As flexographic printing continues to evolve through advances in presses, plates, anilox rolls and automation, one critical factor often remains overlooked: process consistency. Speaking at the Flexo Forward Conference in Ahmedabad (5 June 2026)– jointly organized by apex International, Miraclon, Bobst and Polymount – Tarak Trifaley, regional sales director, Polymount India, argued that true profitability is not determined by any single technology but by how effectively the entire printing process is controlled.
Presenting on the theme Optimizing Flexo Printing Process: Maximizing Profitability – A Technical Perspective, Trifaley challenged converters to look beyond equipment upgrades and focus on the hidden sources of inefficiency that continue to affect print quality, waste generation and operating costs.
“Quality is not random, it is controlled,” he said. “Mounting accuracy, impression control, ink transfer and vibration management are all interconnected. A small inconsistency at the beginning of the process can become a much larger problem on press.”
According to Trifaley, the industry has made significant strides in improving flexographic technology over the years. Presses have become faster and more sophisticated, plates have evolved considerably, and anilox technology continues to improve. Yet one aspect of the workflow has remained largely unchanged: plate mounting tape.
“Many of the losses we experience are accepted as normal because they have existed for years,” he observed. “But these are often systematic loss generators that directly impact productivity and profitability.”
He explained that variations in tape thickness, air entrapment during mounting and gradual compression of foam layers can create inconsistencies in print performance. These inconsistencies can contribute to common flexo challenges such as dot gain, print defects and registration issues, all of which increase waste and reduce efficiency.
The solution, he suggested, lies in reducing variability wherever possible. By eliminating unnecessary process steps and introducing more stable mounting methods, converters can achieve greater repeatability from job to job.
“Consistency is the foundation of standardization,” Trifaley said. “You can standardize presses, plates and anilox rolls, but if inconsistency is introduced at the mounting stage, the process can never be fully controlled.”
A recurring theme throughout the presentation was the direct relationship between process stability and profitability. Faster job setups, reduced waste and predictable print performance all contribute to lower production costs and improved press utilization.
Drawing on installation data, Trifaley highlighted examples where converters were able to reduce setup times, lower startup waste and minimize downtime through better process control. The cumulative impact of these improvements, he noted, can be substantial.
“When you save 30% of setup time, you create capacity for additional jobs. When you reduce waste, you improve margins. These gains translate directly into profitability,” he said.
Another area that received attention was plate maintenance. Manual cleaning practices, while common across the industry, can sometimes damage delicate highlight dots and reduce plate life. Automated cleaning systems, Trifaley argued, help preserve plate quality while ensuring consistent performance over multiple production runs.
“Every time you extend plate life, you reduce replacement costs,” he explained. “Protecting the plate is ultimately protecting your profitability.”
Beyond economics, Trifaley also highlighted the sustainability benefits that emerge from a more efficient workflow. Reduced material waste, lower chemical consumption and fewer consumables not only support environmental goals but also strengthen the business case for process optimization.
Concluding his presentation, he distilled the message into a simple equation: “Work efficiency plus consistency equals profitability.”
