Turning press rooms into precision engines

At the forefront is Miraclon, whose FLEXCEL NX Technology is helping converters squeeze better efficiency, quality, speed and sustainability benefits from every print run. With scientific precision and an eye on the future, Miraclon has been helping to transform flexo into a leaner, sharper and more reliable force on the modern flexo print production floor.

At its core, the FLEXCEL NX System is more than just a plate making solution. It’s a precision instrument that has fundamentally altered the physics of ink transfer. ‘We’ve created a system where consistency is no longer an aspiration – it’s the default,’ explains Stephen McCartney, Miraclon’s regional commercial director for EAMER. ‘When you control ink flow with the precision our multi-form surface patterns allow, you don’t just reduce waste – you make productivity scalable.’

The secret sauce, if there is one, lies in the surface patterning. While earlier iterations of the technology – from DIGICAP NX in 2010 to NX Advantage in 2016 –  made significant strides by improving ink laydown and controlling dot gain, Miraclon’s latest PureFlexo™ printing technology pushes it even further. Multi-form surface patterns are now embedded into each dot, allowing printers to calibrate ink flow with surgical accuracy. The result? Cleaner highlights, sharper text and the kind of colour fidelity that would make offset printers jealous.

‘Flexo used to have a reputation for compromise,’ Stephen reflects. ‘Now, those using FLEXCEL NX technology experience increased efficiency, quality, productivity and sustainability benefits. And we’re seeing our customers push the envelope with every job.’

This transformation was centre stage at drupa last year, where Miraclon showcased its ‘Champions of Modern Flexo’ – a series of case studies from around the globe that highlighted real-world gains. This included reports of 50% fewer press stoppages, a 33% increase in press speed, plate lifetimes doubling, 30% less ink used and a staggering 50% drop in material waste. These aren’t just incremental improvements – they’re seismic shifts in performance metrics.

Miraclon has also been laser-focused on improving upstream processes in the plate room – most recently with its multi award-winning Shine LED lamp kits. Rather than forcing converters into costly system overhauls, Shine LED offers an elegant retrofit for existing fluorescent exposure units, providing all the benefits of LED plate exposure without the capital expense.

‘Faster exposure times, no warm-up and zero degradation – LED just makes sense,’ says Stephen. ‘We’ve seen customers reduce exposure times by over 20% and eliminate the need for constant bulb changes and recalibration. It’s plug-and-play sustainability with a measurable ROI.’

By driving down set-up times, reducing ink consumption and enhancing plate life, FLEXCEL NX technology isn’t just lowering environmental impact – it’s simultaneously improving profit margins. It’s a rare example of sustainability and financial performance walking hand-in-hand.

‘Our customers aren’t interested in greenwashing,’ Stephen adds. ‘They want solutions that deliver on the bottom line while reducing their environmental footprint. FLEXCEL NX technology allows them to do both, without compromise.’

Preparing customers for the future is another area where Miraclon sets itself apart. Together with its South African channel partner, Kamboo Marketing, the company invests heavily in customer support, knowledge transfer and long-term relationships. Hardware and applications engineers aren’t just on call – they’re embedded in customer operations, helping printers adapt, scale and navigate a shifting economic landscape.