The development of the flexo proof press revolutionised the flexographic printing industry, allowing for high-quality and cost-effective proofing. Initially dominated by the rotogravure process since 1879, printing technology faced challenges with expensive and time-consuming cylinder production. Early proofing presses were developed to verify the quality before mass production, setting a precedent for proofing in the industry.

In the early 1940s, flexographic printing emerged but lacked the precision of gravure printing until advancements in the 1980s. Initially, single-color flexo printing did not justify the cost of proofing. However, as flexo printing evolved to multi-colour processes, the need for proofing became apparent to ensure quality and minimise production errors.

John M. Heaford played a pivotal role in the development of flexo proof presses. In the early 1980s, Heaford created a machine for the wall covering industry, allowing for multiple colour samples without interrupting production. This initial machine used a large steel drum with a rubber blanket, suitable for the industry’s needs at the time.

By 1985, Heaford introduced an alpha design flexo proof press featuring a small diameter, high tolerance impression roller to control dot gains. This design led to the use of high magnification microscopes for accurate plate positioning, later evolving into MicroDot technology with high magnification cameras.

The flexo proof press gained traction in the flexible packaging market, allowing printers and reprographic houses to verify plates before production, reducing material waste and increasing efficiency. Early successes included a machine for DSS of Liverpool, which specialised in plates for the paper sack market, confirming plate accuracy and eliminating costly errors.

As flexo printing technology advanced, Heaford developed cantilever mandrel machines for sleeve technology and embraced servo drive technology for higher proof accuracy over longer lengths. These innovations allowed for international trade, with proofs sent to global brand headquarters for approval, streamlining the approval process and reducing costs.

Despite the rise of digital proofing, which offers basic job layout indications, traditional flexo proof presses remain essential for precise production results due to the many variables in the flexographic process.

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