LABELS & PACKAGING
INNOVATION ASIA
10- 2020
2020
ENTRY DEADLINE 5th NOVEMBER
From Idea to Market Read the full article on page 10
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A specialty chemicals supplier in the innovative and challenging printing industry From Idea to Market Launch of the Domino N730i digital label press Connectivity will disrupt and transform label print production Singifcantly improve machine efficiency Engineered to deliver fast growth for businesses of all sizes and markets The key to handling surges in e-commerce packaging demand: during COVID-19 and beyond Fotolito Veneta: Success through vision and innovative flexo technology “World’s First” recyclable flexible retort pouch In conversation with Patrick Masson Business Director of Koenig & Bauer Post -Press Sheetfed
The Xeikon FEU - Fusion Embellishment Unit Pioneering innovative E-Commerce solutions for Corrugated Packaging in Unprecedented Times Fully automated flexographic plate processing World first EcoLeaf metallization unit on a digital hybrid press New Sustainable packaging portfolio Gallus Labelfire with Low Migration successfully passes field test Global Flexible Plastic Packaging Market to Register Exponential Growth Effective way to make a brand’s label stand out in a crowd of labels Iconex and Martin Automatic – a 25-year partnership that’s helping to beat Covid-19 Going back to go forward! Creating better consumer product packaging News from around the world and around the region
2020
Asian Print Awards Management Pte Ltd 65 Chulia Street #46-23 OCBC Centre Singapore 049513 Chairman Paul Callaghan paul@printinnovationasia.com Conference Director Elizabeth Liew elizabeth@printinnovationasia.com Editor Sha Jumari sha@printinnovationasia.com
Chairman Judging Panel 2019 Packaging Excellence Awards Judges -Wim Swiggers - Phee Boon Eow Ben Kwok SHIFT_20 (AFTA) has 11 active Committee members for 2019/2020 For everything you need go to www.printinnovationasia.com
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A specialty chemicals s innovative and challen Printing is one of the most fascinating ‒ and also challenging ‒ of all industries. Print meets a fundamental need to convey a message to a broad audience in the chosen form, whether this is a magazine, a book, a label, packaging material or any other printed product. The printing industry, like many others, will emerge profoundly changed by the coronavirus pandemic, but this might not necessarily be all negative. It will certainly accelerate a digital transformation that was already foreseen and desired, and it will completely reinvent this industry. We at SONGWON only recently started to look at the ink market from the specialty chemicals perspective. SONGWON has long been wellknown for producing additives such as antioxidants and light stabilizers for
the plastics industry, which supplies many of the substrates that end up being printed. A few years ago, having expanded its range to the development and manufacture of specialty chemicals, SONGWON started to supply products to ink formulators and was confronted with the challenges and requirements of different types of innovation. The growth of technologies such as UV curing and digital and ink-jet printing brought significant opportunities for SONGWON products, for
example photoinitiators for both UV stabilizers and antioxidants. These products are marketed under the brand names SONGSORB® CS and SONGCURE® CS. As a newcomer to these industries, it was important for SONGWON to involve the global application team and the R&D team of chemists to ensure development of the right sets of products to meet the needs of customers and the industry. Both teams are based in Maeam, South Korea, in close proximity to SONGWON’s largest production site for antioxidants and various specialties and near to some of the largest printing markets in the world. SONGWON has a global network of sales managers and distributors as well as regional warehouses, enabling it to supply the same products everywhere in the world. In a global industrial world, this has proven to be a very important part of the whole equation. With strong expertise in light and thermal stabilization as well as in photo-curing, the SONGWON team can supply customers with the best product recommendations for their needs and formulation targets. Large
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supplier in the nging printing industry bulk and pilot production facilities allow SONGWON to respond increasingly to requests for customized products and to offer tailor-made solutions where specific limits apply to certain chemicals used in more demanding printing applications. Recently, company experts also developed a whole range of water-borne products for ink applications and successfully introduced the products in the market after an initial testing phase. These products are marketed under the brand name SONGSORB® CS WB.
weather fastness are incorporated in the final ink or adhesive formulation, this greatly helps to deliver the right messages in the printed product.
Specialties or specialty chemicals such as the products mentioned above are clearly not familiar to the consumer world, but if thermal stability and
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From Idea to Market Innovators win in this fast-moving print market. That is why equipment manufacturers (OEM) need technology and resources that speed up product development and bring products to market faster and more efficiently. The idea can start anywhere—a customer’s site, your research department, the back of a napkin. But once an OEM is ready to turn its idea into a printer, it needs to find the resources to make it successful. Most vendors provide just a printhead and leave the rest of the printer development to the OEM. But there are many variables to develop a good printer. Developing or even sourcing those components—and ensuring they successfully work together—is a big, time-consuming task. And, they must do all of this in time to successfully deliver on its business plan. Memjet takes a different approach. We have developed printing technology that has combined all the functions of a printing system into specific modules. This modular approach, along with Memjet’s engineering support, speeds up the development time for our OEM partners so they can get their printing solutions to market faster and more affordability. New Innovation Powered by Memjet In the past, customized envelope printing was a time-consuming and expensive process, requiring the printer to order and inventory different types of preprinted envelopes. Personalization was limited to what was preprinted on the envelopes. If any changes needed to be made — a likely event — the printer would need to reorder preprinted envelopes and discard the unused envelopes.
The new Powered by Memjet OPHRYS IRICOLOR inline envelope overprinter by Varioprinting changes that paradigm – giving users the flexibility to make personalized envelope printing part of the production process. Because the overprinter is integrated with the inserter machine, envelope printing now becomes part of the production process. The user inserts blank envelopes into the inserter machine. The OPHRYS IRICOLOR overprinter’s vision system applies a code that is then read by the printer manager software. Based on that code, a personalized design and/
DuraLink Printhead
or graphics are printed directly on the stuffed and sealed envelope. Once printed, the vision system checks the printout and applies production tracking. “We came up with the initial idea to develop a solution for the inserter lines to overprint envelopes after the envelopes were already stuffed and sealed,” says Zoltán Szabó, CEO of Varioprinting Kft. “We have been waiting for the digital print technology to match the speed of the inserter machines going at least 150 meters per minute. When Memjet announced its DuraLink™ technology, we were one of the first OEMs to jump on board not only because it was developed to run at 203 meters per minute and could keep pace with the fastest inserter lines on the market, but also for its ability to produce full-color, high-resolution graphics with the durability required for today’s direct mail. Memjet’s modular design made it very easy to integrate the whole system together.”
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DIGITAL PRINTING TECHNOLOGY THAT POWERS THE WAY WE PRINT TODAY.
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application,” says Szabó. “Like in our case, the high speed and high-quality combination was the key to open the door in the mailing industry to an develop an application like ours.”
DuraLink Maintenance Module
Memjet’s DuraLink technology was developed to meet the needs of printers in high-volume print markets. The technology features a new longlife printhead as well as aqueousbased, durable pigment inks and a range of versatile modules. Together, these features enable fast and costeffective development of solutions for commercial, packaging and industrial printing solutions.
“I believe we are providing a key tool for the mailing industry to completely replace offset with inkjet technology and gain numerous efficiencies” says Szabó. 100% Inkjet Production Today, marketers demand highly personalized printed direct mail that can cut through the noise and capture the attention of a distracted consumer. Varioprinting selected Memjet’s DuraLink technology for its OPHRYS IRICOLOR envelope overprinter to give print providers a fast, costeffective way to print high-quality customized envelopes that meet this marketing trend. “Our customers are requiring more and more envelopes with variable data. They don’t want to deal with monitoring and stocking envelopes. Instead, they simply want to upload data files,” says Gergely Molnár, the CEO of EPDB Zrt., a subsidiary of the Hungarian Post and largest mailing company in Central Europe. “We produce 200 million letters per year. Previously, we produced this volume with seven envelope inserter machines. Now with our added OPHRYS IRICOLOR in-line envelope overprinters, it is sufficient to operate only five inserter machines each day. We
also reduced our warehouse volume by 60% due to our new print on-demand capabilities.”
By choosing DuraLink, OEM partners like VarioPrinting ensure their presses can produce full-color CYMK in offsetlike quality and a maximum resolution of 1600 dpi at speeds up to 203 meters per minute.
“I believe we are the first mailer company in the world with 100% inkjet envelope production,” proclaims Molnár.
Like the envelope overprinter from VarioPrinting, these solutions have the potential to bring new opportunities to print service providers – and to the industry as a whole.
The Power of DuraLink/Memjet -- Conclusion – Moving the Market Forward “When developing a new printer, it is essential that the printing technology meets the key requirements of the
Meeting today’s market needs requires OEMs to take an innovative approach; they need to develop new solutions and they need to do it quickly -- that's why Memjet technology is so important right now.
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Launch of the Domino N730i digital label press Domino Printing Sciences globally announced the launch of the Domino N730i digital label press via a live virtual broadcast earlier today. This is a ground-up development and the first to use its new Domino Generation 7 ink jet platform. Philip Easton, Director of the Domino Digital Printing Solutions division commented “This is the most significant new product we have launched since we started in the digital label press business. It has been a huge collaborative team effort, spread over five years, involving our colleagues at Brother Industries, supplier partners, our development team and our existing customers. Today, we are so proud of what the N730i delivers, as we truly believe it is setting new standards in high performance ink jet label printing.” The N730i incorporates a host of brand new features including the revolutionary Brother BITSTARTM 1200dpi piezo print head, the SunLight graphical user interface, and the latest automated Domino i-Tech intelligent Technology features i-Tech SetAlign and i-Tech CleanCap2. Louise Adcock, Global Product Manager at Domino Digital Printing Solutions highlights, “We have almost
1,000 global installations already using our existing Generation 6 ink jet platform. During the development of the N730i, we really listened to our customers, so we are confident that this press will enable label converters to get the best return from their digital printing investment. Based on customer feedback, we focused on three key areas: providing consistent print quality at high speed, ease of use and flexibility.” Unlike other systems where higher printing speed is at the cost of reduced print quality or reliability, the N730i is designed to print all jobs, including those with ‘silk-screen-like’ white at 70m (230ft)/min, but still with the same consistent high print quality. The Brother BITSTARTM 1200dpi print head uses a combination of the smallest drop sizes of 2.1pl and nominal drop sizes of 2.8pl and 3.3pl to provide consistent ink density across the image, with sharper edges and smoother gradients. Patented
triple-layer polycrystalline micro piezo technology minimises cross talk and delivers precise nozzle control for optimum drop placement accuracy. Domino’s unique intelligent Technology or i-Tech features represent developments designed to measurably improve efficiency, use, function and reliability. i-Tech SetAlign is a new automated system that sets density and accurately aligns the print heads. The result is uniform and seamless print quality across the full web width. Domino has also enhanced performance with i-Tech CleanCap2, an automated print head cleaning and capping system, which is a controlled process reducing manual operator intervention and waste. Other i-Tech features include the established i-Tech ActiFlow, UltraMix, and WebRev. Louise continues, “In basic terms, our customers win business against their competitors on the labels they can produce, they make a profit from delivering them efficiently. The N730i’s
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consistent high print quality will mean they will win more business, while high speed combined with reliability means they can also print it efficiently.”
up and reporting. This also means upward integration with the leading management information systems can be readily achieved.
