Flexographic Printing Case Study for Flexible Packaging
Selecting flexographic printing equipment for a flexible converting business is rarely a matter of choosing the fastest press available.
TCL Hunt operates across flexible converting equipment and related technical products in the New Zealand and Australian markets. Its equipment portfolio covers several stages of flexible material processing, making printing equipment one part of a larger production picture. This case looks at how LISHG approaches that requirement through substrate, production volume, printing width, color count, register requirements and machine structure.
What Made Flexographic Printing Selection Important?
The printing machine had to make sense within the wider converting application, not simply perform well as a standalone press.
Who Is TCL Hunt?
TCL Hunt supplies equipment, materials and technical products for industrial and flexible converting applications.
What Was the Main Issue?
Different converters may need different substrates, widths, color counts, production speeds and automation levels.
How Was It Approached?
LISHG assessed the application first and then considered CI, gearless CI and stack flexographic configurations.
What Was the Practical Outcome?
The equipment selection became a clearer process based on application requirements rather than a single machine specification.
Printing Was One Part of a Larger Converting Workflow
Flexible converting projects often connect several processes. That changes the way a printing machine should be evaluated.
Flexible Converting Supplier
TCL Hunt's flexible converting portfolio serves customers looking for equipment and technical support across different converting processes.
More Than Printing
Flexible converting equipment can include printing, laminating, slitting and rewinding, extrusion coating and other material processing technologies.
Different Jobs, Different Conditions
Film and paper jobs can differ in width, colors, repeat length, speed, tension control, register requirements and production volume.
Match the Press to the Job
LISHG's CI, gearless CI and stack platforms provide different starting points for customers with different production profiles.
Where Different Flexographic Configurations Fit
There is no single press structure that is automatically right for every flexible converting application.
| Application | Typical Requirement | Possible Direction | Selection Reason |
|---|---|---|---|
| Flexible Film Packaging | Multi-color roll-to-roll printing | CI Flexo | Central impression structure supports stable web handling for flexible materials. |
| High-Volume Flexible Packaging | Higher operating speed and demanding register control | Master / King / Apex | Different CI platforms allow speed, automation and investment to be balanced. |
| Paper Packaging | Paper bags and coated paper applications | CI / Stack Flexo | The structure can be selected according to paper characteristics and production requirements. |
| Non-Woven Applications | Printing on flexible non-woven substrates | Stack / Dedicated CI | Material handling and production requirements determine the appropriate structure. |
The Machine Should Follow the Production Requirement
A flexible converting supplier may face one customer looking for a practical film printing solution and another looking for a high-speed, highly automated press. Treating both projects as the same machine-selection problem can lead to an unsuitable configuration. The starting point should be the material and production profile.
Four Things to Check Before Selecting a Flexo Press
These are the points that should be settled before comparing individual machine models.
Material Range
Start with the actual substrate range. PE, PET, BOPP, paper and non-woven materials can behave differently during web handling and printing.
Width & Repeat
Feeding width, printing width and repeat length affect the machine size and printing configuration that should be considered.
Speed & Colors
The target operating speed and number of colors help determine whether a practical stack, servo CI or higher-speed gearless platform is appropriate.
Automation & Support
Register control, tension control, drying, winding, installation, training and after-sales support should be considered before the purchase is finalized.
Comparing LISHG Flexographic Printing Platforms
The following comparison is intended to show the role of each platform in the selection process. Actual machine configuration should be confirmed against the final production specification.
| Platform | Material Direction | Published Speed Class | Drive / Structure | Typical Selection Logic |
|---|---|---|---|---|
| Master Series | Film & paper | Up to 500 m/min class | Full-servo gearless CI | High-speed and highly automated flexible packaging production. |
| King Series | Flexible films & paper | Around 300 m/min class | Servo gear CI | Higher-volume production where a balance between performance and investment matters. |
| Apex Series | Film & packaging substrates | Around 250 m/min class | Servo gear CI | Balanced production speed, register control and investment. |
| Ultra Series | Film & paper | 150 - 200 m/min class | CI configuration | Practical entry and mid-speed production requirements. |
| Honor Stack Series | Paper, film, non-woven & woven substrates | Configuration dependent | Stack flexo | Flexible production, paper bags, flexible bags and applications requiring stack architecture. |
Build the Machine Requirement Before Comparing Models
A short production profile can eliminate unsuitable machine families before detailed technical discussions begin.
Substrate
What material will be printed? Record film or paper type, thickness and relevant surface characteristics.
Printing Width
Confirm feeding width, effective printing width and the range of jobs the machine is expected to handle.
Colors & Repeat
Define the normal color count and repeat range rather than selecting the machine from a maximum specification alone.
Operating Speed
Identify the target production speed that will actually be used for regular jobs.
Automation
Define the expected level of register control, tension control and operator assistance.
