What Is Hybrid Flexo Printing?
Hybrid flexo press merges digital inkjet and flexographic printing technologies into one integrated system.
This allows you to produce labels with both customization and decorative effects in a single pass.
How Hybrid Flexo Printing Works?
The digital press units handle variable content like text, graphics, and images.
The flexographic stations add decorative touches like varnishes, foils, and specialty coatings.
This means you don’t need to move your materials between different machines.
The digital component prints first, then the flexo units apply embellishments on top.
Hybrid Flexo vs Traditional Printing Methods
Traditional flexographic printing requires new plates for every design change, making short runs expensive.
Furthermore, digital printing alone can’t match the premium embellishments that flexo provides.
| Method | Best For | Setup Time | Embellishments |
|---|---|---|---|
| Traditional Flexo | Large runs with consistent design | Long | Excellent |
| Digital Only | Very short runs with variation | Minimal | Limited |
| Hybrid Flexo | Medium runs needing both | Moderate | Excellent |
The break-even point for hybrid printing typically hits at run lengths where traditional methods struggle. You avoid the high plate costs of flexo while accessing effects that digital printing can’t replicate.
Benefits and Capabilities of Hybrid Flexo Printing
Enhanced Print Quality and Consistency
Hybrid Flexo Printing can achieve high-quality print results with hybrid systems that combine the precision of digital printing with the rich colors and finishes of flexo.
The labels maintain consistent quality throughout the entire print run because hybrid presses control each printing station independently.
The technology also lets you add premium embellishments that make your products stand out. You can include:
- Specialty varnishes for texture and shine
- Cold foils for metallic effects
- Rotary screens for unique patterns
- Precise diecutting for custom shapes
Customization and Variable Data
Hybrid Flexo Printing personalize your labels with variable data while keeping premium flexo embellishments.
Your marketing campaigns become more targeted when you can customize labels for different markets or consumer segments.
Hybrid Flexo Printing Applications
Food and beverage companies rely on this technology to create attractive labels that include special effects like metallic finishes and spot varnishes.
Cartons and corrugated packaging have adopted hybrid printing for smaller runs that previously weren’t cost-effective. You get the quality of traditional flexo with the flexibility to customize designs without expensive plate changes.
Label production represents one of the strongest applications for hybrid flexo printing. Your pressure-sensitive labels can include both digital variable data and flexographic embellishments in a single pass through the press.
You can add cold foil, texture varnishes, and specialty inks while still managing the variable content needed for different varietals or limited releases.
Hybrid Flexo Printing’s Impact on the Cosmetic Packaging Industry
Hybrid flexo printing has become a strategic technology in cosmetics packaging, capturing significant traction especially in Europe where adoption is accelerating.
Why Cosmetics Brands Are Adopting It?
- Brand Differentiation: Direct printing on curved containers (jars, bottles, tubes) enables complex artwork and personalization without traditional plate costs
- Short-Run Economics: Ideal for limited-edition launches, seasonal collections, and testing new designs—critical for high-margin beauty products
- Regulatory Compliance: Supports low-migration inks and recyclable materials demanded by EU 1935/2004 and similar regulations
- Speed to Market: Rapid changeover enables quick responses to beauty trends
Technical Advantages for Cosmetics
- High color fidelity and precision for brand-critical aesthetics
- Compatibility with UV and water-based inks for eco-conscious formulations
- Inline embellishment capabilities for premium finishes
- Waste reduction through combined digital-flexo workflows
Somewang is a professional manufacturer specializing in cosmetic packaging materials. If you’re in search of eco-friendly cosmetic packaging solutions that balance quality with affordability, we’d be delighted to hear from you—feel free to reach out anytime!
Frequently Asked Questions
What are the advantages of using hybrid flexo printing compared to traditional printing methods?
The most important is the the less material waste compared to traditional flexo printing.
How does hybrid flexo printing contribute to sustainability and eco-friendliness in the printing process?
Hybrid printing reduces material waste by using digital components for customization instead of creating new plates for every design variation.
The single-pass process lowers your energy consumption compared to running separate digital and flexo operations.
What kind of quality and resolution can I expect from hybrid flexo printing for high-detail designs?
The digital components can provide precise detail and color accuracy for your base designs and variable elements.
The flexo stations add tactile and visual effects that enhance your design’s shelf appeal. Cold foils, specialty varnishes, and raised textures create premium finishes.