The existing user interface has been completely rewritten for the N730i with the development of the new Domino SunLight. This flexible graphical user interface with its modern look and feel is completely intuitive and highly configurable. A new enhanced version of the industry standard ESKO Digital Front End has been adopted, including improved variable data printing performance, and producing process colours including orange and violet, for lower ink usage and an increased colour gamut. Support for the industry standard JDF/JMF data transfer format allows for automated job set-
Offering label printers maximum flexibility, the N730i is available with optional flexo stations for priming to facilitate consistent quality even on the most challenging media types, and for spot colours or varnishing, increasing the range of jobs that can be achieved, or for reverse white for cost-effective shrink sleeve applications. These flexo stations can be retrofitted, providing our customers with greater flexibility as their business needs change. The N730i includes Domino’s own inhouse developed UV90 ink set with excellent fade resistance, achieving a
maximum Blue Wool Scale of eight on certain substrates. It has excellent mechanical properties including abrasion and scratch resistance. The UV90 white ink is commonly used by customers as a silk-screen replacement achieving an opacity of up to 76%. The Textures by Domino printing capability enables tactile three-dimensional label design effects to be created for greater shelf appeal. Domino has an established global reputation for providing proven and reliable digital printing solutions, but is equally renowned for its unrivalled customer service and support. So, there is a complete range of services to support the N730i. These include flexible in-house leasing options and the Domino Digital Solutions Programme, which offers advanced operator training, sales training, production efficiency enhancement and job costing, as well as tailored consultancy services. In addition, there is a range of SafeGuard maintenance products based on a monthly subscription, whereby skilled Domino technicians take responsibility for all maintenance, replacement parts and full breakdown cover. Philip concludes, “When we introduced our N600i and then the N610i digital label presses, our focus was to be as good as flexo. With the N730i, we believe we are offering a quality of output that sets a new high performance ink jet standard, and perhaps now flexo needs to start catching up!”
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Connectivity will disru label print production Every F1 team has this dedicated operations room filled with monitors where the entire behaviour of their race cars is tracked. They know everything about their cars, as a huge amount of information is measured with sensors placed throughout every F1 car. Data is measured and processed about the engine, wheels, tires, and factors such as brake temperatures and wear, tire pressures, G-Forces, and vibration. Information from this data is not only used to win the current race, but is also analyzed and used to improve the cars and win future races. Switching gears to the world of label printing Let’s start with the printing press. It’s a machine that can cost between EUR 300,000 and EUR 3million. And the information we get from this machine is typically basic: speed, mechanical or electrical errors, sometimes pressure information (anilox vs. plate and impress roller vs plate cylinder) plus registration information. You don’t really get information as to how the machine peforms such as how long it takes to set up the unwinder, waste, uptime, downtime, and speed over a day or week.
Of course, you can ask your operators to type or scan actions they have done. But this is certainly not real-time, nor hundreds of measurements per minute, and probably not that accurate. Big expensive black box Many print companies use workflow automation systems like CERM, Label Traxx or HYBRID Software. These systems do a great job focusing on job data and prepress information. But they can’t look inside and know what’s happening with the press - only what’s going on around it. So basically, we’re dealing with a big expensive black box. This is quite strange if you think about it, because this possibly milliondollar machine is paying your salaries. Shouldn’t you know everything about the press and ensure it runs as efficiently as possible? If you look at other industries, many
are much further ahead than the label printing industry. Consider automobiles, especially the F1 but normal passenger cars too – think about the development of self-driving cars and trucks. The airline industry – a plane can automatically ascend and descend without any pilot interference . Why it’s important to know how your press is performing These high cost label printing machines are for a large part of the day not running. In fact, from what we’ve seen, many printers aren’t running their machines 70% of the time. This is a significant amount of downtime. Obviously, to earn back your machine investment, you must run it as much as possible to maximize the uptime. Another point is your machine might
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upt and transform
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By Tim Klappe Managing Director MPS Asia/Pacific Improvements that can be made are not just a minute here and there. On the contrary: savings are up to hours per day. That is incredibly good news, as these hours can be used instead to print labels and earn extra profit! Make your printing press on par with the F1 car By placing hundreds of sensors in the press, continuous streaming data can be collected and analysed to understand bottlenecks, benchmark, and to continuously improve the press performance.
be running, but you don’t know how efficiently. For example, you don’t know exactly how long it took to set up the unwinder, how long it took to get into registration and the way the registration button was pressed to get into registration. Actually, you have very little idea at all how the machine is run. You might have some basic input done manually by the operator. Certainly no actual, streaming, continuous, dynamic data. This is interesting, as companies are very particular during the selection of their new press. Which press gives the fastest set up time and lowest waste? But after installation of that fancy press, they can’t really determine how efficiently the machine is being run.
What we discovered is the biggest gain in efficiency can be generated by analysing how the machine is operated to reduce bottlenecks and weak points.
We call this press mirroring: essentially creating a digital twin, together with performance reporting. With the ability to analyze streaming data, you can get real-time insights to
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18 understand exactly what’s happening at any given point in time with your press, in great detail. Not just the 10 to 20 scans that the operators are making during the run of the job at their own pace. Having a digital twin with streaming dynamic data enables better decisionmaking as it gives you exact details to improve the overall print operation. Real-time information at your fingertips Analytics from streaming data is accessible in real-time, online on a dashboard. You can access this important information from anywhere you are in the world, provided you have internet access. More detailed analysis can also be made by zooming in on specific details. This is particularly important. For example, you don’t have to wait to receive reports by email. Reports are available online and can be accessed, reviewed, and re-reviewed at any time. With analytics from streaming data, you’re more agile and responsive to the realities of what’s happening in your label print operation. Streaming analytics allows you to be proactive with real-time processing and decision making instead of being reactive.
You’ll be faster than your competitor who does not use this valuable resource and you’ll gain a lot of extra capacity due to the continuous implementation of best practices, reductions of errors and downtimes. All at a much earlier stage. The type of reports can be of performance of one machine, comparing different machines at one company, or benchmarking with industry leaders. You can group performance such as: Best in Class, Better than Average, and Less than Average.
• Identifying bottlenecks, gaps, worst and best practices • Decisions on productivity improvements based on Accurate data. All of this leads to higher productivity and profit! And it will be a continuous process. Operations management will now have a super powerful tool to increase uptime and efficiency of production. As a result, net capacity will increase to run more jobs and generate more income.
With average users, you can discuss what they must do in order to move to the best in class. Is it feasible? Is more training needed?
The time is now This technology is not future music. It’s all available today. The sensor technology – the IoT or so called Fourth Industrial Revolution – is a real revolution.
The whole purpose of this exercise is to identify areas of improvements and subsequently a to do list to make improvements.
At MPS, all our new presses are equipped with a server. We can collect data from all machines delivered since the beginning of this year (2020).
What are the benefits of press mirroring and performance reporting?
The technology gives you information and knowledge about your operation. We can even give you reports about what we - with a team of experts think and should happen to improve your operation.
In a nutshell, they are: • Continuous, real-time transparency in production • Benchmarking with industry leaders
However, this technology, analytics,
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SPEED UP YOUR PROCESSES with optical systems for UV curing and drying
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20 will integrate these streaming analytics to move from a reactive to a more proactive approach for achieving operations excellence. The added value is in the possibilities offered by the data. The knowledge it gives you about weak and strong points in your production enables you to take the right actions for continuous improvements: to lower your cost of operation, increase your capacity, and increase your profits.
and performance reports alone will not bring success. You must have the willingness to analyze and interpret the data, and implement actions for improvements. MPS works closely with partners for connectivity such as UV, anilox roller, and inking systems suppliers. Technically, interconnectivity is possible with all parties. This development won’t stop: it will only grow faster, especially with 5G being implemented soon which will enable even quicker data transfers.
Are you ready for your F1 Mission Control room? It’s important for every label printer to understand these developments in connectivity. What’s press mirroring? How can performance reporting help me? What investments should I make to implement this technology? Does it already fit my organization, or do I need to first change processes?
One thing is certain: connectivity will disrupt and transform label print production. It’s wise to make small steps in implementing these technologies and have processes in your organization for continuous improvements. Questions about connectivity and how we can help you get started? Get in touch. t.klappe@mps4u.com
Real-time production performance data can be used to give management an immediate perspective on how business is developing. Successful companies
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Seeking optimal printing results in corrugated postprint A cooperation of industrial partners in the development and launch of the nyloflex® FTL Digital. Smurfit Kappa was founded in 2005 and is currently the leading supplier in the production of corrugated packaging, containerboard and ‘bag in box’ in Europe. Smurfit Kappa has 350 production sites worldwide, 21 subsidiaries in Europe and 12 in America, making Smurfit Kappa the leader in its industry. The Chespa Group was founded as a family business in 1991 in Krapkowice, Poland. After almost 30 years of activity as a specialist in prepress services and printing support, the company established itself internationally in the flexible packaging and corrugated board sector. Worldwide Chespa employs approximately 600 people at more than 11 locations in 6 European countries as well as other production facilities and agencies in South America, Asia and Africa. Their focus is on the preparation and processing of graphic repro as well as the production and distribution of auxiliary and process materials for the packaging industry. The company is the only European supplier to produce flexographic printing plates, cutting tools and printing inks (flexographic, offset, gravure, digital printing) from a single source. Over 15 years Chespa has been an indispensable partner of Flint Group in the distribution of nyloflex® printing plates in Germany, Austria and Eastern Europe. Development of products together with industry partners The quality requirements in corrugated postprint has always been a great challenge, especially when it comes to poorer quality (or lower cost) board grades. Not only half-tone images but good solid ink transfer is an important quality criteria, where an even ink
laydown is an important quality criteria. The main influencing factors are the quality of the liner, the type of flute and the relief geometry on the flexographic printing plate. Flint Group always aims to develop new products as closely as possible to the market needs and in cooperation with industry partners, in order to address customer demands in a targeted manner and work out a solution together. During the development of the nyloflex® FTL Digital, Flint Group found two very qualified and committed companies in Chespa (reproduction and
through extensive testing under production conditions. For Flint Group it was important to test the printing plate in a real production environment to ensure that the development was as close to the markets needs as technically printing plate production at the Leipzig site) and Smurfit Kappa (printing at the Lübbecke site) for the evaluation of the nyloflex® FTL, which accompanied the test phase of the product development up to the market launch. Real test conditions for repetitiveness and quality of the printing result Chespa and Smurfit Kappa were ideal partners in the product development of nyloflex® FTL and made valuable contributions to the product launch
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possible and to validate the product performance in the development phase. The test series were printed at Smurfit Kappa's Lübbecke site, which offered suitable conditions for the application fields of the nyloflex® FTL. The test panels printed at Smurfit Kappa were all produced at Chespa Leipzig, where the data preparation was also handled. First test forms were printed to evaluate the limits of the printing plate. Production jobs were then implemented in order to test not only the good printing performance of the first tests but also the quality over the entire print run with several jobs and designs. " The most important challenges in meeting our customers' needs are the repeatability and quality of the print result", explains Lutz Klemm, Managing Director at Chespa. nyloflex® FTL Digital is an inherent flat top dot printing plate for corrugated postprint as well as for paper and board applications in combination with water-based inks. Amongst others, it is suitable for printing on sustainable substrates with a higher proportion of recycled fibers. The result is a significant reduction in fluting The nyloflex® FTL has inspired and
convinced Smurfit Kappa from the first print. The potential of this printing plate was already apparent during the first print runs. Thanks to better ink transfer and improved ink laydown, Smurfit Kappa was able to improve the print quality, especially in the solid coverage. The ability to reduce the impression setting minimises the fluting effect and thus achieves excellent printing results on uncoated testliner or kraftliner in combination with B-flute. Less deformation of the corrugated board makes it easier for the printer to meet the specified crush tolerances of the end customer in order to
guarantee optimum packaging stability. Alternatively, it is possible to use printing substrates with lower grammages to save packaging material. "With Flint Group we have a qualified and innovative partner for printing plates on our side. Both the Flint Group and the Chespa Group thrive on close exchange, cooperation and the great trust of their customers. Our central task is to develop ourselves further, to push ahead with innovations and the latest production technologies and to offer customized products and services tailored to the customer's specific requirements," says Mr. Klemm.
