Welcome back to our Let’s Go Flexo! series. In Part 1, we examined simplifying color builds, and in Part 2, we solved reverse type and gradient issues. Now, in Part 3, we’re wrapping up with some essential design guidelines to help your labels print cleanly, consistently, and affordably on a flexographic press.
These aren’t hard-and-fast rules, but they are time-tested best practices our team uses every day to turn great artwork into print-ready, flexo-friendly labels.
Keep It Simple: Minimize Color Usage
The first principle is straightforward: use fewer colors whenever possible.
This applies to both:
- Total number of ink colors on press, and
- The number of colors used to define any single shape or object
Why it matters:
- More colors = more printing plates = more chance for misregistration
- Shapes built with multiple colors (like CMYK) have edges defined by overlapping inks, which can shift slightly on press
Better option?
Use black or a solid Pantone color to define edges—this gives you cleaner, more reliable results.
Favor Solid Pantones Over Screens
When using spot colors, stick to solid Pantones as much as you can.
- Screens (tints or fades) can fill in during printing, especially in smaller areas
- Solid Pantones deliver richer, more saturated colors
- They also offer better color stability and press performance
When to use screens:
Only when necessary for gradients or subtle effects—never as a default.
Watch Your Type and Line Weights
Fine type and thin lines can be a major trouble spot in flexo printing. Our guideline:
- Minimum line thickness: 0.005 inches (or 0.35 pt)
- Minimum type size (especially for reverse type): 4 pt
Why it matters:
- Thin strokes can fill in, making type or lines unreadable
- This risk increases in reverse type (light text on a dark background)
- Fonts like Helvetica Thin or other lightweights are especially prone to this
Quick Tip: Test Your Type
If you’re not sure whether your type is thick enough:
- Convert your type to outlines in your design file.
- Measure a lowercase “l” or capital “I” with your design software’s tools.
- Compare it to a 0.35 pt reference line.
- If your stroke is thinner, consider bolding the type or switching fonts.
This simple check can save you from blurry or broken/filled in type on your final label.
Not Rules—Just Really Good Guidelines
As we like to say, these aren’t strict rules… more like the “general guidelines” from Pirates of the Caribbean. But follow them, and you’ll be well on your way to a design that looks fantastic on press and saves you time and cost.
Thanks for joining us for the Let’s Go Flexo! series. If you have a label project that needs flexo printing, our team is ready to help make your design production-ready.Visit www.rosecitylabel.com to get started.