Let’s Go Flexo! – Part 2: Solving Reverse Type and Gradient Challenges
Welcome back to our series on making your label designs flexo-friendly! In Part 1, we covered how simplifying color builds can reduce misregistration and improve print quality. Today, we’re tackling another challenge: reverse type and gradients in four-color process designs.
These design elements can look great on screen but often complicate things on a flexographic press. Let’s walk through how to adapt them without sacrificing style or breaking the bank.
The Challenge: Reverse Type in 4-Color Builds
Reverse type (white or light-colored text knocking out of a darker background) can be tricky in flexo, especially when that background is made from all four CMYK colors.
- Fine lines get fuzzy when each color registers slightly off.
- The result? Blurry, unreadable type—even if your layout looked great digitally.
The Solution: Use Pantone Solids and Strategic Layering
Instead of relying on CMYK blends, try this approach:
- Pick a rich, solid Pantone color for your background.
For example, a warm yellow-brown makes a great base. - Overlay a second Pantone as a gradient.
Choose something light, like Pantone 211 (a light pink). At first, it won’t look like much alone, but when combined with the brown underneath, the two create a rich, saturated gradient that mimics CMYK without the registration issues.
Avoid fading both colors at once.
Don’t let both colors disappear into each other; this creates muddy, gray areas. Instead, keep one solid color in the background and fade just one on top for a cleaner, more consistent look.
What About Fine Type on That Gradient?
If you’ve got small reverse type knocking out of your gradient area, here are two good options:
Option 1: Add a Dedicated Spot Color
Use a third Pantone, like the same brown in your background, to fill in the small text. Because it’s a single plate, your type will print clean and crisp.
Option 2: Outline with Black
If adding another color isn’t in your budget, use a black outline around your small type:
- It adds structure to the edges and reduces the impact of minor misregistration.
- If done subtly, the outline blends into the darker background.
You still define your text with just one ink, making it far more reliable on press.
The Bottom Line
Reverse type and gradients don’t have to be dealbreakers for flexographic printing. With thoughtful design tweaks—like using spot colors and smart layering—you can retain your design’s visual impact while making it faster and easier to print.
Watch the video below for a visual walkthrough. See the original label design and how our team adjusted it to solve these issues without drastically changing the look.
Stay tuned for Part 3, where we’ll explore some general guidelines for Flexo printing.
Need help making your design flexo-friendly? Contact us today. We’re here to help you save time, reduce costs, and print with confidence.