Industry Overview
Flexible packaging comprises packages whose shape can be readily changed, including bags, pouches, liners, and wraps made from paper, plastic films, aluminum foil, metallized or coated paper and film, or combinations of these materials. Manufacturers of flexible packaging are commonly known as converters because packaging materials such as paper and foil rolls or plastic resin are converted into finished packages or packaging rolls.
Flexography is a roll-feed web printing process widely used for high-volume printing on labels and packaging. Flexographic presses can print on films, foils, paper, corrugated board, and paperboard at speeds of 500 to 2000 feet per minute. The basic process uses a fountain pan or tray, fountain roll, doctor blade, anilox ink-metering roll, plate cylinder, impression cylinder or roll, and substrate.
Flexographic printing is used for adhesive and shrink-sleeve labels, cartons, shopping and plastic bags, pouches, packets, gift wrap, tissue, envelopes, wallpaper, and disposable plates and cups. Flexible packaging printing is primarily conducted using rotogravure and wide-web flexographic processes. Printing, coating, and laminating may be performed on or in-line with printing presses, while converters may also manufacture non-packaging materials such as gift wraps and hot stamp foils.
Cost Estimation
| Cost Parameter | Value |
|---|---|
| Plant Capacity | 500000 Pcs /day |
| Land & Building (600 sq.mt.) | US# 92400 |
| Plant & Machinery | US# 585000 |
| Working Capital for 2 Months | US# 1001208 |
| Total Capital Investment | US$ 1748308 |
| Rate of Return | 64% |
| Break Even Point | 26% |
Content Index
- INTRODUCTION
- HISTORY OF FLEXOGRAPHIC PRINTING
- CLEAR PACKAGING
- TYPES OF PRINTING PROCESSES
- OFFSET LITHOGRAPHY
- ROTOGRAVURE PRINTING
- FLEXOGRAPHIC PRINTING
- TYPES OF PRINTING INKS
- TYPES OF FLEXOGRAPHIC INKS
- CHOICE OF SUBSTRATE IS ALSO ONE OF THE MAIN FACTORS IN INK SELECTION.
- SUBSTRATES CAN INCLUDE:
- 4 COMMON TYPES OF FLEXOGRAPHIC INKS
- HERE ARE SOME MORE DETAILS ON THESE TYPES OF INKS, AND WHAT APPLICATIONS THEY'RE BEST FOR:
- 1. WATER BASED
- 2. SOLVENT BASED
- 3. ULTRAVIOLET (UV) AND ELECTRON BEAM (EB)
- 4. OIL BASED
- FLEXOGRAPHIC INKS ARE SEPARATED INTO TWO CLASSIFICATIONS: VOLATILE AND ENERGY CURABLE.
- THE UNCOATED FILMS USED FOR UV BASED INK-
- FLEXOGRAPHIC INK FOR POLYETHYLENE FILM
- UV INK
- HOW FLEXO PRINTING WORKS
- THE STEPS FOR PREPARING PHOTOPOLYMER PLATES ARE
- INKS
- SUBSTRATES
- FLEXOGRAPHIC INK DELIVERY SYSTEM
- PRESS CONFIGURATIONS
- COMMON IMPRESSION CYLINDER (CIC) PRESS
- STACK PRESS
- CORRUGATED PRESS
- REPEAT LENGTH
- PLATE TYPES
- MOLDED RUBBER
- PHOTOPOLYMER
- LASER ABLATED PLATES
- PLATE ELONGATION
- DISTORTION
- TYPE WEIGHT
- DOT GAIN IN FLEXOGRAPHY
- PLATE DUROMETER
- INKS
- WATER-BASE INK
- SUBSTRATES
- CHEMISTRY OF UV (PHOTOINDUCED) CURING TECHNOLOGY
- THE MAIN COMPONENTS OF SUCH FORMULATIONS BASED ON RADICAL POLYMERIZATIONS ARE:
- PROPAGATION
- TERMINATION
- USES AND APPLICATION
- MARKET CATEGORIES
- CORRUGATED
- FLEXIBLE PACKAGING
- GIFT WRAP AND WALLPAPER
- FOLDING CARTONS
- RIGID PAPER BOXES
- ENVELOPES
- PAPER GROCERY BAGS
- PLASTIC CARRIER BAGS
- MILK CARTONS
- TAGS AND LABELS
- PRE-PRINTED LINERBOARD
- APPLICATION AREAS OF UV CURING INKS
- PROPERTIES OF MACHINE
- ADAVANTAGE & DISADVANTAGE
- ADVANTAGE:-
- BENEFIT: HIGHLY AUTOMATED
- BENEFIT: COST EFFICIENT
- BENEFIT: FAST
- DISADVANTAGE:-
- DRAWBACK: NOT IDEAL FOR SMALLER JOBS
- DRAWBACK: SETUP CAN BE TIME CONSUMING
- MARKET SURVEY
- KEY PLAYERS
- FLEXOGRAPHIC PRINTING INKS MARKET, BY APPLICATION
- FLEXOGRAPHIC PRINTING INKS MARKET, BY REGION
- COMPETITIVE MARKET SHARE
- MACHINERY SUPPLIERS
- RAW MATERIAL SUPPLIERS
- INK
- SUBSTRATE
- MACHINERY PHOTOGRAPHS
- RAW MATERIAL PHOTOGRAPHS
- PRODUCT PHOTOGRAPHS
