Flexo Envelope Printing: Key Benefits & Applications

Wondering if flexographic envelope printing is the best choice for your next project? Here’s what you need to know about flexo envelope printing – what it is, advantages and limitations, and when to use it.

What is Flexo Envelope Printing?

Flexo envelope printing is a type of high-speed printing where ink is transferred from a roller to a flexible relief plate, then pressed onto the paper. This method is often used for high-volume, cost-effective printing.

There are two types of flexo envelope printing:

• Flexo web convert: Prints on continuous paper rolls then converts (cut, folded, and glued) on the same machine, ideal for printing 100,000 or more envelopes
• Die-cut flexo: Prints on a die-cut blank before the envelope is folded. Die-cut flexo is limited to 2 colors over 1 and no bleeds with light to medium coverage. It’s best for printing less than 100,000 envelopes

Flexo Advantages

Flexo envelope printing offers multiple advantages, especially in speed and cost.

High Speed Production

Flexo envelope printing is fast and efficient for mass production.

Cost Effective

This method offers low per-unit costs, making it ideal for higher volumes.

Die-Cut Flexo Advantages

Die-cut flexo is perfect for short to medium runs and can print on specialty envelopes such as those with windows or security tints.

Web Flexo Advantages

Web flexo is suited for large runs and can print up to 4-color process over 1 (four colors on the outside side, one color on the inside). It can also print full bleeds and screens. Though it’s not quite offset quality, it’s a cost effective way to print envelopes.

It’s worth noting that Priority Envelope has earned multiple awards from the Flexographic Technical Association (FTA) for our work with flexo envelope printing.

Flexo Limitations

Flexo does have some limitations to consider, including:

Color Production

With flexo printing, colors aren’t as sharp or detailed as with litho/convert or conventional jet printing. Full bleeds might not be available, and color production is limited. For example, gradients and fade-to-zero shadows can prove challenging.

Compatibility

Flexo printing is not compatible with all paper stocks and finishes, though it can work on both coated and uncoated paper. In some cases, a particular paper might not be available in roll form.

When to Consider Flexo Envelope Printing

Flexo envelope printing is an excellent choice for:

• High-volume orders
• Mass mailings (low per-unit costs)
• Quick turns (rapid production, capable of 90,000 envelopes per hour)
• Die-cut flexo is a good choice for smaller and specialty envelopes – such as those with custom sizes or windows – in quantities of 100,000 or less
• Web flexo is best for large orders that require fast, high-volume production of 100,000 or more envelopes

Still not sure if flexo printing is the right choice for your next envelope project? Priority Envelope is here to help. Our in-house experts have decades of experience helping our customers identify the best envelope printing and converting processes to meet their unique needs.