This article is part of the FLEXO FLAW FIXING series

There are some challenges to working with flexo printing, and one of these is a significant area printing defect. 

This means that the ink spreads out to create a halo, affecting the finished product. 

In this blog article, we’ll break down what causes these defects and how they affect your final product.

These defects can occur when the ink doesn’t adhere to the printing plate correctly, resulting in large areas of printing that are blurry or distorted.

If you’re experiencing significant area printing defects with your flexo prints, there are several things you can do to try and fix the problem. 

You can try adjusting the settings on your printer, increasing the amount of ink used, or replacing your flexo printing plate.

Types of the significant area printing defect

Large area printing defect is the most common type of printing defect. It is caused by the error in the design of the large area printing plate. 

Large area printing defects can be divided into three types: belt buckle, pocket, and web.

Belt buckle: 

This large-area printing defect is caused by a misalignment between the print head and the large area printing plate. 

The result is a buckle-like pattern on the printed material.


This large-area printing defect results from a build-up of ink on the print head and large-area printing plate.

 The raised areas on the printed material are called pockets.


This type of large-area printing defect is caused by an uneven ink distribution on the large area printing plate. 

As a result, small areas of print become webs or nets.

Here are some signs to watch for when printing with flexo:

● Prints that are jagged or irregular in shape

● Prints that have large areas of missing color or texture

● Rough or unfinished edges on prints

A side effect of the significant area printing defect in flexo printing

Large area printing In flexo printing can cause side effects and may cause problems with the quality of the finished product. 

1. The print quality may be affected, making it difficult to read the text or graphics on the printed material.

2. The print may be curved or distorted, making it difficult to use for promotional materials or other purposes.

3. The print may fade over time, leading to a loss of legibility and an overall poorer appearance.


If you have experienced a significant area printing defect in flexo printing, don’t despair. You can take steps to minimize the impact of this type of print defect and get your product to market as quickly as possible. 

While it is unfortunate that this type of defect has become so common, using the right equipment, procedures and software can help ensure that your products reach consumers without any significant issues.