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Flexible packaging is packaging that can readily change shape and is made from flexible materials such as paper, plastic films, aluminum foil, metallized or coated films, or combinations of these materials. Common forms include bags, pouches, liners, and wraps. Flexible packaging converters transform rolls, films, foils, or plastic resin into packaging products or packaging materials. The industry supports applications across food, consumer products, retail, industrial goods, and other sectors where lightweight and printable packaging is required.
Flexographic printing is widely used for high-volume printing on packaging materials and labels. Typical applications include plastic bags, pouches, packets, shopping bags, folding cartons, corrugated materials, gift wrap, tissue, envelopes, wallpaper, and disposable plates and cups. The process can print on films, foils, paper, corrugated board, and paperboard, making it suitable for diverse packaging requirements. Printing, coating, and laminating operations can also be integrated with flexible packaging production.
Flexographic printing transfers ink from an ink delivery system through an anilox roll and printing plate onto a moving substrate. The basic arrangement includes a fountain pan or tray, fountain roll, doctor blade, anilox roll, plate cylinder, impression cylinder or roll, and substrate. The anilox roll meters a controlled quantity of ink, while the raised image areas of the flexible plate transfer the ink to the substrate. Press configurations can vary according to the substrate and application.
Flexographic printing can use water-based, solvent-based, ultraviolet (UV), electron beam (EB), and oil-based inks. Ink selection depends on the substrate, printing requirements, drying or curing method, and end-use application. The report also distinguishes between volatile and energy-curable flexographic inks. UV and EB systems use energy-based curing, while water-based and solvent-based systems rely on removal of their volatile components. Selecting an appropriate ink is important for print quality, adhesion, drying, and product performance.
Flexographic printing can be applied to a wide range of substrates, including films, foils, paper, corrugated board, and paperboard. The appropriate substrate depends on the intended packaging or printed product, required print performance, ink system, and press configuration. Flexible packaging applications commonly involve plastic films, foil-based materials, coated materials, and paper. Substrate selection is also a major factor in choosing the appropriate flexographic ink because surface characteristics influence adhesion, drying, curing, and print quality.
Flexographic printing offers high automation, cost efficiency, and fast production for suitable high-volume applications. Its ability to print on different substrates makes it particularly useful for packaging and label production. Modern flexographic presses can integrate printing with coating and laminating operations, supporting efficient manufacturing workflows. However, the report also identifies limitations, including its reduced suitability for smaller jobs and the possibility that setup can be time-consuming. Process configuration, substrate, ink, plate, and production volume should therefore be evaluated together.
Flexographic technology can support production of a broad range of printed packaging and related materials. Applications identified in the report include corrugated products, flexible packaging, gift wrap, wallpaper, folding cartons, rigid paper boxes, envelopes, paper grocery bags, plastic carrier bags, milk cartons, tags and labels, and pre-printed linerboard. The same printing and coating capabilities may also be used for certain non-packaging materials. The specific product range depends on the press configuration, printing plates, substrate, ink system, and other converting capabilities installed at the facility.
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