Mottled print is a common problem , when trying to print good quality consistent solids in flexo. The surface of the print appears like orange peel, with inconsistent colour and non-uniform appearance

Printing form with uneven or un-clean surface
Ink viscosity or concentration, too low
Residual chemicals from the plate-making process, still on surface
Dirty or scratched impression cylinder
In-correct ink transfer on the printing form or substrate
Ink not wetting on printing form or substrate

1 Increase the printing pressure between the printing form and substrate
2 Increase the ink viscosity or ink film thickness.
3 Modify ink to correct viscosity or opacity. Check the balance of solvent in the ink. If necessary change the ink
4 Wash the printing form to remove residual chemicals. If necesary remake the printing form
5 Properly clean the impression cylinder
6 Use softer or more compatible plate or cushion tape
7 Check surface treatment of the substrate

Helmut Mathes, troubleshooting defects supplied curtesey of Flexo & Gravure Int''l 2011


The shape and consistency of anilox cells makes a huge impact on ink transfer and cleanliness of the inking process to the printing plate.

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Dried ink in anilox cells, can cause significant change in print densities. The FlexoStar laser can clean dried ink from even the smallest cells.

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The advantage of Direct Computer to Print

The advantage of Direct Computer to Print

Fast overall process with a simple digital workflow.

Total digital dot creation controls dot shape, relief depth and dot height

Direct engraving of ITR seamless continuous sleeves

Direct engraving eliminates washout and drying process

Perfect registration of plates and sleeves

'Cal-Kwik' automatic material calibration for engraving Polymer or Elastomer

'Perfect Balance' automatically re-balances the print form for high-speed printing