“Quality is never an accident. It is always the result of intelligent effort.” John Ruskin
Martin intentionally designs each piece of equipment so that it is easy to use, easy to understand, and easy to maintain. We do the hard work so that you don’t have to.
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Singifcantly improve machine efficiency With modern retrofit solutions from W&H, older machines can be brought back up to the level of new machines. And new machines can also become even better: Innovative automation modules simplify work processes and increase plant efficiency. Completely new potential in particular offers the innovative IoT system RUBY, which uses machine data to improve packaging production. At W&H, around 50 employees are responsible for retrofit solutions for extrusion, printing and converting machines and provide customerspecific advice. In 2019 alone, more than 600 machines were modernized at customers around the world. Efficiently functioning plants are a major factor for productivity in industry. Older machines often no longer meet the technical requirements necessary for efficient production. In order to keep up with technical progress, machines must therefore be modernized. The purchase of a new machine is not always the best solution. The more
cost-effective alternative are retrofits. “A retrofit solution can be a retrofit to replace discontinued - i.e. no longer available - machine parts, such as a host computer. In addition, the functions of a machine can be expanded. There are various retrofit solutions for our different business areas to increase efficiency and productivity,” explains Thorsten Uebbing, Product Manager Retrofits in Service. New IOT System Ruby can retrofit even older machines A classic example of a retrofit solution
from the printing sector is the addition of an inline printing unit to a flexographic printing press, which among other things, can apply additional varnish to the printing webs. In the extrusion area, the productivity of a blown film line is increased many times over by using a modern high-performance cooling ring . Generally the addition of automation to the machine portfolio contributes to the increase in efficiency. In the converting area, for example, the “Easy Stop” add-on for tubers can save up to 2 minutes per reel change. “Completely new potentials for retrofitting machines are opened up with our new RUBY , with which we make data from our machines usable for monitoring, automation and improvement of packaging production. Even old machines can be retrofitted with RUBY”, Uebbing continues. In 2019 more than 600 machines were retrofitted The Retrofit Service at Windmöller & Hölscher has been in existence since 2002. Up to 50 employees are processing an average of 500 orders per year: “We prepare an individual offer for each customer based on their requirements - starting with the 1:1 replacement of an obsolete machine part and ending with overall concepts,” says Reinhard Kipp, Head of Service Construction & Retrofit. Retrofitting a machine can be done at very short notice within a few days, or can be planned over a long period of time, depending on the complexity of the order.
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Engineered to deliver fast growth for businesses of all sizes and markets Scodix has announced the commercial launch of the next generation of its Ultra Digital Enhancement Press Series, consisting of six presses, each targeted to a specific market segment.
Having demonstrated its expertise in equipment for the commercial, packaging and W2P markets, Scodix has developed the Ultra Press Series to fully address the needs of each sector. Scodix CEO, Eli Grinberg, elaborates:
of companies such as Shutterfly and District Photo in mind, the Ultra 3000 focusses on Web2Print, whilst the Ultra 4000, allowing larger format substrates and pallet feeders and stackers, is aimed at Web2Pack printers.
“As the world’s most innovative and experienced company in digital print enhancement, with over 400 presses installed around the world, we’re now launching one expanded product line that’s been designed to meet the needs of all of our customers across all of these industry sectors. Whatever the application, enhancement, or budget requirement, we have a solution within this series. Print service providers can choose the press that will best support the future growth of their business.”
Commercial & Speciality Offering the same print areas and range of substrates, the Scodix Ultra 1000 and 2000 presses are distinguished by the number of applications available – and consequently are offered to the market at different price points. The Ultra 1000 delivers accessible digital enhancement whilst the Ultra 2000 offers all Scodix applications on one platform, including automatic polymer switching for superior productivity.
Web-2-Print Aimed at the W2P market, the Scodix Ultra 3000 and Ultra 4000 presses both incorporate Scodix Studio W2P software. Developed with the success
Packaging
The Scodix Ultra 5000 and 6000 both allow the thicker substrates required for packaging applications – up to 2mm – and incorporate industrial pallet feeders
and stackers. Whilst the Ultra 6000 offers a larger format, it comes with a simplified range of enhancements. The six new presses in the series succeed the Ultra 101 and 202, whilst the Scodix E106 press is still available for B1 folding carton applications. Grinberg adds, “By incorporating digital enhancement, print providers can expand their service offerings with attention-grabbing applications, improving customer retention rates in these notoriously fickle times, whilst boosting margins and ultimately profitability. Whether the products are purchased traditional or through Web2Pack or Print channels, Scodix enhances products from premium business and greeting cards, folders, head-turning book covers, audienceengaging brochures to stand-out labels and packaging, folding cartons, rigid boxes, point-of-display and security markings always with a focus on fine detail and high quality results. “By launching this segmented product portfolio, we are increasing the number of customers that can employ Scodix, and we are offering Scodix value to more brands, print buyers and consumers of print. This is truly the next era for the Scodix business.”
We print your world
We combine inks and substrates, so that ingredients become an experience. Because printing is our world. Contact your agent to learn more. Koenig & Bauer (SEA) Sdn Bhd +603 7885 8860 digitalsalescenter@koenig-bauer.com
koenig-bauer.com
The key to handling surges in demand: during COVID-19 and
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E-commerce was already a booming market before COVID19, hitting sales of over 3.5 trillion US dollars in 2019 and projected to reach 6.5 trillion US dollars by 2022.1 But since the pandemic hit, online spending has increased even further. There has been a 20% surge in sales worldwide2 and in some countries, the figure is even higher. For example, in the US, online sales of consumer packaged goods (CPG) grew 56% for the one week ending April 18th, compared to the same period a year earlier3. It’s a pattern being replicated in countries all over the world. A lot of this is a surge in demand for the essentials – food, drink, household cleaning products, pharmaceuticals – for living at home during the pandemic. But non-essential items including household goods, clothing, toys and games have all seen major boosts in online sales as people try to make the best of their new lives in lockdown. Interestingly, there has been a 40% increase in the number of unique online buyers in the first quarter of the pandemic, showing that people
FFG 8.20 EXPERTLINE
are adapting2. Many of the changes in consumer behaviors will likely persist after the pandemic has ended. The corrugated sector needs to keep pace The majority of packaging for e-commerce products is corrugated board. This sector is set to expand at a rapid CAGR of 14.3% through to 2022, compared to a CAGR of 2.9 for packaging overall.4 However, the impact for packaging manufacturers has been mixed, depending on their customer portfolio. While those supplying groceries and at-home entertainment industries will have seen a tremendous surge in demand, those supplying industries whose demand has plummeted – foodservice packaging for restaurants for example – may have seen a decline. What’s certain is that such unpredictability is hard to plan for. Unexpected surges in demand can be very challenging to deal with,
particularly during the pandemic, given the impact that lockdown and social distancing restrictions have had on staffing. “In the new normality we find ourselves in, manufacturers know they must prepare for such surges and unexpected circumstances,” said David Arnaud, Product Marketing Director, BOBST Lyon. “The days of slow, predictable growth are gone. These are disruptive times – even before the global pandemic, technology had disrupted retail and manufacturing on a global scale. Unpredictability is an element of modern day business planning.” BOBST: enhanced automation to keep you one step ahead Although nobody could have predicted the pandemic, BOBST had already been leading a necessary transformation in the industry to ensure it is prepared for a rapidly-changing world. BOBST has built this transformation around four main pillars: connectivity, digitalization, automation and sustainability. Right now, these
e-commerce packaging d beyond
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Author: Alexandre Pauchard, Head of Group R&D
values – particularly automation and connectivity – are more essential than ever. “At BOBST, we develop highly automated machines, which operate as part of a highly connected system,” said David. “Short setup times and high speeds mean that high volume orders can be met. Fully automated lines and integrated quality control systems mean that fewer operators are needed, and social distancing regulations can be adhered to without impacting production.” In the corrugated sector, two BOBST products exemplify this perfectly – the FFG 8.20 EXPERTLINE and MASTERFOLD 230. Both machines are equipped to help manufacturers thrive through the current situation and beyond. The FFG 8.20 EXPERTLINE is a highly automated complete line, which can process up to 24,000 boxes an hour, with an incredible set up or change time of only one to two minutes. This is possible because it is so highly automated, with non-stop feeding at rated speed and smooth and ultra-quick order changeover. Prefeeding is automatic without operator intervention, as is the introduction of the first sheets of each order. The machine uses Sequential Order Change (SOC) to achieve these ultra-quick set-up times. Each part of the line begins its set-up of the next job while sheets from the previous order are still clearing its downstream units. With this advanced level of automation, fewer operators – only two – are needed. They benefit from an extremely user-friendly interface, with an intuitive HMI (human machine interface) allowing full control of the
machine through box visualization. The user-friendliness of the line allows for a very fast learning curve for new operators, in case of mobility is needed between production lines. Folding is all fully automated and crucially, the reliability and quality of the boxes are extremely consistent. But the key aspect of EXPERTLINE for e-commerce packaging is its extraordinary productivity. This enabled Mitchel-Lincoln Packaging Ltd in Quebec, Canada, to break the record for producing corrugated boxes. In a single eight-hour shift, the company produced 162,136 printed, folded and glued boxes. “If I had to pick a phrase to describe this machine, it would be total productivity,” said company president Jimmy Garfinkle. “It has provided the capabilities we were looking for, including the quick-changeover and ‘set while run’ capabilities. Not only did we replace an aging machine with the new capabilities, but we more than doubled
our productivity on that line and the efficiency turn has been great!” On top of this exceptional productivity, the line is able to produce multiple high boxes to reduce environmental impact and costs for e-commerce through optimization of the shipping volume, of which 40% is currently air. The world’s best folder-gluer? Meanwhile, MASTERFOLD 230 from BOBST is the workhorse of corrugated box production for many companies and arguably the world’s best foldergluer. With fast running speeds, fully automatic setting, several uprated systems, and high configurability, MASTERFOLD is the most highly automated and versatile folder-gluer available today. With its modular design, single box set-up and superb reliability, MASTERFOLD is built to last and it’s perfectly placed to meet not only current production needs, but
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MASTERFOLD 230
also any future changes in business and markets. Fast make-readies give the responsiveness needed on short runs, while features such as anti-jam technology and video monitoring mean that on longer runs, users can make the most of its amazing speed. What’s more, it now has a dedicated configuration specifically for e-commerce, arguably making it the reference machine for e-commerce box production, able to produce complex, multipurpose boxes faster and more efficiently than ever before – in one go. “To help get that extra edge over competitors, MASTERFOLD can be also augmented by a range of BOBST complementary devices that let companies make the most of its huge productivity,” said Pierre Binggeli, Product Marketing Director FolderGluers at BOBST. “These exceptional devices – which have been especially developed for e-commerce business – will drive the creativity, productivity and efficiency of the MASTERFOLD lines and turn boxes into added value and profit.” The EXTENDED FEEDER provides the smoothest start possible for the feeding of extra-long boxes. It features a timed feeder and motorized feeding assistance, ensuring the regular and precise feeding of large boxes. POLYVACUUM XL is a module for inline application of strips, self-adhesive tapes and special folding devices. It features lower vacuum transports for perfect stability of the blanks and bespoke upper transports, allowing the installation of external applicator devices.