Five Steps from Application Requirement to Machine Selection
This sequence keeps technical discussions focused on the production requirement before moving into individual machine specifications.
LISHG Flexographic Printing Machines for Flexible Converting
The following series represent the main product directions relevant to film, paper and flexible packaging applications.
| Product Series | Material Direction | Application | Positioning |
|---|---|---|---|
| Master Series | Film & paper | High-speed flexible packaging | Full-servo gearless CI |
| King Series | Flexible films & paper | Higher-volume packaging | Servo gear CI |
| Apex Series | Film & packaging substrates | Flexible packaging | Balanced servo gear CI |
| Ultra Series | Film & paper | Entry and mid-speed production | Practical CI platform |
| Honor Stack Series | Paper, film, non-woven & woven | Bags and flexible production | Stack flexographic platform |
Flexographic Printing Questions Buyers Ask Before Purchasing
1. Which flexographic press is suitable for flexible packaging?
The answer depends on substrate, printing width, color count, repeat length, production volume, target operating speed and automation. CI flexo is often considered for continuous flexible film production, while stack configurations can suit other material and production requirements.
2. Should maximum machine speed determine the purchase?
Not by itself. A machine should be evaluated against its normal operating speed, substrate range, register requirements, changeover needs and expected production mix.
3. What is the difference between CI flexo and stack flexo?
CI flexo uses a central impression cylinder to support the web through multiple printing stations. Stack flexo arranges printing units in a vertical stack. The appropriate structure depends on substrate, production requirements and application.
4. When should a buyer consider a gearless CI press?
A gearless CI platform can be considered when high-speed production, precise motion control, register stability and a higher level of automation are important to the production plan.
5. What information should be provided for a flexo press quotation?
Provide substrate type, thickness, feeding width, printing width, number of colors, repeat length, target operating speed, ink system and finished application.
6. Can one flexographic platform handle different substrates?
A properly configured press can support a defined range of substrates, but the final configuration should be checked against the actual material range, thickness, web behavior and production requirements.
7. Can LISHG customize a flexographic printing machine?
LISHG states that machine configurations can be customized according to customer requirements. The final specification should be based on the actual production application.
8. What should be checked besides the machine itself?
Buyers should also review technical testing, documentation, installation and commissioning, operator training, spare parts and after-sales engineering support.
A Better Flexographic Printing Decision Starts Before the Machine Quote
The TCL Hunt case highlights a common issue in flexible converting equipment: printing cannot always be treated as an isolated machine purchase. The press has to make sense for the material, production volume, width, color requirements and the rest of the converting workflow.
For that reason, LISHG's approach starts with the application and then moves toward the appropriate machine structure. The Master Series provides a full-servo gearless CI direction for demanding high-speed applications, while the King Series and Apex Series provide alternative CI configurations for different production requirements.
For buyers evaluating flexographic printing equipment, the practical starting point is therefore straightforward: define the material, define the production requirement, compare machine structures and then confirm the detailed configuration. That process provides a much clearer basis for selecting a press than comparing maximum speed alone.
Need Help Selecting a Flexographic Printing Machine?
Send your substrate, printing width, number of colors, repeat length and target operating speed. LISHG can review the production profile and identify the machine structure and configuration that best matches the application.
Related topics: LISHG Flexo Solutions for Titanium Plastic Machinery case study · customer success: Supporting MAK PAPER's Paper Cup & Food Packaging Productio...
Customer voice
““LISHG's application-based approach helped us evaluate flexographic printing requirements by substrate, width, colors and production capacity.””
Recommended machine logic
King Series
Based on your profile: Flexible Packaging · Film, BOPP, PET, PE · 1000–1300mm · 350m/min
King Series is the strongest fit for Flexible Packaging because Best fit when the plant runs high-speed film jobs and needs reliable register control, fast ramp-up, and strong production stability. At your target speed of 350m/min, this platform keeps register stable, startup waste low, and changeovers practical for repeat jobs.
You selected Film, BOPP, PET, PE. King Series is engineered for thin film, BOPP, PET, PE. Core substrate window: thin film, BOPP, PET, PE. This reduces tension surprises and ink-transfer issues on your primary material.
Width target 1000–1300mm and speed 350m/min sit inside the King Series envelope (1000-1300mm, 300m/min). Budget Mid to high range and High automation align with very high-automation workflows at this output level.
Key advantages: Servo gear precision; low startup waste; strong register at speed. Tradeoff to confirm: Higher initial investment than Master or Honor, and not the primary choice for FFS heavy-duty sacks. If your mix shifts toward ultra-thin film at 400–500 m/min, compare with another LISHG line before finalizing.
Pick press family, then sub-series model.
Compare allBest fit when the plant runs high-speed film jobs and needs reliable register control, fast ramp-up, and strong production stability.
Discuss a similar project
Share your substrate, width, and speed targets with our engineering team.
Contact Desk
