{"id":3217,"date":"2026-09-19T15:18:48","date_gmt":"2026-09-19T13:18:48","guid":{"rendered":"https:\/\/kablonex.pl\/knowledge\/flexo-file-preparation\/"},"modified":"2026-09-19T15:18:48","modified_gmt":"2026-09-19T13:18:48","slug":"flexo-file-preparation","status":"publish","type":"page","link":"https:\/\/kablonex.pl\/en\/knowledge\/flexo-file-preparation\/","title":{"rendered":"Preparing files for flexo printing on film: NEX PRINT guidelines"},"content":{"rendered":"\n<!-- NEX PRINT: file preparation guidelines for flexo printing. 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Values for PE, PP and PET film and paper, Kablonex machine park. Reading time: 8 minutes, time saved: 1-2 days per round of corrections.<\/p>\n  <div class=\"toc\"><a href=\"#geo\">1. Geometry and repeat<\/a><a href=\"#plik\">2. File<\/a><a href=\"#kolor\">3. Colours<\/a><a href=\"#min\">4. Minimum sizes<\/a><a href=\"#kto\">5. Who does what<\/a><a href=\"#check\">6. Checklist<\/a><a href=\"#faq\">7. FAQ<\/a><\/div>\n  <p>Reversed-out text 0.15 mm thick, an EAN code in red, a gradient down to 0%, a 333 mm design on a 1000 mm repeat: these are four typical reasons why a file goes back to the customer with a list of corrections. None of them is creative, each of them costs a day or two.<\/p>\n  <div class=\"num\"><div><b>370-1350<\/b><span>mm repeat (depending on the press)<\/span><\/div><div><b>up to 10<\/b><span>colours on the Miraflex<\/span><\/div><div><b>72 h<\/b><span>PDF Check + Technical Fit<\/span><\/div><div><b>0.2 mm<\/b><span>min. positive line<\/span><\/div><\/div>\n  <h2 id=\"geo\"><span>1.<\/span>Before you open Illustrator: geometry and repeat<\/h2>\n  <p>Flexo prints from a sleeve with a fixed circumference. The length of your design must be a multiple of the available repeat, otherwise you get waste or the package dimension changes. This is the first thing to agree with purchasing, not the last.<\/p>\n  <table><tr><th>Parameter<\/th><th>Miraflex \/ Novoflex (CI)<\/th><th>Bonardi<\/th><th>Flexa (stack)<\/th><\/tr>\n    <tr><td><b>Repeat<\/b><\/td><td>370-1130 \/ 370-1250 mm, sleeves per list (incl. 400, 500, 600, 650, 700, 800, 900, 1030, 1130)<\/td><td>400, 420, 500, 600, 800, 900 mm<\/td><td>450-1350 mm<\/td><\/tr>\n    <tr><td><b>Print width<\/b><\/td><td>400-1300 mm<\/td><td>250-1800 mm<\/td><td>up to 400 mm (tube), up to 1300 mm (flat)<\/td><\/tr>\n    <tr><td><b>Colours<\/b><\/td><td>10 \/ 8<\/td><td>6<\/td><td>6<\/td><\/tr>\n    <tr><td><b>Substrates<\/b><\/td><td>PE, PP, PET, PA*, paper<\/td><td>PE<\/td><td>PE, PP, BOPP<\/td><\/tr>\n    <tr><td><b>Tube \/ two-sided print<\/b><\/td><td>yes \/ yes (10\/10, Miraflex)<\/td><td>yes \/ yes (3\/3)<\/td><td>yes \/ yes<\/td><\/tr><\/table>\n  <p class=\"fine\">Sleeve circumference correction: -10 \/ +5 mm. * PA: range depends on configuration.<\/p>\n  <div class=\"ok\"><b>Rule of thumb:<\/b> design length \u00d7 number of designs per revolution = repeat \u00b1 5 mm. Example: 250 mm design \u2192 500 mm repeat (2 designs) or 1000 mm (4 designs on the Flexa). 333 mm design \u2192 670 mm (2 \u00d7 335 mm, +4 mm correction).<\/div>\n  <p>You set the design dimension together with the dieline (package layout): cut lines, seals, folds, perforations, unprinted area under the seal. The dieline is supplied by Kablonex or by the manufacturer of your packaging machine. Do not design to the finished bag size &#8220;by eye&#8221;.<\/p>\n  <div class=\"cta\"><a class=\"btn\" href=\"https:\/\/kablonex.pl\/en\/services\/nex-print\/#kontakt\">Check the repeat in the configurator<\/a><\/div>\n  <h2 id=\"plik\"><span>2.<\/span>File format and structure<\/h2>\n  <div class=\"grid\">\n    <div class=\"card\"><h3>File<\/h3><ul>\n      <li><b>PDF\/X-4<\/b> (preferred) or PDF\/X-1a from a vector file: Illustrator, ArtPro+, InDesign.<\/li>\n      <li>Scale <b>1:1<\/b>, units in mm, no marks inside the design.<\/li>\n      <li>For complex files: source package (.ai + links + fonts).<\/li>\n      <li>Name: <code>customer_product_size_version_date.pdf<\/code>.<\/li><\/ul><\/div>\n    <div class=\"card\"><h3>Geometry<\/h3><ul>\n      <li><b>Dieline<\/b> on a separate layer, spot colour &#8220;Dieline&#8221;, overprint, non-printing.<\/li>\n      <li><b>3 mm bleed<\/b> beyond the cut line for solids and backgrounds.