GYROBOX XL meanwhile enables blank rotation from 0°up to 180° in any direction. It is associated with outstanding quality and high-speed production of complex designs, such as double folded boxes, in a single pass. ACCUEJECT XL enables automatic ejection of boxes that do not conform to the defined standard, ensuring zero fault packaging and complete customer satisfaction. Importantly, it does this without slowing down the production process. In a market where competitiveness is key, these add-ons will provide a decisive advantage. Preparing for uncertainty Meanwhile, to ensure business continuity in a period when sending Field Service Technicians to fix problems is not viable, we are still providing remote assistance through BOBST Helpline Plus and Premium services for all our machines. BOBST technicians use a secure internet connection to directly access the
machine, and solve 80% of electrical problems remotely. And with Helpline Plus AR, you can also use a Smart Headset to connect immediately with a BOBST expert through video live streaming. Your Smart Headset uses augmented reality (AR) to enable the BOBST technician to see exactly what you see, troubleshoot the problem and guide you through the solution steps in real time. “Recent events have taught us that it is impossible to predict the future,” said David. “However, it is possible to prepare for uncertainty. For packaging manufacturers, that means being ready for surges in demand as they rise, particularly online. For those that work in the corrugated sector, this means taking some uncertainties out of the equation, by utilizing greater automation, connectivity, flexibility and quality control in production lines to reduce risk, and ensure that challenges become opportunities.”
DIGITAL PRINTING SOLUTIONS LIKE NO OTHER Ready for the next turn. Just like you. As truly direct and dedicated printing technology specialists, we believe you should deal with your challenges in your very own way. That is why we offer a wider range of digital technologies for a wide range of applications. From wine labels to wall decoration; from toner to inkjet – how can we help you to make your business ready for the next turn? www.xeikon.com
Direct. Dedicated. Digital.
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Fotolito Veneta: Success through vision and innovative flexo technology Since it was founded in 1969 in Verona by Giulio Storace, through a combination of vision and innovation, Fotolito Veneta has grown to become one of the leading packaging businesses in Italy – though it counts Europe as its domestic market and is able to guarantee next day delivery of its flexo plates to countries such as Britain, Poland, Greece and Spain.
pandemic, the business experienced a surplus in orders during what was a challenging period for most Italian companies in lockdown. He says: “We were aided by the fact that some of our clients happened to be launching new products when the lockdown came into effect, and as such, new packaging designs were required, which put both our productivity and our creativity to the test.” During this time, Fotolito Veneta dealt with longer than usual print runs of up to 500,000 metres, as well as shorter ones requiring very short make-ready times, for which the company relied on automated workflows and digital colour-proofing to help cope with the volume of work.
Initially specialising in the provision of high-quality, offset pre-press services to the book and magazine publishing industry, Storace later foresaw the growth opportunity packaging would offer, embraced flexo technology and refocused the company’s attention on offering the full range of packaging pre-press services. Andrea Storace, Packaging Sales Manager at Fotolito Veneta sums up the impact that flexo has had on the
family business with this fact: “In 2010, flexo only represented 30% of our turnover – today it’s 100%.” Food packaging in particular accounts for 60% of Fotolito Veneta’s business and the company includes a number of the industry’s brands among its clients, including Bofrost, Dal Colle and Le Mantovanelle. Andrea goes on to elaborate that, due to the recent heightened requirement for food packaging during the COVID-19
No flexibility without flexo Miraclon’s flexo plate technology has played a pivotal role in Fotolito Veneta’s journey to becoming a major player in the flexo print sector. After acquiring a KODAK Thermoflex in 2000, the company made the decision in 2014 to incorporate Kodak’s integrated solution, the FLEXCEL NX System, into its production environment. By investing in the FLEXCEL NX imaging equipment, Fotolito Veneta would be able to produce a wide variety of finished FLEXCEL NX plates for individual print jobs.
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COMING SOON!
A new approach to business in the Print/Packaging/Textile industry The world changed forever in 2020, and the industry must evolve with new ways to get the job done. Industry Online Network will give you the tools to stay informed, reach your market and thrive in a changed business. Pre-register below and as we get closer, we will update you when we launch. Industry Online Network — The key to your future success.
www.industryonlinenetwork.com
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36 “With flexo print, there is no standardisation – every company is different and has different requirements,” explains Andrea. “As such, we need to be able to change our mind-set and adapt to each and every new customer. This degree of flexibility would not be possible without FLEXCEL NX technology.” The FLEXCEL NX imaging equipment and plates are designed to work together to enable optimum print performance. As a result, Fotolito Veneta is able to adapt its plates to numerous flexo printing systems to suit a variety of specifications. “Whether our customers need to print on film or paper, or use solvent inks or water-based inks, we are able to meet their requirements. It’s highly personalised approach to business and one that is greatly appreciated by our customers,” says Andrea. He is also keen to highlight a common issue that Miraclon’s system is able to address: “The FLEXCEL NX System’s flat-top dot structure solves a problem inherent with traditional digital flexo
platemaking technology, where oxygen inhibition during UV exposure results in bullet-shaped dots that are prone to surface wear and result in unpredictable inking and printing. The FLEXCEL NX System’s unique technology eliminates all oxygen during UV exposure to produce full amplitude, flat-top dots with sturdy bases and strong shoulders across the entire tonal range. The result is a printing form that is consistent, repeatable and resistant to changes in impression and wear from substrate or cleaning.” Andrea and his team have been so impressed with the results yielded by the FLEXCEL NX’s capabilities that they have expanded their capacity by investing in the technology’s largest format the KODAK FLEXCEL NX Wide 5080 System, with an installation scheduled for autumn 2020. With an increasing need to produce bigger plates for Fotolito Veneta’s customers, the 5080 system offer large format production, efficient plate layouts, operator-friendly functionality, and significantly improved imaging speed.
The need for speed As is the case across most industries, customer demands surrounding turnaround times have evolved in flexo packaging, with next day delivery becoming a common expectation. The challenge is to ensure that quality standards are maintained despite this expectation.
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37 “This will be a major future-proofing exercise,” explains Andrea. “If we want to be faster, we need to make the right investment. Our goal is to produce double the plates that we produce now, as well as to be able to run bigger plates at higher speeds.” Ongoing innovation As a previous Global Flexo Innovation Award winner, Fotolito Veneta has always placed significant importance on investing in the advancement of its flexo technology offering. Therefore, the lockdown that was imposed in Italy as the result of the coronavirus pandemic presented an opportunity for the Storace family to drive innovation. “No matter how many orders we get and how many thousands of metres we print, the quality of the final product needs to remain consistently the same throughout,” acknowledges Andrea. As such, Fotolito Veneta is in the process of launching a new, bigger production line by the end of the year, and one in which FLEXCEL NX technology will have a key role to play.
During this time, Andrea and his brother Alfredo, Production Manager at Fotolito Veneta, spearheaded the development of a stochastic screening solution enabled by the one-to-one image to plate reproduction capability of the FLEXCEL NX System. The solution has been trademarked as ‘Diamante’, the Italian word for ‘diamond’.
For the uninitiated, stochastic screening is a type of digital halftone screening which varies the pattern of dots while keeping the size of the dots constant. It is particularly suitable for colour printing intricate images that involve complex textures, repeating backgrounds, and other geometric shapes that tend to cause interference or moiré problems when printed using conventional screens. “This is what market is now demanding from flexo,” says Andrea. “We are true believers in its benefits and advantages, but some jobs are difficult to pull off even for flexo. With this new solution, printers will be able to print to a larger gamut scale and in high definition. We’ve already run some on-site trials with a selection of customers, who have witnessed first-hand the results of this innovative technology. We believe that with Diamante we’ll be able to bridge the gap between flexo and rotogravure print.”
color your process
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“World’s First” recyclable flexible retort pouch Amcor has partnered with Nestlé to launch what the companies are describing as the world’s first recyclable flexible retort pouch. The new high barrier pouch, using Amcor’s AmLite HeatFlex Recyclable solution, will be available in-store from October 2020.
Amcor and Nestlé joined forces to overcome what they identify as one of the largest challenges facing the industry – the inability to recycle retort flexible packaging.
The companies collaborated during the product development process to test for heat resistance, machine performance, shelf-life, and recyclability in the real world.
