The amount of ink used in label printing is typically determined by the size of the image and text area, which are designed by the customer. The printing company can make minor adjustments to the layout, so a bit of "nail" spirit—meaning attention to detail and efficiency—can help reduce costs effectively.
1. Pay Attention to the Difference Between Two-Layer and One-Layer Ink Printing
When printing on large areas, most label printers use two layers of ink to prevent smudging. However, there's another important reason: under the same color density, using two thin layers of ink consumes less than one thick layer. For example, a job required 500 lines per inch with a 4.0 BCM anilox roller to print a special red. To avoid ink stains on foamed PS material, a two-layer method was used: the first layer was printed with a 1000 lines per inch, 1.5 BCM anilox roller, and the second with an 800 lines per inch, 2.2 BCM roller. Visually, the results were nearly identical, and instrument readings were all within acceptable limits. However, when printing with a thicker ink layer, the ink’s flatness often suffers, leading to blooming, a less realistic appearance, and a lighter color. On coated paper, this issue becomes worse due to ink penetration. With two layers, the first layer is thinner, helping to remove dust and fill surface imperfections. The second layer then creates a smoother, more consistent finish with a higher measured density.
2. Decide Whether Polishing Is Necessary
Polishing serves two main purposes: enhancing gloss and protecting the label from wear. If the goal is just to increase shine, flexo ink already has sufficient brightness, so polishing may not be needed. However, if protection is required, some labels might not experience much wear during transport or use, making polishing unnecessary. In many cases, polishing is a common practice driven by habit rather than actual need. Blindly applying it can lead to wasted varnish. Although varnish is cheaper than regular ink, it's often applied in full-coverage, thick layers, resulting in excessive usage and waste.
Therefore, it's essential to plan carefully early in the process. Consider whether polishing is truly necessary, or if full-coverage varnish is required. If the label won’t be rubbed during application, transport, or use, a transparent label can remain uncoated. For special-shaped labels, where a large die-cut area is involved, partial polishing may be sufficient. When polishing is needed, ensure the varnish thickness meets the customer's requirements. For labels requiring wear resistance, sufficient varnish thickness is crucial, and sometimes anti-wear additives are added. Ultimately, it's about meeting the customer’s needs without over-engineering or adding unnecessary costs. Extra steps only lead to resource waste.
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