<\/li>\n      <li><b>5 mm safe zone<\/b> from seals and design edges for text, codes, logos.<\/li>\n      <li>Fonts outlined or embedded; for variable text include the fonts.<\/li><\/ul><\/div>\n  <\/div>\n  <div class=\"no\"><b>We do not accept for printing:<\/b> files from Canva, PowerPoint, Word, JPG\/PNG as the main artwork, PDF exported from a browser preview. Send them as a brief; the production file will be prepared by your studio or our prepress (additional service).<\/div>\n  <h2 id=\"kolor\"><span>3.<\/span>Colours and separations<\/h2>\n  <p>The number of separations in the file is the number of printing units you occupy on the press, and therefore directly the cost and availability of the press. A product photo on transparent film is CMYK + white = 5 separations, with a brand colour 6: that is already the limit of the Bonardi and the Flexa.<\/p>\n  <div class=\"rule\"><b>1 colour = 1 name<\/b><div>Each Pantone as a separate spot colour, no duplicates (&#8220;PANTONE 485 C&#8221; and &#8220;P 485&#8221; are two separations in the RIP).<small>Line artwork: Pantone. Photos: CMYK, plus Pantone for the brand colour if repeatability is required.<\/small><\/div><\/div>\n  <div class=\"rule\"><b>Opaque white<\/b><div>On transparent film a separate &#8220;White&#8221; separation, no screen, no fine detail.<small>State in the brief: surface print or reverse print (laminate, reverse, mirror image).<\/small><\/div><\/div>\n  <div class=\"rule\"><b>Black<\/b><div>Text: 100 K. Rich black only in large solids, e.g. 60 C 40 M 100 K; the build is agreed at the first order.<\/div><\/div>\n  <div class=\"rule\"><b>Overprint<\/b><div>Only intentional. Accidental overprint on white text = the text disappears. Trapping (0.2-0.3 mm) is set by our prepress; do not add your own.<\/div><\/div>\n  <div class=\"rule\"><b>Screen 2-98%<\/b><div>A dot below 2% does not transfer to film, above 95% it fills in. End a gradient &#8220;to zero&#8221; with the background colour or change the design.<small>Screen ruling typically 40-54 l\/cm on film; NEX PRINT prepress selects it for the specific substrate.<\/small><\/div><\/div>\n  <div class=\"rule\"><b>Metallic, pearl<\/b><div>No screen, no fine text, outside the seal zone.<\/div><\/div>\n  <h2 id=\"min\"><span>4.<\/span>Minimum sizes: lines, text, codes<\/h2>\n  <p>During printing dots and lines grow (dot gain), and a polymer plate will not hold detail below the threshold. On PE film, especially on tube, tolerances are wider than on a paper label.<\/p>\n  <table><tr><th>Element<\/th><th>Minimum<\/th><th>Note<\/th><\/tr>\n    <tr><td><b>Positive line<\/b><\/td><td>0.2 mm<\/td><td>one colour<\/td><\/tr>\n    <tr><td><b>Negative (reversed) line<\/b><\/td><td>0.3-0.4 mm<\/td><td>a reverse out of several colours at once increases the registration risk: avoid<\/td><\/tr>\n    <tr><td><b>Positive text<\/b><\/td><td>5-6 pt<\/td><td>no thin serifs or light weights<\/td><\/tr>\n    <tr><td><b>Reversed text<\/b><\/td><td>7-8 pt semibold<\/td><td>in one colour, never out of CMYK<\/td><\/tr>\n    <tr><td><b>Text in opaque white<\/b><\/td><td>7 pt<\/td><td>no screen<\/td><\/tr>\n    <tr><td><b>EAN-13 code<\/b><\/td><td>scale 100-120% (absolute min. 85%)<\/td><td>bars parallel to the printing direction, one dark colour on a light background, quiet zone min. 3.6 mm, no red or pastels<\/td><\/tr>\n    <tr><td><b>Bar Width Reduction<\/b><\/td><td>set by NEX PRINT prepress<\/td><td>typically 20-40 \u00b5m, depending on substrate and plate<\/td><\/tr>\n    <tr><td><b>Registration spacing<\/b><\/td><td>\u2265 0.3 mm<\/td><td>indicative registration tolerance between colours; the value for a specific press is given by the technologist<\/td><\/tr><\/table>\n  <div class=\"warn\"><b>Raster images:<\/b> min. 300 ppi at 1:1 scale, CMYK, no profiles embedded in objects, no lossy compression. Higher resolution does not help: detail below the screen ruling will not transfer to film anyway.<\/div>\n  <h2 id=\"kto\"><span>5.