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Water-based ink printing has emerged as a hip and eco-friendly alternative to traditional solvent-based printing. The technology is increasingly being utilized in various industries of business, from packaging to apparel, due to its green aspect and excellent quality. Here in this article, we will learn the flexible packaging manufacturing process, and how it is done.
The flexible packaging manufacturing process consists of the following nine steps.
Confirm the Design
After receiving the client’s design manuscript, first of all, we will confirm the design file, and then print the file in CMYK format. Why use CMYK? This is because the effect of film printing is different from that of electronic displays. The film medium cannot present RGB colors, so it is necessary to use CMYK colors for printing confirmation.
After confirming that the file is correct, we will send the manuscript to the client for the client to confirm whether any parts need to be modified.
Design Analysis
After the client confirms that the manuscript is correct, we will analyze the product, including whether the product color can be achieved, whether other special processes are needed, whether the product details can be perfectly presented, and so on. During this process, we will keep communicating with the client until the client is satisfied.
Color Decomposition
After finalizing the design, we will break down the number of colors required for the product. Generally, five colors of CMYK are used for decomposition. For parts where the client needs precise colors, such as trademarks, large areas of color, etc., we will add molds to adjust the colors.
Determine the Process
After decomposing the colors, we will analyze the contents of the product to recommend and confirm whether the performance of the materials can meet the product standards, and replace unsuitable materials promptly.
Mold Fabrication
After full confirmation, we will start the fabrication of the mold. Before that, we will collect a partial deposit or mold fee. Please understand. The mold fabrication time is approximately 1-3 days. Modifications made during the mold fabrication process will incur fees. Please confirm all design modifications before the mold fabrication.
Install the Mold
After the mold is completed, we will inspect the mold. If there is no problem, we will arrange for production.
When production starts, we will install the mold on the machine and confirm whether there are any shape changes in the mold through the machine’s self-balancing function. If there is no problem, we will proceed to the next step.
Color Mixing
After the trial printing, we will make fine adjustments to the colors until the sample is the same as the file, and then we will enter the formal production. (The colors of gravure printing can be more than 90% close to the electronic file, but it is impossible to achieve 100%, and some trade-offs need to be made in the design.)
Full-Automatic Printing
After the preparatory work is completed, the machine will automatically perform color registration and printing. Since the diluent will not volatilize during the printing process of water-based ink, the color fluctuation of the product is extremely small, which is the advantage of our factory.
Confirm the Finished Product
During the flexible packaging manufacturing process, we will confirm the product several times, and at the same time, cooperate with the online monitoring system for confirmation to ensure the perfect production of the product. （In the picture above, the sample manuscript is on the left and the finished product is on the right.）The above are the detailed steps of water-based ink printing. It is impossible to present the entire process to you with text and pictures. If you want to know other parts, you can contact me via Email.
My Email : zkprintpack@gmail.com
Zhongjia Printing: Custom Wholesale Flexible Packaging with Water-Based Ink Technology
Zhongjia Printing is a custom flexible packaging manufacturer that harmoniously combines your brand concepts and creative designs. Having the capacity to offer robust OEM and ODM capabilities, Zhongjia Printing is well-equipped to design wholesale flexible packaging that complements your products to your specific requirements, fine-tuning every product to reflect your brand’s image.
One of the best things about Zhongjia Printing is that it is a cutting-edge company with an environmental conscience. They employ top-of-the-line water-based ink printing technology that not only produces sparkling, precise, and long-lasting results but also causes the least amount of harm to the environment. The green printing technology helps ensure fewer toxic solvents are used, hence preserving the environment and also both companies and consumers.
No matter if you need to create impulse-buy packaging for food, cosmetics, or other products, Zhongjia Printing turns your designs into a reality with unparalleled quality and eco-friendliness.