In the packaging and paper industry, flexography is a very fast and versatile printing process. Through it, a wide variety of jobs can be carried out, ranging from self-adhesive labels to rolls for food products. Each job requires a combination of precision, experience, and parameter control.

The pressure related to quality and achieving excellent results is greater than ever. Color variations, printing errors, or excessive setup times are issues that manufacturers must address. In this context, customized converting solutions demonstrate their value by ensuring consistent print runs without interruptions or losses.

Tailored solutions for every job

Because these types of applications have specific requirements, the printing process is not the same every time. The substrate used for printing, the graphic design, and the print run length can differ for each job. Printing food packaging on transparent films, for example, requires a different density compared to printing self-adhesive labels.

One of the main objectives pursued in the process is preventing errors during the print run. For prevention, the mounting solutions must be adapted from the preparation stage. In this context, MDE acts as a technical partner, configuring specific combinations of density, adhesive, and geometry.

Our customized solutions include:

1. The careful selection of the right density
2. Ensuring compatibility based on the substrate
3. Processing the tapes to the cylinder dimensions
4. Selecting the optimal combination for each application

Our customized approach ensures consistent quality regardless of the application. By adapting all the details to the specific requirements of each job, we eliminate the need for adjustments during the process and reduce the risk of errors during printing.

Repeatability and stability during the print run

Often, the result is determined not only by how the plate is mounted but also by how the tape behaves during the process. A job may start well, yet even a small air bubble or thickness variation can compromise the image. That is why stability and consistency are critical for maintaining quality.

The solutions we develop are designed so that the tape can perform efficiently along the entire length of the roll, not just at the beginning. We can eliminate the risk of tension build-up or weak spots by using a controlled structure of the substrate and adhesive. This allows the operator to work without interruptions and without constantly adjusting the pressure.

Here are some advantages that can be achieved:

• Firm mounting of the plate
• Consistent thickness
• No edge lifting during the print run

Thanks to the achieved stability, unplanned stoppages can be avoided, and consistent color and ink transfer can be maintained from the first to the last meter. Operators can focus on the finesse of printing rather than making adjustments. This way, manufacturers benefit from a predictable workflow with minimal material waste.

Easy and damage-free disassembly

The disassembly stage is just as important as mounting, as any damage to the flexographic plate can compromise subsequent jobs. It can also generate additional costs. For this reason, the tapes used in the printing process must provide firm attachment as well as residue-free and distortion-free removal.

To achieve such a result, we select the adhesive so that it maintains its grip during printing. At the same time, we ensure that it allows the plate to be removed without excessive effort. This feature reduces the risk of tearing and can extend the lifespan of the plates. Quality is maintained at the same level for future print runs as well.

Simplifying this stage through the customized technical solutions we provide allows operators to switch between jobs much more quickly. This leads to increased productivity and shorter setup times between orders. In this way, proper disassembly ensures a workflow without resource loss and without compromising quality.

We support performance in flexography

In this complex field, true performance is not limited to image quality but includes all the stages that make it possible. The solutions developed by MDE Converting are designed precisely for this purpose: to reduce variables, prevent non-conformities, and increase operator productivity.

Through this smart approach, we can turn the invisible stages of the flexographic process into measurable benefits. Manufacturers can waste less material, achieve better setup times, and ensure consistent quality across all jobs.