When two or more entities come together or work together, they form a hybrid, meaning the results change, usually for improvement, not necessarily for replacement. New and different results do emerge. Of course, this is what is expected when deploying combined (hybrid) printing. With the increasing popularity, cost reduction and ease of use of digital printing, the understanding of hybrid printing in the narrow web industry has become synonymous with the combination of traditional flexo and digital printing. The advantages of flexo and digital printing in a true hybrid system are clear. By combining the best technologies and adding processing techniques, waste and time savings can be achieved.
However, combination printing or hybrid printing has been around for many years – either inline or as separate processes. It can sometimes look very different from today's assumed digital models. So let’s focus on other combination printing or hybrid technologies. The move from single printing technologies to combination printing or hybrid printing is driven by factors that most of us are aware of - more product customization, smaller batch sizes, more SKUs of a single design, and more efficient and sustainable Production.
We do see that combination printing has stabilized and maintained its position in the market. Combining the unique features of specific printing technologies and leveraging multiple technologies, printers can create compelling products that allow brand owners to stand out.
Flexo printing + offset printing
Over the past few decades we have seen flexo gobble up traditional offset printing jobs, however, offset still has a place in the modern narrow web label and flexible packaging markets. It is true that flexo printing has evolved from a relatively low-cost, low-quality, high-volume technology to a very high-quality technology, which has largely helped it replace traditional high-quality technologies such as offset printing.
Nonetheless, the combination of flexo and offset printing is here to stay. At the same time, there will always be certain applications that require unique technologies due to functionality, such as sealing, coating and lamination. Unlike in the past, modern printing presses have made the process more efficient by combining it into one machine and processing it inline, eliminating multiple process steps.
Regardless of whether the basic machine is based on offset or flexo printing, other technologies and decorations such as silk screen, coating or lamination can be easily integrated. Offset and flexo printing are an ideal combination for high-quality special labels. When talking about security printing, specific security offset printing technology can easily be combined with flexo printing technology for special varnishing, spot colors, silk screen printing to add another security step. Digital solutions such as heat stamping for special effects, adding decorative barcodes or variable data printing can also be easily integrated.
Flexo printing + silk screen printing
Flexo and screen printing are well-known combinations of label and film jobs. The high opacity of white that silkscreen has, and the possibility of having extreme layers of ink to be able to print text/tactile, makes this combination widely accepted.
Flexo printing + gravure printing
Gravure printing appears to be phasing out as a standalone technology when it comes to narrow webs, but it can still be beneficial when used in a flexo or offset line. All host manufacturers offer gravure printing stations suitable for specific applications. Adding a gravure printing unit to a narrow web press allows printers to perform more process steps inline, making it more cost-effective.
Printing special metals instead of using cold or hot foil, special coatings and opaque whites are just examples. Modern gravure units integrated into narrow web presses are often also hybrid, meaning they can handle both water-based and solvent-based inks and coatings. Today, narrow web UV presses can be configured, some with solvent-based printing units (flexo or gravure), for special applications that were previously difficult to combine with industry-standard UV ink technology. Depending on the size of the job, adding water-based or solvent-based white ink to most UV printing products can be very beneficial and cost-effective.
interconnected
One can also view hybrids in terms of data and information. Traditional machine manufacturers have historically focused on developing and optimizing the actual printing press, while other companies have focused on workflow-related data. In the narrow web area, no machine data is collected other than data provided and entered by the operator or other employees on the production floor. This data is used to create an overall view of printer performance and is often integrated into the factory MIS, which are separate and separate information streams.
As the Internet of Things (IoT) matures, the capabilities integrated into the latest generation of printing presses allow us to see these information flows come together, eliminating human input and interpretation. Combination printing is here to stay. With the aforementioned advancements in modern flexo presses, combined with increased knowledge of prepress technology, flexo printing may push offset printing into desperation. However, it won't replace it.
At the same time, expectations are that digitization will continue to grow and costs will continue to fall, creating challenges for flexo printing. For the foreseeable future, combination printing will bring additional functionality and attractive decoration. Like all other decisions, it all comes down to the math before investing. Understanding the product portfolio and customers and calculating return on investment in detail is only the first step. Fully understanding and maintaining the total cost of ownership (TCO) of portfolio printing is as valuable, if not more, than the initial ROI. Work with the press manufacturer to determine the tools and time required to determine the best approach for your specific situation.