The challenge with standard retort pouches is that they are made of mixed materials, typically layers of PET, aluminium foil, and polypropylene (PP). While it is high performing, Amcor reports that this mixed-material structure is not recyclable anywhere in the world today.
“Amcor and Nestlé together have been able to create a unique solution that for years was thought impossible,” says Michael Zacka, president of Amcor Flexibles EMEA, “This high-barrier, high-heat resistant packaging can be easily recycled within plastic recycling streams already existing in several European countries.”
The new solution, which has been independently confirmed as recyclable by cyclos-HTP, is a polypropylene (PP) pouch, that uses an ultra-thin AmLite transparent barrier coating for product protection.
Flexible retort packaging is being marketed as a modern alternative to metal cans, and the companies say that it can improve the carbon footprint of hundreds of consumer products
thanks to its light weight, resource efficiency, ease of transportation, and by minimizing food waste. According to Amcor, adding recyclability to its list of properties will improve the environmental footprint of this packaging solution by up to a further 60%. The new pouch also meets the packaging guidelines for a circular economy recently published by the CEFLEX Consortium. Project coordinator and workstream consultant for CEFLEX, Graham Houlder, says: “This is a great example of how – through innovation – companies can solve even the biggest challenges to recyclability. Recyclable retort packaging is a revolutionary advance and will have a huge impact on pet food and beyond.”
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In conversation with Patric
Business Director of Koenig & Bauer Post -
Patrick Masson has more than 35 years of experience in the paper and paperboard industry, starting at Dow Chemical as a Sales Manager of emulsions for paper and board coating technology. After nine years at Dow he joined a European supplier of diecutters, foldergluers and printing machines to the packaging industry. He has been with Koenig & Bauer since 2015. Initially he was based in Koenig & Bauer Sheetfed headquarters in Radebeul, Germany. In 2017 he moved to Barcelona to head up Koenig & Bauer Iberica. LPIA Patrick, Koenig & Bauer now offers a full suite of post-press options through its acquisition in 2016 of Iberica AG S.A., based in Barcelona and Istanbul-based Duran Machinery in 2018. What role did you play in those acquisitions and what are your current responsibilities? PM Koenig & Bauer has a leading position in sheetfed offset and wanted to extend its corporate competencies to new opportunities within the packaging industry. I first focussed on defining how to increase sheetfed products and solutions for the folding carton packaging industry. In other words, we were looking for supplementary products to offer. Knowing rather well all the key suppliers of equipment and market trends, we decided to get closer to strong players of converting equipment. We were convinced that our
production efficiencies, technologies, sales and service market rationalizations and our functional skills would make a valuable partner. For almost two years my task was to screen and approach and communicate with the identified candidates that offered the greatest mix of technology, market recognition, key managers and talents. Today, I keep working hard on further developing that activity in postpress. I am also Managing Director of Koenig & Bauer Iberica and a member of the board of directors of Koenig & Bauer Duran. LPIA How is the integration of Iberica and Duran going and is there more to be done? PM These two integrations were managed in a transparent and structured process to meet our expectations and to offer new solutions to the industry. Let’s look at what I would see as the four success factors. - Synergy is necessary to creating value and presenting satisfactory solutions to the market. This is going rather well. We have quickly achieved a deep and close integration of the companies. Therefore, we are already realizing synergies to a great extent.
- Having a Turkish company and a Spanish company join a German company could have been a challenge, but the cultural differences were beneficial and management changes went smoothly. For many years, up to 20 years, we’ve known each other quite well, as we have the same drive for technology and customer approach. We managed to smoothly change a few managers while keeping key talents, consolidated the team with some new leaders and strengthened the overall existing team with new competencies. - Timely completion of the technical objectives and organization improvements. We had initially in Barcelona and in Istanbul several ‘booster’ meetings with the full support of Koenig & Bauer Sheetfed management to implement changes to mitigate the potential risks and to meet our agenda of product developments and organization strengthening. - Quick first successes. It went very well, right from the start, producing excellent results in terms of sales, market success, new products, higher customer
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ck Masson
-Press Sheetfed
satisfaction and bottom-line results. This is just the beginning of a new story. There is much more to come shortly. LPIA Drupa was going to be the first major expo for Koenig & Bauer PostPress Division. Now that the event has been moved to April 2021, can you reveal any of the new innovations that had been planned? PM We will be launching a completely new series of post-press equipment that will be industry leading in terms of automation, speed, quality and productivity. Everything we do will take into consideration our customer’s future needs to ensure they can offer cost-effective as well as unique solutions to the market. We have competence teams from all divisions that have come together to help our converter customers be more profitable, enter new markets and be environmentally responsible. I can’t go into specific details, however it will be worth the wait! LPIA With another full year before the show, what does this extra time provide in terms of new machine introductions?
PM In 2020 we are machine ready but not fully geared up for production, so the postponement has given us time to build up our capabilities for immediate delivery of the new technology. What we are going to show at Drupa in 2021 will be ready to go to our customers immediately. It also gives us the opportunity to have some alpha and beta sites, so during the show we will have customers who can speak about the machines running in a production environment. LPIA What trends are you seeing in post-press technology around the world? PM I would see three trends coming shortly – sheetfed diecutting at speeds closer to sheetfed offset printing, European made full line
packaging solutions and Connectivity and Industry 4.0. Sheetfed diecutting at running speeds that exceed today’s industry standards is now successfully achieved with the Koenig & Bauer rotary diecutter for folding cartons. We are able to offer rotary and flatbed solutions to fit every printer’s exact needs. Our team of highly skilled experts can evaluate a printer’s total job mix along with their vision for the future that enables us to offer the optimum solution. The second trend would be to continue our rich 203-year-old heritage of offering customer based solutions. We have had a very strong research and development strategy since we entered the post-press arena. I am confident we will continue to launch
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42 new diecutters and gluers that will be ground breaking technology. The third trend would be connectivity. Post-press equipment will be able to communicate with devices such as PCs, tablets, smart phones and other machines (on-line), in order to comply with Industry 4.0. LPIA From your perspective, what are the newest innovations in diecutting within the last 12 months or so? PM We have been hearing a lot about sheetfed laser diecutting, but this is not a solution for industrial production. As I mentioned earlier, the newest unique innovation in diecutting within the last 12 months was the introduction of a sheetfed rotary diecutter equipped with flexible dies for folding carton applications. We have also seen major improvements in setup times, simultaneous processes and autonomous running of the machine. On our printing presses there are many simultaneous processes and autonomy in the setup of the machine. We are transferring that innovation to
explaining the features of a product, providing operating instructions and offering additional information. All these developments will create new demands utilizing new and special types of substrates. They will require more versatile diecutters and foldergluers with all kinds of new capabilities. With these new substrates and further roles of packaging, the importance of folder-gluer customizations and upgrading possibilities will become even more important. LPIA What would you say are some of the less obvious signs or indicators (other than bottlenecks in WIP) that folding carton plants need to upgrade their post-press operations? PM This is an interesting question. Indeed, we always speak about the performance of the post-press equipment, which is a very important element of the productivity of a folding carton plant, but it’s only a part of it.
at blanking; the overall tools changing and repeatability; the overall reliability of the diecutter construction; the ease of maintenance; the possibility to integrate complete logistics around the machine and the machine’s mechanical speed. LPIA Switching to current news, particularly the global pandemic, how do you see this changing the way machinery suppliers conduct business? PM The main impact will be an acceleration of the already known need for strong regional service support. It is of utmost importance to get local field technicians to solve any issues and have local parts. Moreover, machine robustness becomes even more vital and this is our top priority. They should be userfriendly and easy to maintain. Koenig & Bauer is continuously expanding and training our regional service force for all its post-press equipment. LPIA How is Koenig & Bauer currently communicating with customers for maintenance and breakdowns to maintain production? PM We are in continual contact with all our users to define what methods they prefer for communication.
post-press where it used to be more manual, so in diecutting and gluing you can accomplish multiple processes at the same time.
PM In the future, packaging will take on further roles in terms of offering a wider range of substrates to fit the brand owner’s visions.
Diecutting operations need to address the following to ensure they are efficient and competitive in the marketplace. For example, the feeder performance needs easy setup and efficient automatic nonstop operation. The infeed technology needs to be seamless and continuous to meet productivity goals; the movement of the platen needs to be rigid and precise for perfect cutting quality and there needs to be smoothness and reliability of the stop and go gripper bars.
Smart packaging will be integrated further with the Internet and will also communicate with the buyer via smartphone, in-store as well as at home,
Additional considerations include: the vibration-free movement of the stripping and blanking tool; the interleaving sheet insertor technology
LPIA What about the future of folding and gluing for paperboard substrates? What do you envision?
We do many repairs via a remote maintenance system as well as via video or telephone calls. Of course, we still have on-site service around the world. Our parts department is in full operation and running as normal. We are regulating this on a daily basis and adjusting to each customer’s exact needs to ensure they are operating at full capacity. LPIA In regard to global sales and installations, how is Koenig & Bauer coping with travel restrictions for engineers? Are they being asked by customers to quarantine prior to visiting the plant and then self- isolating when they return home? PM This varies by each country and on a regular basis but we are following all government regulations and working with our customers to plan ahead for where proactive services can take place.
Our World-class Post Press Innovations European made, with all of the quality and support you expect from Koenig & Bauer The Optima 106 K die-cutter and the Omega Allpro folder-gluer are capable of producing the most complex range of carton styles minimizing make ready and maximizing productivity and profitability. All this combined with the ultimate service and support from Koenig & Bauer. Contact your agent to learn more. Koenig & Bauer (SEA) Sdn Bhd +60 3 7885 8860 digitalsalescenter@koenig-bauer.com koenig-bauer.com
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The Xeikon FEU - Fusion Embellishment Unit Xeikon is delighted to announce the launch of its new Fusion Embellishment Unit – Xeikon FEU.
Similarly, for foiling applications the digital label area can receive digitally controlled foil with or without raised 3D effects with limited complexity compared to analogue.
