If there’s one thing we’ve learned over more than three decades of supporting packaging and label printers, it’s that producing consistently exceptional print goes far, far beyond simply selecting premium inks or substrates.
At Contact Originators, we’ve seen first-hand how one technical element, screening, can make the critical difference between an acceptable print run and a truly outstanding one.
Walk into any technical discussion about flexo platemaking and you’ll likely be bombarded with a dizzying array of terms: AM vs. FM screening, hybrid screening, stochastic processes, amplitude modulation, frequency modulation, flat-top dots… the list goes on. It’s enough to make even experienced print professionals scratch their heads.
When we sit down with our customers, whether they’re production directors at major packaging converters or brand owners looking to elevate their packaging and labels, screening is often the unsung hero that doesn’t get enough attention. Yet it’s fundamental to delivering the razor-sharp images, vibrant brand colours, and consistent finishes that today’s demanding market requires.
Let’s cut through the technical jargon and explore what screening really is, why it matters for your specific print challenges, and how choosing the right screening approach – backed by Contact’s expertise and support – can transform your flexo print quality.
Screening Demystified: What It Actually Is
At its core, screening is the process that converts continuous-tone images (think photographs or subtle gradients) into printable dot patterns that can be replicated on packaging and label runs. These carefully arranged dots vary in size to create the illusion of different tones and colours when printed and for flexo printing specifically, the challenge is ensuring these dots maintain their integrity throughout the printing process.
Let’s decode some of that terminology:
- AM (Amplitude Modulated) Screening: The traditional approach where dots are arranged in a fixed grid but vary in size. Great for solid areas but can struggle with subtle highlights and softer tones.
- FM (Frequency Modulated) Screening: Also called “stochastic” screening, where dots are the same size but vary in frequency or spacing. Excellent for fine details but can create a grainy appearance in some areas.
- Hybrid Screening: Combines both AM and FM approaches, typically using FM in highlight areas and AM in mid-tones and shadows for the best of both worlds.
- Flat-Top Dots: A technology that creates dots with flat tops rather than rounded ones, offering more stability and less deformation during printing.
- Surface Screening: Micro-texturing on the plate surface to improve ink transfer, especially in solid areas.
The flexographic printing process presents unique challenges – photopolymer plates mounted on cylinders can compress during printing, potentially causing dot gain or loss, particularly in highlight areas. Effective screening technology used by a partner like Contact can combat these issues, ensuring your prints maintain consistency from the first impression to the last.
Beyond the Technology: Why Expertise Makes the Difference
While many repro houses have access to similar screening technologies, what truly sets a partner apart is the knowledge of when and how to apply each option. This expertise isn’t developed overnight – it comes from years of solving complex print challenges across diverse applications and substrates.
At Contact Originators, we believe that screening technology, while important, is only as effective as the expertise behind it. Having the right tools is one thing; knowing precisely how to use them for your specific printing challenges is another entirely.
When speaking with our packaging and label printing partners, we often hear frustration around several key areas where screening expertise plays a pivotal role:
- Brand Colour Integrity: “Our biggest challenge is maintaining consistent brand colours across multiple print runs and substrates.” The right screening approach, selected by experts who understand how different screening technologies interact with various inks and substrates, ensures dependable ink laydown for colour-critical elements.
- Fine Detail Reproduction: “We’re seeing more designs with intricate patterns and micro-text that test the limits of our process.” Our team’s experience with different screening options can dramatically improve the reproduction of these challenging elements.
- Press Downtime and Material Waste: “We need to minimise waste while maximising throughput.” When screening is optimised by experts who understand your specific press setup, you’ll experience fewer stops, reduced waste, and better overall efficiency.
- Challenging Substrates: “We’re printing on everything from recycled corrugated to ultra-thin films.” Each substrate interacts differently with ink, making experienced screening selection essential.
The Contact Approach: Where Technology Meets Expertise
What sets our approach apart isn’t just the screening technology we offer, but our deep understanding of how to apply it effectively. Many suppliers can provide screening options, but few can match our team’s ability to select and implement the perfect solution for each specific job.
We’ve invested in market-leading technologies tailored to each packaging segment we serve: For flexible packaging and labels, we utilise Esko Crystal Screening with V3+ Optics – making Contact the first company in the UK to invest in it The V3+ Optics head delivers a 30% increase in productivity for Crystal screens and Pixel+, while achieving better dot size uniformity, more consistent ink laydown, fewer pin holes, and superior solid density. This technology is proving instrumental in our expansion into flexible packaging and label markets. For corrugated packaging, we employ Esko Highlights for high-quality post-print (HQPP) applications, delivering outstanding detail reproduction on corrugated substrates. This is complemented by our proprietary Optimus™ technology, which was specifically developed for corrugated printing challenges.
Optimus™ – Innovation Born from Experience
Our flagship Optimus™ technology perfectly illustrates the power of combining technical innovation with practical expertise. Developed in-house through years of trials on different plate surface patterns, plate types and LED exposures, Optimus™ combines novel studio techniques to provide printers with proven savings while maintaining superior graphics performance.
This innovative technology delivers improved ink laydown and significant ink savings in the corrugated printing process. The sophistication of the approach led to Optimus™ being named winner in the Business Process category at the prestigious Stationers’ Awards.
Optimus™ creates not just visual benefits but tangible cost savings on press – a win-win for quality and sustainability in an era where reducing resource consumption is increasingly critical to both business performance and environmental responsibility.
Technical Expertise with a Human Touch
Beyond specific technologies like Optimus™, our approach begins with conversations – understanding your press setup, anilox inventory, substrate challenges, and design requirements. Where others might overwhelm you with technical specifications about ‘microcell densities’, ‘transitional screening algorithms’ or ‘plate surface energy measurements’, we focus on translating these complex concepts into practical solutions that deliver tangible improvements to your print performance.
With high-speed semi and fully automated plate production lines, we combine technical capability with practical expertise. This means we deliver:
- True Consultation: We’ll assess your specific needs and recommend the screening approach that delivers optimal results for your exact circumstances.
- Consistent Quality: Our automated workflows ensure repeatable quality, regardless of job complexity.
- Rapid Turnaround: With extensive capacity, we can respond quickly to your needs without compromising on quality.
- Press-Side Support: Our technical team can work directly with your press operators to fine-tune results on challenging jobs.
Where Knowledge Creates Value
The real value we deliver isn’t just in providing screening technology, but in knowing exactly which approach will work best for each unique job. This knowledge comes from decades of hands-on experience across every imaginable print scenario. Our team doesn’t just understand screening in theory; they’ve seen how it performs in practice, on countless substrates, with various ink systems, across different press configurations.
When problems arise – and they inevitably do – our expertise allows us to quickly diagnose whether the issue relates to screening or elsewhere in the print process. Rather than costly trial-and-error approaches, we can provide targeted solutions that save valuable production time and reduce waste.
This comprehensive support extends beyond initial plate delivery. We’re committed to ensuring your success throughout the print run and beyond, offering technical guidance whenever challenges arise. For many of our customers, this ongoing support has proven just as valuable as the screening technology itself.
Taking the Next Step
If you’re facing challenges with print consistency, struggling with specific substrates, or simply looking to elevate your quality to meet growing brand owner expectations, we’re here to help. The right screening approach, backed by expert implementation and support, can transform your flexo print quality without necessarily requiring significant press investments.
Contact Originators is committed to being more than just a plate supplier – we aim to be your technical partner in print excellence. Let’s cut through the jargon together and focus on what really matters: outstanding print that helps your customers’ products shine on shelf.
Ready to discuss how our screening expertise can address your specific print challenges? Get in touch with our technical team today.
