic printing, while the digital component allows for rapid setup and changeovers. This synergy offers a harmonious blend of quality and speed.

At Labelservice, our state-of-the-art hybrid presses are equipped to deliver digital flexo label printing that caters to a wide array of needs. Whether you’re aiming for a specific price point for large runs or seeking the numerous advantages of digital printing for smaller, customised projects, our innovative solution provides a highly adaptable and cost-effective answer to the diverse challenges faced by businesses across multiple industry sectors.

For flexographic printing, the industry is increasingly focusing on the use of sustainable and recyclable materials, thereby lessening its ecological impact. Technological advancements in thermal plate-making systems are also contributing to a greener process by eliminating the need for harmful solvents. Additionally, the adoption of water-washable plates is not only enhancing operational efficiency but also reducing water waste. Cutting-edge technologies are further reducing the environmental footprint by minimising the amount of washout solvent or plate material used in the process.

On the digital printing front, the method has proven to be more efficient in terms of paper waste, reducing it by approximately 10%. This efficiency is a significant step towards making the process more eco-friendly. Moreover, digital printing is helping to lower carbon emissions during production, aligning with global sustainability goals. The process has also evolved to minimise chemical and physical waste, adding another layer of environmental responsibility.

At Labelservice, we are fully committed to integrating these sustainable practices into our flexographic and digital printing operations. Our aim is to align with the broader industry’s shift towards environmental sustainability, ensuring that our clients benefit from the most eco-friendly label solutions available.