The Flexo Synergy event, held at the Taj Hotel in Chandigarh, brought together key industry players under the theme ‘Innovation Through Collaboration.’ The event was a joint initiative by Acme Rolltech, Alliance Printech, Miraclon, and tesa, aimed at fostering knowledge exchange and addressing the evolving needs of the flexographic printing industry. The event served as a dynamic platform to share insights on the latest industry trends, upcoming technological advancements, and the daily operational challenges faced by flexo printers. Experts from the collaborating companies emphasized how strategic partnerships and collaborative efforts can help overcome these challenges, enabling the industry to build a stronger, more resilient ecosystem.
In his presentation, Aryaman Julka of Alliance Printech delved into the intricacies of flexographic printing, emphasizing key components like anilox rollers, substrates, inks, doctor blades, and plates. Julka outlined the critical role of these components in achieving high-quality print outputs, discussing technological advancements such as the Nova pure dot for minimizing friction and improving print stability. Julka said, “Flexo is not just about the press – it’s about the ecosystem. Anilox, inks, tapes, plates, substrates, operator skill – they all play a role in the final print quality.”
A critical takeaway from Julka’s presentation was the importance of plate mounting accuracy, especially in label applications with multiple ups. “Operators might resist change, but tools like video plate mounters can make a real difference in quality, especially when dealing with multi-up label jobs,” he emphasized, urging the industry to embrace advanced tools for better results.
The second presentation was delivered by Sandeep Sharma of Acme Rolltech, who emphasized the critical importance of precision engineering in anilox manufacturing. “We use robotic thermal plasma coating and advanced laser engraving machines – same as top global manufacturers. Ceramic is hard but brittle and porous, and those properties need to be carefully managed to avoid print issues like clogging and cell damage.”
Clarifying frequent industry misconceptions, he added, “There’s a lot of confusion around LPI, LPCM, and BCM values. A mismatch in these units can lead to major printing issues. Printers must ensure alignment between their anilox and plate specifications to avoid unnecessary R&D, press downtime, and wastage.”
On handling and maintenance, Sharma noted, “The anilox is the heart of flexo printing. But even the best anilox roll can’t deliver results if other elements – ink, plate, tape, and blade – aren’t in sync. Improper cleaning, rough handling, or even rings on fingers can damage the cells. Operators must be trained, and rolls should be regularly audited.”
Speaking about innovation, he said, “We’ve developed specialized solutions – from high-opacity white rolls and tactile-effect engravings to glitter-compatible rolls customized by particle size. These aren’t just technical upgrades – they solve real customer pain points.”
He concluded with a note on ECG printing: “Don’t jump into ECG without first standardizing your substrate, inks, and workflow. Especially in narrow-web where you deal with diverse substrates, standardization is key. Once that’s in place, you can build towards ECG with confidence.”
Hersh Lulla of Miraclon emphasized the critical role of precision and standardization in flexographic printing, especially in the context of digital flexo plate making. He began by acknowledging the industry’s operational challenges and set the tone for a deeply technical session focused on minimizing variability and maximizing ink transfer efficiency.
“People often think of a flexo plate as just an image transfer medium. But it’s really an ink transfer medium. That distinction makes all the difference,” said Lulla.
Lulla highlighted Miraclon’s proprietary Square Spot Imaging Technology, which offers a significant advantage over conventional ablation laser systems. Unlike traditional ‘torch-like’ lasers, Square Spot provides consistent, pixel-precise imaging that minimizes dot gain and maximizes fidelity.
He walked the audience through the closed-loop imaging-to-plate process, explaining how Miraclon’s high-resolution thermal imaging layer, precise lamination, and oxygen-free exposure ensure a true 1:1 dot transfer, enabling reliable and repeatable print quality. “Accuracy and precision right from the word go is critical. If something goes wrong at the plate-making stage, the problems will only get amplified downstream,” he said.
Lulla highlighted common pitfalls in plate storage and handling, such as improper stacking, lack of interleafing, and storage in uncontrolled temperature/humidity environments. He cited misuse of harsh chemicals and cleaning methods that degrade plate surfaces, causing dot loss, plate swelling, and dimensional instability. “Ask yourself – how are you storing your plates today? That might be the root of recurring issues on press,” Lulla said.
Case studies shared by Lulla during the session demonstrated that by selecting the right plate, pattern, anilox, tape, and ink, printers could match opacity targets using a single white plate, rather than doubling plates or overusing ink – resulting in cost and substrate savings without compromising print quality.
Lulla said, “The most expensive words in any pressroom are: ‘This is how we’ve always done it.’” Lulla advocated for scientific, numbers-driven press fingerprinting to match patterns to press variables, warning against guesswork-led troubleshooting, which leads to press downtime and material wastage.
The presentation closed with a bold but substantiated claim: paying slightly more for the plate can unlock substantial savings across ink, substrate, and productivity, especially in high-throughput environments.
Anand Kulkarni from tesa presented the company’s comprehensive adhesive solutions for the printing and packaging sector, with a special focus on flexo plate mounting tapes. The presentation emphasized tesa’s strong manufacturing footprint, including the recently added production site in India, and the company’s five key verticals – electronics, electricals, automotive, industrial applications, and printing and packaging. Specifically, in the flexo segment, Kulkarni highlighted three core products – Breakmount tape, Twinlock, and EasySplice.
He explained the classification of tesa’s plate mounting tapes into five color-coded hardness levels – extra soft to extra hard – each suited for different print dot requirements and print quality needs. For instance, extra soft foam is ideal for fine dot reproduction, while harder variants support high-density solid printing.
He addressed common challenges like plate edge lifting and ink seepage, offering solutions such as specially developed hard tapes and sealing tapes to prevent solvent penetration. Kulkarni also walked through a six-step best practice guide for optimal tape and plate mounting – starting from cylinder cleaning to proper plate re-mounting.