This latest addition to its already broad portfolio of digital equipment for labels, builds on the company’s ambition to provide and equip label printers and converters with the most comprehensive portfolio of innovative digital equipment for the broad scope of label print manufacturing. The Xeikon FEU offers label printers and converters maximum flexibility to meet the demands of brand owners and designers striving to achieve high end, eye catching, unique, entertaining and creative labels. With complete digital finishing and embellishment capabilities, Xeikon’s FEU is based on MGI technology and provides UV spot varnish, tactile varnish, foiling, 3D textures and holograms across a wide range of substrates including clear on clear, common BOPP and paper facestock up to natural structured papers. The Xeikon FEU will be commercially available in Europe and North America as from October 2020. Filip Weymans, Xeikon’s VP marketing says: “In a world of ever-evolving consumerism, we are seeing significant and ongoing changes in behavioural patterns. Consumers are more discerning and brand owners are demanding more
from their designers and printers. In packaging and retail, there is increasing pressure for creative innovation and higher levels of productivity. To that end, Xeikon is first and foremost addressing the needs of its customers. We continue to adapt to current trends and with the launch of the Xeikon FEU we are offering our customers maximum opportunities. The workflow integration built around our X-800 Vectorizer will ultimately provide our customers with all they need to effectively move towards total digital label print manufacturing.” Using Xeikon’s Fusion Embellishment Unit, label printers with an existing portfolio of wine, premium beer, gourmet food, spirits and health & beauty labels will be able to achieve easy and fast proofing of new designs and faster times to market. With no need for tooling and reduced setup times, this economical solution offers superior levels of creative quality finishing on smaller volumes of labels. Using inkjet technology, any defined label area can automatically receive spot UV varnish with or without raised 3D texture effects.
Xeikon’s FEU is a stand-alone solution. This enables it to embellish printed materials originating from different technologies. It is also able to preprint foil onto substrates, thus meeting the many new brand-owner needs for today’s label designs. Optionally Xeikon’s FEU can be equipped with a semi rotational die cut unit so that it will deliver fully embellished and finished labels. Whilst Xeikon’s focus at present is on label applications, the new FEU has the potential to address other applications over time. Weymans concludes: “Xeikon’s long term goal is to offer its customers the broadest range of products which address the digital transformation of print manufacturing Well established industry partners, like in this case MGI digital technologies, very often haven proven products that integrate very well in this digitization process. With this latest addition to our portfolio, one of the most important benefits for our customers is the availability of integrated digital technologies – all provided and supported by supplier which ensure maximum productivity throughout the manufacturing process. The combined provision of digital printing and digital embellishment will enable label printers to run highend, short to medium sized jobs at substantially reduced costs with a shorter time to market. Xeikon continues to lead the way as a trusted advisor and supplier of innovative digital systems for the global label community.”
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Pioneering innovative E-Co Corrugated Packaging in Un We spoke with large format specialists, Billboard Media, as it celebrates its move to a larger purpose-built site and their innovative expansion into the E-commerce corrugated packaging space. By Sha Jumari. Based in Melbourne, Australia, Billboard Media (BBM) is a wellestablished company specialising in digital printing. Recently, the company completed its move to a bigger facility in Oakleigh South standing at 10,000m2 – twice the size of its last site. The move was especially momentous, as it was done amidst the COVID-19 pandemic crisis. Thanks to the dedicated staff and local engineering team from HP, BBM was able to complete the challenging move. BBM specialises in all forms of digital print and converting. From billboards to street posters, transit signage, construction wraps, vinyl banners and general sign and display, the company is a major force in digital production and distribution. Through additional investment in state-of-theart packaging equipment, BBM also produces corrugated products to small and large companies, such as boxes, cartons, shippers and in store stands for the retail sector. At the helm of BBM is founder Randal Shreeve, who is no stranger to large format with 38 years under his belt. Randal had his start as a sign writer in
1982, working on the shops in all the major streets of Melbourne. When he purchased a Gerber vinyl cutting machine, it pivoted him into a whole new world of signage. “As the business grew, an opportunity arose to buy another signage company which had a paper digital printer and laminator. This led me to get into digital printing,” said Randal. “As we grew even more, it took me into longer prints of 5-metres wide. This then made me look worldwide to find a 5-metre printer… which ultimately became the HP 5100.” Randal installed three HP 5100s along with two HP Turbo Jets. Soon after, he purchased three 5-metres and two 3.2-metres solvent printers. Adding to his arsenal, Randal bought HP Latex printers; two HP 3000 Latex printers and two HP 1600 Latex printers. Equally impressive is his armoury of HP Industrial Flat Bed or rigid board printers. He has invested in three HP Scitex 11000 Industrial Press as signage devices and two high end HP Scitex 17000 Corrugated Presses for packaging printing purposes, to complete his offering.
Founde Randal’s philosophy is “Never let the customer down”, and it shows. “I always ensure I have redundancy. We are fully committed to our customer needs and timelines and always deliver ‘on time, every time.’ At this stage I believe I have purchased HP’s leading solutions for the signage industry. I’m now open to widen my offering to corrugated packaging,” said Randal. The new Oakleigh South site holds five factories, each one catering different areas of work. The massive facility has:
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ommerce solutions for nprecedented Times On the move! Inke Packaging – Customised Corrugated Packaging A branch of BBM, Inke Packaging (Inke) is an e-commerce platform that provides a fool-proof way for brands to custom-create packaging. Business acumen runs in the family; Inke was started by Randal’s son, Jordan Shreeve, in late 2018. Jordan was in corrugated sales in BBM after the company installed its first HP Scitex 17000 Press. He noticed there needed to be an easier way for customers with little to no experience in the industry to be able to order their packaging on much simpler terms.
er Randal Shreeve with the HP FB17000 Corrugated Press of which they have two units a printing site with a total of 19 printers and stock; a cutting building housing robotic cutting tables, die cutter and guillotine; a manufacturing area with hot air welders, eyeleting machines and keder; a stock area with a large array of stocks; and finally a 1,000m2 office with plenty of room for display. With over 80 highly skilled and long term staff supporting the operation and expansion into new E-commerce opportunities, BBM is well positioned for all customer demands and supply requirements.
“Our team is second to none across all facets of the digital process. From creatives to production and quality control we excel. The team knows the importance of meeting deadlines and ensuring customer satisfaction,” commented Randal. To further compliment their capabilities Randal revealed that they see opportunities with the HP PageWide C500 Press as part of the next phase in its expanding e-commerce packaging business, Inke Packaging.
“The industry worked in a very traditional way, with little to none innovation in terms of manufacturing options for small to medium businesses who didn’t need 10,000 boxes on each order,” said Jordan. To fill in this gap and to capitalise on the increasing demand for high quality short runs for packaging, Inke was born: “We looked overseas for inspiration and seeing the success custom packaging was having, we decided to start the e-commerce website. Using BBM as its manufacturing partner, we were able to simplify and streamline the process,” Jordan continued.
The three HP FB11000 Industrial Press’s
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This highlights the appeal and fit of the HP PageWide C500 Press which can deliver offset print quality for mainstream production. The C500 supports a wide array of corrugated applications on both coated and uncoated paper. It utilises food-safe true water-based inks, which comply with even the most stringent global food safety regulations, including Nestlé guidance and Swiss Ordinance, to allow Inke’s F&B customers to produce packaging with peace of mind. Since its inception, Inke has taken into account the feedback it has received and made significant investments to continuously improve the user experience of the e-commerce platform. “We’ve built a platform that uses advanced technology to cater to multiple markets in the packaging sector for both small and large business. We also expanded our product catalogue, with plans to continually increase it,” said Jordan. In addition to the new products, Jordan added that Inke’s platform provides customers with an effortless way to purchase what they need. It also allows for more freedom in terms of customisation and self-quoting tools. The platform has a live order status tracking and personalised dashboard, so that customers can save their products and artworks for easy reordering inventory management. TM
Randal with one of several Zund digital industrial cutting tabels in the new factory or large enterprises, an easy and affordable way to simplify the process and self-service their packaging supply chain. As we are backed by BBM, our customers know they are partnered with a reliable manufacturer that can provide state-of-the-art custom and sustainable packaging,” said Jordan. Inke now has over 1000 customers in Australia which is growing every day. Inke is also planning to expand its services to New Zealand very soon. On top of that, Randal commented that there will be new partnerships and company acquisitions on the agenda as BBM’s train keeps steaming, or perhaps better put, rocketing along!
Together with the potential of the HP C500 Press, BBM’s facilities will become an almost exclusive HP powerhouse: “HP has been terrific over the long journey of 20 years. There have been many obstacles, but we have managed to work around them. It was important to choose a company that will be there for us when things go wrong - I made the right choice. HP is a reliable company that can deliver ink, parts, service and support 24/7 and the right technologies to both keep the machines working and ensure we are always at the equipment forefront in high quality digital print production,” Randal concluded.
“We’ve also partnered with global design freelance leaders 99designs, creating a collaborative landing page that simplifies the design brief process to easily transfer their ideas to freelance designers to create a print ready file for us to print. This will open the doors for a lot of customers who want custom packaging but do not have design skills,” Jordan added. “We stand out due to our ability to offer customers, whether small business
The company has their own dedicated board storage centre on site
www.xeikon.com
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Fully automated flexographic plate processing The revolutionary fully automated plate processing line consists of equipment modules which were announced earlier by the group; Catena - E (UV LED exposure), Catena - W (solvent plate processor), and Catena - DLS (dryer, light finisher and plate stacker combination with robotized plate transport). · Fully automated line with minimum operator intervention, resulting in more plate production even after the end of a shift · An open system allowing easy loading of plates even from other Imagers into the Catena line · Access to production data of all modules, provides a brand new level of pro-active maintenance, minimizing the need for physical service interventionCatena means “connected chain” and just as the name reveals, the Catena+ line is a modular system, which can join together for various levels of automation. A Catena-DLS module can be connected to a Catena-W for automatic plate-processing. The Catena-DLS has 10 drying units, 7 stacking positions and a light finisher. Robotic movement ensures that plates are fully finished with no operator intervention after loading into the washer.
“We are proud to announce the CatenaDLS, the missing piece on our way to fully automated flexo plate processing. In combination with our ThermoFlexX imager, the recently released Catena-W and the Catena-E UV LED exposure, we provide a state-of-the-art, fully automated and integrated flexo plate processing system, which allows our customers to produce flexo plates at lowest total cost for every application“, explains Uwe Stebani, General Manager Xeikon Prepress. “And in combination with our groundbreaking ThermoFlexX Woodpecker surface screening software and best-in-class Flint Group flexographic plates, we enable our customers to rival any other system in the market.” Catena+ brings the whole chain together, resulting in leading edge fully automated flexo plate making. Once the operator has removed the cover sheet the plate is automatically loaded into the imager, and is completely processed and fully finished with no
further operator interventions needed, eliminating any damage caused by manual plate handling. Designed as an open system, Catena+ allows easy loading of plates from other imagers into the Catena-E LED exposure unit. Plates from other exposure frames can also be easily loaded to take advantage of the highly productive WDLS. The full line Catena+ also includes Catena Cockpit, which provides a highly visible status report on plate processing, progress and expected time of completion. With Catena ProServX software, the machine health status of all modules is constantly monitored, thus, enabling a new level of pro-active support and maintenance. The need for physical service-interventions is minimized.
