Miraclon launches flexcel prime plate to boost flexo pressroom productivity

INDIA – Miraclon has unveiled the Flexcel Prime plate, a next-generation flexographic plate engineered to improve pressroom efficiency, extend plate life, and reduce production interruptions.

The technology builds on the established Flexcel NX platform and integrates seamlessly into existing Flexcel NX workflows used by converters globally.

The Flexcel Prime plate combines a new plate and film structure developed through a multi-year research and development program.

The technology has already been installed at over 30 customer sites across 14 countries and validated in more than 5,000 commercial print jobs, underscoring its practical performance in real-world applications.

“Flexographic printing is operating in an environment of tighter tolerances and greater production demands than ever before,” said Reid Chesterfield, chief technology and innovation officer at Miraclon.

“With Flexcel Prime, we set out to push the performance boundaries of the plate itself, reducing ink build-up and lowering impression requirements, which extend plate life.”

The new plate introduces three core innovations that enhance flexographic printing performance.

First, the Lift Resist formulation improves plate flexibility and stability, helping to reduce plate curl and making mounting and remounting easier.

This advancement supports greater plate reuse while ensuring consistent performance across multiple print runs.

Second, the plate features Stay Clean properties, which minimize ink build-up on the plate surface.

This reduces the need for frequent cleaning and contributes to smoother press operations. Early trials have shown a 23% reduction in press downtime related to plate cleaning, highlighting its impact on overall efficiency.

Finally, the Seamless Fit Printing capability allows the new plate to operate alongside existing Flexcel NX plates without requiring workflow changes, reprofiling, or press adjustments.

This ensures that print density and surface characteristics remain consistent, delivering reliable and high-quality results across jobs.

In addition to pressroom gains, Miraclon has optimized the platemaking process. The detack or light finishing step has been shortened from approximately 20 minutes to five minutes, allowing faster plate production and higher throughput in the plate room.

“By helping plates stay cleaner longer, improving reuse, and maintaining performance with lower impression, Flexcel Prime enables printers to run longer and potentially faster while maintaining high print quality,” said Emma Weston, chief marketing officer at Miraclon.

The Flexcel Prime plate is now commercially available, with a global rollout to customers planned over the coming months.

Miraclon’s launch aligns with broader trends in flexographic printing focused on pressroom efficiency and sustainability.

Earlier this year, companies like TCPL Packaging in India invested in energy and production optimization projects to reduce operating costs and improve manufacturing reliability.

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