<\/span>What you do, what we do<\/h2>\n  <table><tr><th>Stage<\/th><th>Who<\/th><th>Time<\/th><\/tr>\n    <tr><td>Preflight per checklist (section 6)<\/td><td>You \/ your studio<\/td><td>30 min<\/td><\/tr>\n    <tr><td>PDF Check + Technical Fit Assessment: separations, geometry, codes, repeat<\/td><td>NEX PRINT technologist<\/td><td>up to 72 h, report with a list of corrections<\/td><\/tr>\n    <tr><td>Trapping, plate distortion, BWR, step and repeat<\/td><td>NEX PRINT prepress<\/td><td>in process<\/td><\/tr>\n    <tr><td>Contract proof \/ ink drawdown \/ press proof<\/td><td>NEX PRINT<\/td><td>per order, sample from 14 working days<\/td><\/tr><\/table>\n  <p>You do not calculate distortion yourself: prepress scales the artwork in the sleeve circumference direction depending on plate and mounting tape thickness. Your file should be at nominal size. The Miraflex inspects PDF files and barcodes in-line, so an error in a code stops the job before it leaves the press, not after delivery.<\/p>\n  <h2 id=\"check\"><span>6.<\/span>Checklist before sending<\/h2>\n  <div class=\"steps\">\n    <div>PDF\/X-4, 1:1, from a vector file, name with version and date.<\/div>\n    <div>Dieline on a separate layer, as a spot colour set to overprint.<\/div>\n    <div>3 mm bleed, 5 mm safe zone from seals.<\/div>\n    <div>Design length matches the repeat (checked in the configurator).<\/div>\n    <div>Number of separations = number of colours in the order, one name per colour, white as a separate separation.<\/div>\n    <div>No RGB, text black 100 K, no accidental overprints.<\/div>\n    <div>Screen within 2-98%.<\/div>\n    <div>Lines \u2265 0.2 mm (positive) \/ 0.3-0.4 mm (reversed), text \u2265 5-6 pt \/ 7-8 pt.<\/div>\n    <div>EAN: scale, colour, direction, quiet zone.<\/div>\n    <div>Images 300 ppi CMYK, fonts outlined or included.<\/div>\n    <div>In the brief: substrate, thickness, surface or reverse print, quantity, deadline.<\/div>\n  <\/div>\n  <div class=\"cta\"><a class=\"btn sec\" href=\"https:\/\/kablonex.pl\/en\/services\/nex-print\/#preflight\">Interactive checklist with a readiness score<\/a><\/div>\n  <h2 id=\"faq\"><span>7.<\/span>Frequently asked questions<\/h2>\n  <div class=\"faq\">\n    <h3>Can I send a file from Canva or PowerPoint?<\/h3><p>Not for printing. Send it as a brief, and the production file will be prepared by your studio or our prepress (additional service, quoted with the order).<\/p>\n    <h3>How many colours do I need for a product photo on transparent film?<\/h3><p>CMYK + opaque white = 5 separations, with a brand colour 6. That is the limit of the Bonardi and the Flexa; the Miraflex gives headroom up to 10 colours.<\/p>\n    <h3>Does printing on tube limit the artwork?<\/h3><p>Yes. Registration and print width (up to 400 mm on the Flexa) are tighter than on flat web. Avoid fine reversed text and thin lines running across the fold.<\/p>\n    <h3>Will I get a proof before printing?<\/h3><p>Yes: a contract proof for CMYK, an ink drawdown for Pantone, a press proof on request. Plan it in the schedule: sample from 14 working days.<\/p>\n    <h3>What about PPWR markings on the package?<\/h3><p>The requirements of Article 12 (labelling) depend on delegated acts that are not yet finalised. Reserve space for pictograms in the safe zone and come back to the topic before printing.<\/p>\n  <\/div>\n  <div class=\"box\">\n    <h2>Have a file? We will check it within 72 h.<\/h2>\n    <p>We send back a report with a list of corrections and a preliminary match to the press, not a &#8220;file rejected&#8221;. No obligations, no price on the screen: the quotation comes back together with the report.<\/p>\n    <div class=\"cta\"><a class=\"btn\" href=\"mailto:ask@kablonex.com.pl?subject=Files%20for%20PDF%20Check%3A%20flexo%20printing\">Send files for PDF Check<\/a><a class=\"btn sec\" href=\"https:\/\/kablonex.pl\/en\/services\/nex-print\/#kontakt\">Check packaging feasibility<\/a><\/div>\n  <\/div>\n  <p class=\"fine\">Machine parameters per the NEX PRINT technical sheet (RW_2025_12_15). Threshold values (lines, text, screen, EAN) per industry practice for flexo on film; binding parameters for your order are confirmed by the NEX PRINT technologist in PDF Check.<\/p>\n<\/div>\n","protected":false},"excerpt":{"rendered":"<p>Prepress guidelines for flexographic printing on PE, PP and PET film: formats, separations, minimum lines and text, EAN codes, opaque white, repeats of 370-1350 mm. 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