PrimeBlade ®
900
Nano
THE SWEDISH DOCTOR BLADE
MADE IN SWEDEN PrimeBlade Sweden AB
Sweden: Phone +46 565 101 09 | sales@primeblade.se www.primeblade.se
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World first EcoLeaf metallization unit on a digital hybrid press First EcoLeaf™ installation on a Mark Andy Digital Series HD hybrid press - Technology combination enables profitable and sustainable metallization of small to medium-length labels ACTEGA Metal Print GmbH announces that the specialist highquality labels printer, Barthel Gruppe – one of the largest labels printers in Germany and the Netherlands – has joined its beta program with the world’s first installation of an ACTEGA EcoLeaf™ Metallization unit on a digital and flexo hybrid press. Recently installed on a Mark Andy Digital Series HD press, at its eprint facility in Bünde, Germany, the EcoLeaf unit enables the company to offer an alternative to traditional cold foil, while providing its cosmeticsbased customers with high quality, cost effective but sustainable short to medium-run metallized silver labels. Additionally, by using the Mark Andy press to overprint the EcoLeaf trigger image, the Barthel Gruppe can now offer new forms of profitable decorative effects including a rainbow of metallic colors. “We are always looking for new ways to support our customers with labels that leap of the shelf and increase retail sales. Through finding and testing new technologies, we ensure that we have an eye on sustainable production processes that could reduce our
environmental impact. EcoLeaf is a great opportunity of this, and one we wanted to utilize,” explains the owner of Barthel Gruppe, Mr. Barthel.
complete its portfolio. The company now has printing and storage facilities across Central Europe, enabling it to successfully serve its worldwide customer portfolio.
“Our team has already run commercial jobs through EcoLeaf. As a result, we are now very optimistic that EcoLeaf will provide us with an important competitive edge – while enabling us to dramatically reduce our use of foil. We can also see that in time, we’ll be able to expand our business with new types of spectacularly decorative, profitable metallic labels too,” confirmed Mr. Barthel.
Jan Franz Allerkamp, Managing Director of ACTEGA Metal Print, comments: “It has been a privilege to add Barthel Gruppe to our beta program. Not only is their new facility at eprint just an hour’s drive from our own location, but they also share our vision for superior customer service as well as the future of sustainable and profitable metallized labels.”
Barthel Gruppe – with headquarter in Essen, NRW – specializes in providing labels for some of the world’s leading brands in markets including chemicals and auto, food, pharmaceuticals, wine and spirits. In January 2020, Barthel Gruppe acquired the cosmetics specialist eprint to expand and
“As our first unit in a hybrid solution, we can’t wait to see how Mr. Barthel and his team utilize our technology to develop their business. With eprint now being part of the larger Barthel Gruppe, we expect EcoLeaf to help them unlock many other growth opportunities,” concludes Allerkamp.
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New Sustainable packaging portfolio
Parkside, a leading innovator in flexible packaging, has announced the launch of a new range of sustainable packaging solutions that respond to growing consumer concerns regarding the use of plastics on the environment. The new portfolio is aimed at boosting the recyclability of the company’s existing range of flexible packaging designs, which is used across a wide range of markets including food and drink. The new range also incorporates the company’s award-winning collection of compostable packaging solutions, Park2NatureTM. Paula Birch, Global Sales Director at Parkside, explains: “As a sector, we are intensely aware of the importance of protecting the environment and reducing consumer dependence on single-use plastics. However, we must understand that packaging in all formats and materials is sustainable – it protects and preserves goods minimising waste and energy, ultimately protecting the environment. “However, the major issue at hand is ensuring plastic materials are
appropriately managed at the end of their service life, whether that be recycling, composting or reuse. Today, making flexible packaging suitable for the current recycling infrastructure in the UK is key to the sector moving forward.” The new sustainable packaging portfolio from Parkside comprises three variations of its Recoflex® technology; a high barrier, single polymer laminate, ideal for recycling processes, which can be manufactured with paper, Polypropylene (PP) or Polyethylene (PE). Recoflex can be widely recycled and is suitable for a diverse range of applications, including pouches and flow wraps. The range also contains the company’s leading Parkscribe™ reclose lidding films, which are manufactured from >30% recycled Polyethylene
Terephthalate (PET). Suitable for use on PET trays used in applications including fresh and cooked meats, fruit and vegetables, this innovative solution creates a single polymer PET complete pack ideal for recycling and reduces waste in the home through the reclose functionality. Paula added: “By strengthening our push towards a circular economy, we can now produce a range of flexible packaging alternatives for brands that can be used in an array of applications where extended shelf life through high barrier performance, and in some cases resealability, are essential. Recoflex PE can be recycled along with carrier bags at supermarket collection points. Parkside lidding and Recoflex paper can also be placed into kerbside collection schemes, where available.”
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Gallus Labelfire with Low passes field test Field test successfully passed: this is reported by Birkhäuser + GBC AG, a subsidiary of SCHELLING AG, only a short time after the Gallus Labelfire was installed with low migration equipment. In the Reinach plant near Basel, the company has been able to print a variety of labels and flexible packaging in accordance with low migration requirements since July 2020. The native print resolution of 1200 dpi and the flexibility of the hybrid label printing press are outstanding. It is already the second Gallus Labelfire for Birkhäuser. Marcel Häsler, COO at Birkhäuser, is impressed: «The new Gallus Labelfire 340 with low migration equipment is the perfect machine for us. This digital printing press is the ideal addition not only to the flexo printing presses in this
segment but also to our first Labelfire. Now we can offer the whole range of applications for the food sector, which meet all relevant low migration requirements – from flexible packaging and labels, paper bags and folding cartons to self-adhesive labels with cold foil finishing or lacquer effects.» Decision for UV inkjet The second hybrid press from Gallus is an important addition to the machinery in the area of labels and flexible packaging. The heart of the Gallus Labelfire is the Digital Print Unit (DPU) with seven colors. Before and after the inkjet printing unit, flexo
New Gallus Labelfire with low migration equipment at SCHELLING AG: Tobias Grolimund (left) and Marcel Häsler (right) from Birkhäuser+GBC AG draw a positive conclusion after the successfully passed field test of the digital press
w Migration successfully
printing units provide more flexibility and cost efficiency in label and packaging printing. This is achieved through the implementation of inline production. For example, cost-effective varnish application, high-quality cold foil embossing or customer-specific printing of spot colors or white can be integrated. The subsidiary of SCHELLING AG once again underlines its technological leadership with the Gallus Labelfire installed in July 2020. With a successful field test, this press is the second of its kind in the subsidiary in Reinach, Switzerland. Four years ago, Birkhäuser was one of the first printers on the market to invest in a Gallus Labelfire 340. Quite a few improvements have been made since then, not only in terms of low migration compatibility, but also in terms of speed, “white line compensation” and Prinect workflow integration. Low-Migration compatibility, reproducibility and short runs Decisive for choosing the second Gallus Labelfire were several reasons. Due to the short set-up times, the
machine system offers a high flexibility. As a result, short runs, i.e. jobs with short run lengths, are part of the daily business, because of the high costefficiency. Tobias Grolimund, Head of Production, confirms: “The set-up times for a digital printing press are very short compared to conventional printing processes such as offset or flexo.” According to SCHELLING AG, different aspects are influencing the choice of how a print job is done. Speaking about the Gallus Labelfire the break-even point between flexo and digital, according to Tobias Grolimund, is around 3000 to 4000 running meters per print job. With longer runs, flexographic printing scores with a higher printing speed, but a print job of 20`000 running meters with changing subjects might be produced much more cost-efficiently and quickly on the Labelfire. The high print quality was a further reason for the investment: due to the inkjet printing unit with seven colors and 1200 dpi resolution, up to 96% of the Pantone Plus color space is covered. Due to the high reproducibility, even complex print jobs can be fully
reproduced with the Gallus Labelfire within a short time – at the push of a button. Another influencing factor for SCHELLING AG in investing in the low-migration edition of the Gallus Labelfire was the positive experience with the first Labelfire: "The system is just great and runs extremely stable," explains Marcel Häsler. "It is still the only digital printing press that can reproduce 1-point fonts, thus, is able to print such small font sizes." According to SCHELLING AG, fonts in this size are common standard requirements for pharmaceutical customers and are needed e.g. for product traceability. Häsler sums up: «I don't know any other machine that is able to do this. This is beyond comparison!» Process security and stability Tobias Grolimund, who has significantly pushed forward digital label printing at Birkhäuser, says: «The Labelfire is a reliable and stable machine. This differentiates this digital press from conventional printing machines.» In advance Birkhäuser's printing experts had reviewed different systems. A toner-based printing process has
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certain advantages regarding the lowmigration ink system, but UV inkjet convinces with its speed and print quality. Tobias Grolimund is impressed: «With the integration of the Labelfire with low migration equipment we have a great extension to the first digital printing press. Also the great ink adhesion was a pleasant surprise. The drying and anchoring of the ink with UV inkjet is very good, even with uncoated paper. » Good ink adhesion without primer The Gallus Labelfire includes a pinning after each print head row. This first drying step ensures that the inks do not run into each other, the foundation for very small fonts or fine lines. The Digital Print Unit (DPU) is followed by UV boosters from GEW to produce applications with low migration compliance even at high speeds. Migration tests were done on the Gallus Labelfire at Heidelberger Druckmaschinen in Wiesloch, Germany. The low migration compliance was confirmed by the Swiss laboratory service provider SQTS (Swiss Quality Testing Services).
The fact that no pre-priming is necessary as well as the procedure for substrate qualification are further advantages for Birkhäuser. The colors do not have to be calibrated every week as with other digital printing machines. Replacing a printhead e.g. may require a new qualification. The qualification serves as the basis for the high level of reproducibility, as Tobias Grolimund confirms: "Once qualified, the Labelfire constantly offers reliable reproducibility!" Positive conclusion Marcel Häsler draws a positive conclusion: "The Labelfire Plus - as we call it internally - gives us the necessary flexibility for our customers and once again confirms our goal of technological leadership. For us, the customers are decisive, not the machine technology. With the Gallus Labelfire, we can offer our food customers lowmigration-compliant and permanently reproducible applications with excellent print quality and very small font sizes as well as short order sizes.” This is also confirmed by Tobias Grolimund: "We
Since July 2020 SCHELLING AG in Reinach, Switzerland is able to produce applications with low migration compliance for the food and pharma segment with the hybrid printing press Gallus Labelfire can now cover more applications and therefore more customer jobs, so I expect that the machine`s full capacity will soon be reached." SCHELLING AG The SCHELLING AG is a Swiss family-owned company and owns six subsidiaries and offices in Switzerland and Germany. As a comprehensive provider of high-quality packaging, displays made from corrugated cardboard and solid board as well as print products, package leaflets and labels, SCHELLING AG provides everything under one roof - the onestop shop for printing solutions and packaging. Based in Reinach Birkhäuser+GBC AG is a fully owned subsidiary and produces, with about 235 employees, especially for the pharma and food segments.
