Why does flexo plate mounting in corrugated printing matter? Success starts before the press runs

By LeadEdge Flexo, 28 September 2026

What determines a successful press run?

Is it the quality of the press, the right choice of substrate, or the skill of the operators? While all are important, a successful print run relies on a series of precise processes that need to be executed long before the press starts running. That’s why proper plate mounting should be seen as the foundation of every productive print business.

When so many minds are focused on AI-powered technology, advanced automation, and sophisticated machinery, mounting is an opportunity to gain the crucial edge that makes all the difference in a highly competitive and quality-focused corrugated print market.

What does flexographic plate mounting involve?

By the time a plate reaches the production floor, all the pieces that make up the final project should already be in place. A press can make adjustments, and the advent of automation and AI means these adjustments can now be made increasingly quickly. However, even the most advanced equipment can’t compensate for a plate that has been mounted incorrectly.

In simple terms, plate mounting is the process of attaching a flexographic printing plate to the relevant cylinder, sleeve, or carrier so that it transfers the image in exactly the intended position.

In corrugated printing, where presses usually operate across much wider formats, the plate is first attached to a shim – a supporting carrier that holds it securely and accurately in position. The completed plate-and-shim assembly is then mounted onto the press so that the image transfers in exactly the intended position.

It sounds simple, but it undersells how many variables exist in the process. Depending on the system and application, the shim may work alongside mounting films, double-sided tapes, cushioning materials, registration systems, and lead and trail edge components. The plate must be aligned laterally and circumferentially, mounted squarely, and secured consistently without distortion, trapped air, or unwanted movement. Each element needs to work together, complementing the others to ensure that the printing process runs optimally.

As it sits between plate production and printing, it also represents one of the last opportunities a printer has to identify potential errors before they become a problem for the pressroom.

A connected prepress ecosystem

The fact that each element of a print run impacts the other means that minor inaccuracies at the mounting stage can quickly become a major problem. Once colour separations start to be layered together on a live print run, these seemingly insignificant variations can become all too visible – not to mention expensive.

Incorrect positioning or skew can contribute to poor registration, misaligned graphics, inconsistent edges, and colour-to-colour variation. Uneven adhesion, unsuitable mounting materials, or trapped air can affect the stability of the plate and the consistency of ink transfer. The operator may then need to spend valuable time adjusting register, pressure, or other settings in an attempt to bring the job within specification. Any defective print goes to waste, which carries a particularly high price in the current market thanks to increasing material costs and sustainability regulations.

This doesn’t mean every defect can be eliminated through proper mounting. Flexo printing is a complete ecosystem in which the plate is just one part. Inks, anilox, substrates, press settings, and operator expertise are all vital. But when mounting accuracy becomes inconsistent, an element of uncertainty is introduced into that ecosystem before the press ever starts running.

That uncertainty can result in real practical consequences that increase costs and throughput. Make-readies take a little longer, trial runs use more sheets, inks and substrates are wasted, and every changeover goes more slowly. And, even when a job runs flawlessly, inconsistent mounting makes it much harder to reproduce that success in future shifts.

Creating more productive press runs

Replacing that uncertainty with consistency and reliability is at the heart of our approach at LeadEdge. We manufacture the shims and associated mounting materials that provide a stable, accurately controlled foundation for the printing plate, using a granular production process to ensure each element performs as intended.

The MATRIX Precision mount, for example, is specifically designed for high-quality post print (HQPP) in corrugated printing applications. The mount is prepared on a bespoke digital large format cutting table, using vacuum manufacturing to add lead and trail edge strips, ensuring linear application. Meanwhile, a digital punching system is used to enhance precision when adding registration punches.

Just as a mounting solution is part of a connected workflow, so too is the production of the mount itself. And, as print businesses manage shorter runs, more frequent job changes, and demanding quality expectations, press capacity is simply too valuable to spend correcting preventable errors.

Even the best press can only work with what it’s given. High-quality printing begins long before the first impression is made – it starts with the mount.