How Does Plate Mounting Work?

In flexographic printing, creating high-quality images and text relies on plate mounting. Proper plate mounting is essential for achieving the best print quality, as even slight misalignments can lead to blurred images, colour inconsistencies, and wasted materials. Given the importance of plate mounting, we want to shed more light on how plate mounting works.

What is a Flexographic Plate?

A flexographic plate is a flexible printing plate made of photopolymer material that transfers ink onto various substrates, such as paper, plastic, or foil. These plates are engraved with the image or text to be printed. The plate wraps around a cylinder on the printing press, allowing continuous printing. The raised areas on the plate receive the ink and transfer it to the substrate, while the recessed areas remain ink-free.

Anatomy of the Plate Mounting Process

The plate mounting process cannot function without the below components and accessories;

Cilindro: The cylinder is the core component around which the plate is mounted. It rotates during printing, transferring the inked image from the plate to the substrate. Ensuring the cylinder is clean and debris-free is crucial for a successful print.

Mounting Tape: The mounting tape acts as an adhesive layer between the cylinder and the plate. It provides a strong bond to hold the plate in place while allowing easy removal and repositioning. The tape must be applied smoothly to prevent air bubbles and wrinkles.

Plate: The plate contains the image or text to be printed. It must be positioned accurately on the cylinder to ensure precise registration. Proper tension and alignment are key to preventing movement and achieving high print quality.

The Importance of Good Plate Mounting

Good plate mounting is vital for several reasons:

Print Quality: Accurate plate mounting ensures sharp, clear images and text. Misalignments can cause blurred or double images, reducing the overall quality of the print.

Colour Consistency: Properly mounted plates help maintain colour consistency across the print run. Misaligned plates can lead to colour shifts and inconsistencies.

Efficiency: Correct plate mounting reduces waste and minimises downtime caused by reworks and adjustments. This leads to more efficient production and lower costs.

The Plate Mounting Process

Cleaning the Cylinder and Plate

Before mounting a plate, customers must ensure that the cylinder and the plate are clean. Any debris, dust, or residual ink can cause imperfections in the final print. Use appropriate cleaning solutions and lint-free cloths to wipe down the surfaces.

Applying Mounting Tape

The next step is to apply mounting tape to the cylinder. The tape acts as an adhesive layer that holds the plate in place. Choosing the right type of tape is important, as it must provide a strong bond without causing damage when the plate is removed. 

Carefully apply the tape to avoid any air bubbles or wrinkles, which can affect the quality of the print.

Positioning and Securing the Plate

After applying the mounting tape, the plate needs to be positioned accurately on the cylinder. Make sure to align the edge of the plate with a reference mark on the cylinder. Press the plate onto the tape, starting from one side and moving to the other to avoid trapping air bubbles. This step ensures that the print is aligned correctly.

Removing Air Bubbles and Ensuring Proper Tension

After positioning the plate, use a roller or squeegee to remove any air bubbles trapped between it and the tape. It’s essential to ensure that the plate is evenly stretched and under the appropriate tension to prevent movement during printing.

Plate Mounter Role

Manual plate mounting can be time-consuming and error-prone. The Heaford range of plate mounting machines automates and streamlines this process, ensuring precision and repeatability. These machines are designed to handle various plate sizes and materials, providing consistent results. They feature advanced technologies such as automated positioning systems and precise tension control, eliminating the guesswork and reducing the risk of human error.

Heaford Options

Heaford offers a range of Montadores de planchas flexográficas known for their accuracy, efficiency, and user-friendly design. These solutions are tailored to meet the needs of flexographic printers through manual, semi-automatic, and fully automatic systems.

Heaford’s expertise in flexo plate mounting and proofing solutions positions them as a trusted authority in the industry. For more information, please browse our range of plate mounters or contact our team directly.