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Achieving high opacity whites with XSYS and Sandon Global

Printing high opacity whites – sometimes, it can prove easier said than done.

White inks form the foundation that other colours need to display vibrantly, with strong white inks critical to achieving bold, bright tones. This is particularly true in flexible packaging, where white ink is often printed onto clear films behind or before other colours to improve the appearance. The resulting quality of the printed colours heavily depends on printers’ ability to achieve strong white ink opacity and laydown, and getting this wrong can lead to the final graphics appearing dull or grey.

Achieving solid white ink layers has historically proved a sticking point for many flexographic printers. Solving this problem is possible but often requires process adaptations that increase complexity and costs while slowing down production. Getting the most out of white inks requires printers to consider and balance variables including inks, doctor blades, plates, substrates, and more.

However, advances in ink and anilox technology mean these barriers are being overcome. Increasingly, ink and coating manufacturers are developing higher pigmented inks capable of the coverage necessary for printing high-quality whites. In the anilox sector, modern plate screening and cell surface technology means today’s printers can access rollers that are capable of printing white inks at high opacity at reduced volumes. The volume and type of engraving used, if correctly tailored to ink formulation, will make a real difference to print performance.

Our recent collaboration with prepress specialist XSYS demonstrated how far anilox technology has come in terms of delivering white ink opacity – as well as outlining the importance of collaboration with expert partners. This partnership brings together our anilox engraving expertise with XSYS’s expertise in prepress equipment, surface screening software and flexographic printing plates resulting in solutions that help converters achieve the highest quality at no extra cost – or even reducing them.

At Sandon Global, we are dedicated to producing anilox technology that facilitates next-generation printing. Our HVP engraving enables customers to combine good solids and tonal areas on one plate. This engraving features a unique cell design that contrasts with conventional 60° engravings because it combines high line counts with high volume, while maintaining release characteristics.

We have built on this technology with our Fluid FP solution – a semi-channelled engraving that facilitates easier, controlled ink flow between cells without compromise on volume control ensuring printers can achieve optimal results when printing with white inks.

XSYS is one of the largest suppliers offering both flexographic and letterpress prepress solutions, including plates, sleeves, processors and workflow solutions. ThermoFlexX TFxX imagers used in combination with Woodpecker Nevis surface screening is a perfect fit to use with higher volume anilox usually used for printing white inks.

In partnership with XSYS, we recently supported a customer in finding the right solution to produce quality, high opacity white printing while reducing ink consumption. In a series of trials using XSYS’s flexographic printing plate nyoflex® FTV (high quality inherent smooth flat top dot plate), imaged with ThermoFlexX TFxX 80D and UV LED exposed with Catena E80, we tested a series of anilox engravings to determine which would result in the best performance.

The customer was previously achieving a maximum opacity of 53.8% with pinholing. Our trials of five alternative anilox engravings, combined with XSYS’s technology, showed a new standard of 53.3% without pinholes. The trial demonstrated a reduction in ink consumption, cost savings for the customer, more efficient operation and increased their printing speed.

Our strategic partnership with XSYS enables both companies to put forward their technologies designed for improving print quality at no extra cost. This achievement shows how by working with partners like Sandon Global, printers can discover what anilox engraving is best suited for their needs, delivering high opacity whites and ensuring they can invest their time and money in efficiencies elsewhere.