Flexo Synergy 2025 champions collaboration to drive innovation

With the central theme, Innovation Through Collaboration, leading players from the flexographic printing ecosystem — Acme Rolltech, Alliance Printech, Miraclon, and Tesa — organised the Flexo Synergy event in Chandigarh recently. 

Bringing together technology experts, converters, and industry veterans, the event addressed critical areas such as process standardisation, component compatibility, print quality, and operational efficiency. It also reinforced a vital message: that flexo success is not defined by a single machine or product, but by how well the entire ecosystem works in harmony.

Alliance Printech: Reinforcing the system thinking in flexo

Aryaman Julka from Alliance Printech kickstarted the technical sessions with an in-depth look at flexographic printing components and how each contributes to achieving consistent, high-quality print output. He emphasised the significance of the flexo ecosystem — anilox rollers, inks, substrates, plates, doctor blades, and operator skill — and how each variable can make or break the print result.

“Flexo isn’t just about the press, it’s about every component working together,” Julka said. He highlighted the importance of Nova pure dot technology for enhanced print stability and reduced friction, and stressed the need for precise plate mounting, especially in multi-up label applications. “Small innovations like video plate mounters can create big improvements in registration and quality,” he added.

Acme Rolltech: Precision, innovation and anilox education

Sandeep Sharma of Acme Rolltech delivered a thought-provoking session on precision engineering in anilox manufacturing. He discussed Acme’s adoption of advanced robotic thermal plasma coating and laser engraving systems, positioning their technology on par with global standards.

Sharma cautioned about common misconceptions around LPI (lines per inch), LPCM (lines per centimetre), and BCM (billion cubic microns), stating that misalignment of these units often causes press inefficiencies. “Anilox mismanagement results in downtime, poor ink transfer, and excessive waste. Alignment across plate and anilox specs is essential,” he said.

He further emphasised operator training and correct anilox handling — highlighting how even small missteps like wearing rings during cleaning could damage ceramic cells. Acme’s innovations, such as high-opacity white rolls, tactile-effect engravings, and glitter-compatible cells, were positioned not just as enhancements but as direct solutions to customer pain points.

On ECG (expanded colour gamut) printing, Sharma advised, “Without workflow and substrate standardisation, ECG can become more of a burden than a breakthrough. Build the foundation first.”

Miraclon: Precision plate imaging for maximum impact

Hersh Lulla from Miraclon delivered a high-impact session on digital plate making and process standardisation. Emphasising that a flexo plate is fundamentally an ink transfer medium, Lulla challenged conventional thinking and urged converters to focus on minimising variability.

He introduced Miraclon’s Square Spot Imaging Technology, which enables pixel-accurate imaging for consistent, low-gain dots. “If something’s wrong in plate making, it snowballs downstream. Precision starts from the first pixel,” he explained.

Lulla’s talk covered oxygen-free exposure systems, closed-loop imaging, and optimized ink transfer strategies that reduce ink consumption and enhance print sharpness. He also identified poor plate storage, overuse of harsh chemicals, and temperature fluctuation as root causes of recurring press issues.

“Stop relying on habits. Scientific fingerprinting of press variables is the way forward. Guesswork has no place in modern flexo,” Lulla concluded.

Tesa: Tape technology for consistent mounting and print results

Wrapping up the event, Anand Kulkarni from Tesa presented an insightful session on adhesive and plate mounting solutions. He showcased the company’s key offerings for flexo, breakmount tapes, twinlock sleeves, and EasySplice solutions, highlighting how the newly launched India production facility enhances product availability and support.

Kulkarni explained the colour-coded hardness range of mounting tapes — from extra soft for fine dot work to extra hard for solid prints — allowing converters to tailor mounting setups for different jobs. He also addressed common issues such as plate lifting, ink seepage, and solvent resistance, offering best practices in plate-tape-cylinger preparation.

A step-by-step demonstration on optimal tape application — including cleaning, mounting, and demounting — rounded out the session, equipping attendees with practical insights for improved print consistency.

Sachit Katyal of Anupama Printing Solutions, one of the attendees, praised the initiative and emphasised the value such technical forums bring to printers.

“The event was brilliant—we walked away with practical knowledge and clarity on challenges in both label and flexible packaging segments,” said Katyal. “What really stood out was the honest conversation around everyday production issues. Unfortunately, there are very few demo centers or knowledge-sharing platforms, especially in North India. Events like these are essential, regardless of who organizes them. In the North, much of the print industry is overly reliant on staff knowledge, with limited peer-to-peer knowledge transfer. While networking over dinner is always welcome, it’s these focused technical sessions that truly drive industry-wide progress.”

By bringing together top solution providers and focusing on practical, shop-floor-level insights, the event successfully demonstrated that innovation in flexo doesn’t always require massive capital investment; it often starts with awareness, alignment, and collaboration.