5th INTERNATIONAL PACKAGING AND PRINTING EXHIBITION FOR ASIA
22- 25 SEP 2021 BITEC • BANGKOK
www.pack-print.de
325
National Pavilions and Groups
leading exhibiting companies from
from Germany, Taiwan, Thailand, China and Singapore
30
countries and regions
International Visiting Delegations
More than
19,000
from the Philippines, Myanmar, Vietnam, Sri Lanka, Korea, Japan and many more, as well as local group visits from Thailand's printing and
trade visitors from
63
countries, making up a 30% overseas participation Supported by:
I
Messe DUsseldorf / Organizer of:
packaging industries
For enquiries:
Within Thailand:
Exposis Co., Ltd Tel (66} 2559 0856 _ Fax (66} 2559 2893 info@exposis.co.th
Overseas:
Messe DUsseldorf Asia Tel (65} 6332 9620 _ Fax (65} 6332 9655 ppi@mda.com.sg
Jointly organized by:
8* au1Aumsuss,il'irurllna
THE THAI PACKAGING ASSOCIATION
The Thai Printing Association
f Messe Diisseldorf Asia
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Global Flexible Plastic Packaging Market to Register Exponential Growth Asia Pacific expected to lead The global flexible plastic packaging market is expected to witness a robust CAGR through 2017 to 2022, according to a new report by Persistence Market Research. The report titled, “Global Market Study on Flexible Plastic Packaging: Asia Pacific Excluding Japan to Lead the Global Market in Terms of Revenue During 2017-2022”, estimates the market for flexible plastic packaging to reach a value of around US$202 billion by the end of 2022. Flexible plastic packaging is one of the growing trends in the packaging industry. Flexible plastic packaging makes use of various types of plastic material for packaging of different products. Depending on the application and type of product to be packaged the material to be used is chosen. The most commonly used material is plastic such as polyvinyl chloride, polyethylene, polystyrene, and polypropylene. Flexible plastic packaging is highly in demand on account of the convenience it provides and prolonged shelf life it offers to the products. Flexible plastic packaging is considered to be effective for distributing and packaging food items, pharmaceuticals, beverages, and consumables. It is an economical way for preserving items. This form of packaging is witnessing much demand on account of the efficient distribution and as it helps minimize losses.
The report segments the global flexible plastic packaging market on the basis of pack type into the sachet and pouches, bags, tubes, films and wraps, and others. Of these, the sachet and pouches segment is witnessing highest potential of growth. This segment has been contributing the most to the flexible plastic packaging market ever since 2016. The sachet and pouches segment is anticipated to expand at the fastest pace, exhibiting a CAGR of 7.7% during the forecast period from 2017 to 2022, and is estimated to portray a high share in the market. This segment is also estimated to show a high BPS by 2022 end. By material type, the global flexible plastic packaging market is segmented into polyethylene, polystyrene,
polyvinyl chloride, polyamide, ethylene vinyl alcohol, and polypropylene. Of these, the BOPP material is witnessing highest demand. The segment is anticipated to be in high demand for packaging potato chips, packing snacks, reusable woven bags for shopping, and in labels and wrapping films. The BOPP material is expected to expand at the highest CAGR of 10% throughout the forecast period. It is likely to gain a high BPS by 2022. The polyethylene segment is anticipated to continue witness steady growth and maintain an attractive market share through 2017-2022. The segment is likely to enjoy a high market share and this is attributed to its use in various FMCG products such as foil pouches, beverages, and in metallized lids. It is also used for packaging of confectioneries, yoghurt, and carton windows. In 2017, the polyethylene segment accounted for a whopping 50% market share in the global flexible plastic packaging market.
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Effective way to make a brand’s label stand out in a crowd of labels Effective product branding on labels and packaging needs to be increasingly eye-catching, original and different from other such products displayed at points of sales. To that effect hot foil embellishment has been growing fast as an application for enhanced brand recognition and product premiumisation. Once a compelling option for the labelling or packaging of luxury products, such as wines, spirits and perfume, hot foil stamping has been growing fast amongst the variety of available enhancement processes, extending its reach to a wider range of products. The reasons are multi-faceted. Hot foil stamping enables to create graphics that are visually compelling and have a huge impact in improving brand recognition, as well as the perceived quality and value of a product. It can be applied with the same quality results on a variety of different substrates: film, laid paper, textured paper, smooth or rough labelstock. Nearly every color is available, both as metallic or pigmented foils, gloss or matt, holographic, pearly and so on.
Other than the undisputed eye-catching aesthetic appeal qualities, technically the hot foil stamped graphics must be applied precisely in register, have a good anchorage on the substrate, and the process must also bring to the brand owner and the converter the economics needed to be competitive on the market. The DigiGold digitized hot foil stamping solution devised by BOBST for its range of narrow and mid-web inline flexo and multi-process production lines delivers flawless hot stamping quality and equipment operational ef-
ficiency, offering the best combination of fine detail and digitalized set-up and workflow. DigiGold is extremely flexible and can be added also after installation to any BOBST inline flexo press without the need to make any adjustment. It can be set in a fixed position or fitted as a mobile unit via a dedicated Ready cart on a Flower head print unit. With the DigiGold unit, the hot stamping set up is very fast, easy and repeatable. Production speed, print quality and consistency are also dramatically improved.
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Iconex and Martin Au
– a 25-year partnership that’s hel The recent installation of four Martin Automatic MBS splicers at Iconex in Morristown, Tennessee, marks a significant milestone in the ongoing partnership of two market leaders – it also comes at a time when the world is witnessing one of the most widespread pandemics in history - one that has prompted a surge in demand for sanitizing and protective products. Iconex has long been one of the leading suppliers of receipt and label solutions to the US market, with two facilities covering a total of 400,000 sq ft in Morristown, plus an additional site in nearby Jefferson. In total, the company now employs close to 500 people in Tennessee with production split between label and point of sale (POS) products.
we’re committed to manufacturing in North America and supporting US families, and we’re willing to invest in equipment that makes us viable and competitive against imported products,” alluding to the extensive range of Martin technology installed across the company’s production sites – it has plants in four other US states, plus Mexico, France and the UK.
Director of Technical Innovation and former Plant Manager, Jim Price, explained: “We like the fact that
The new MBS splicers were fitted to both existing and new ETI Cohesio lines, initially to support the company’s
growth in innovative labels. With a wide range of capabilities on different stocks, Martin Automatic MBS butt splicer technology is ideal for flexible production capacity. But, with the rapid and unprecedented spread of coronavirus across the US, the Martins have been pressed into service by Iconex switching part of its label production capability to converting paper rolls into hand sanitizing wipes. Price says they are currently producing around 20,000 rolls/day for a wipes customer that would gladly take more than twice that capacity. However, Iconex has a long-term label contract with a major international online retailer that it needs to fulfil, and e-commerce has seen a substantial increase since the onset of the virus. To help meet its customer’s need for wipes, Iconex has started converting the product on one of its slitter/rewinders that is customarily used for cash register rolls. Price turned to Stewarts of America, a South Carolina-based manufacturer of precision perforation technology to supply a perforating unit on an accelerated lead time. Needless to say, the Martin unwinds on these lines have no problem coping with this change of use either.
Jim Price with rolls of sanitizing wipe material
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utomatic
lping to beat Covid-19
One of four Martin MBS butt splicers at the Iconex plant in Morristown, TN But, it’s not only their flexible capacity that impresses Price. “We have had other brands in the building that we couldn’t get to work, where the factory support was non-existent. By contrast, some of our Martins date back to the 1990s and are so reliable that we never give them a second thought – they run like they’re brand new, they never break, and never miss a splice - and they’ve been doing that 24/7 for more than two decades. That’s the kind of predictable component you want in your production. Why would you mess around with anything else when you have that sort of consistency in your plant?” Iconex appreciates that it’s the quality of Martin’s design and manufacturing that brings about this reliability, and its commitment to understanding and
responding to customers’ changing requirements. Acknowledging the durability, he commented: “Press technology changes, but a Martin splicer is ageless”, citing as an example, “when it was time to update and upgrade our flexo technology, we purchased new six-colour Mark Andy P5 presses. But we didn’t need to purchase new splicers – we just moved the same Martin units over to the new lines that had been running for so long on our old Webtrons.” With Martin Automatic technology in daily use on both the label and POS side of the operation, Iconex has a breadth of expertise that many of its competitors lack. In 2017, its acquisition of RiteMade and PMCo confirmed its leadership in thermal receipt rolls. Now the largest supplier of thermal paper in the world, it lists
leading home improvement, fast food, and retail giants as part of its prestigious customer portfolio. As Jim Price concluded: “Whether it’s labels or wipes, Martin Automatic’s role in our supply chain is to help us produce as efficiently as possible – I’d say their technology is essential in giving us that competitive edge.” The current global pandemic has put an enormous and unprecedented strain on all manner of resources worldwide. The way in which Iconex and Martin Automatic have responded is indicative both of the companies' history of cooperation and of their long-term visions. Investing in essential resources like Martin splicers provides Iconex with the flexibility to meet ongoing commitments while empowering them with the freedom to employ those resources in critical-need situations.
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Going back to go forward! DG press champions the use of web offset technology for package printing At a time when the whole world is taking stock of life in general and business in particular, the package print industry finds itself at something of a crossroads technology-wise. downtime, and faster delivery. The biggest difference in job costing when we compare the three processes is that of plates, sleeves, and cylinders, and it can be up to a 90% saving.
VSOP technology is well suited to folding carton production - this highspec press has Martin Automatic unwind/splice technology fitted Traditional flexo and gravure printing is being challenged by digital technology on the one hand and by offset on the other. One company that is driving the latter method for labels, flexible packaging, and cartons is DG press, the organisation that emerged ten years ago from the ashes of Drent Goebel when the business forms market disappeared. Nick Cooombes spoke with one of its founding partners and CEO Remko Koolbergen about the thinking behind the business model. NC: What is the case for web offset in package packaging? RK: The main considerations are quality, cost, and flexibility, with a dash of food safety compliance and ‘green credentials’ for sustainability thrown in. The quality aspect is one that will divide today’s converters. For many years flexo was seen as the poor relation to offset, but today’s HD technology has changed all that. There are still, however, areas where offset is superior, and the use of FM or stochastic screening does offer the very highest quality of colour repro and proof matching.
NC: You mentioned comparative costs – why are they so important? RK: In a market where brand managers constantly seek to differentiate their products on the shelf, printed packaging is now being sourced in smaller volumes produced with shorter lead times. How to maintain this highly reactive production capability, and crucially make a profit, is testing many converters to distraction. Offset makes it easier with a shorter time to market – plates are quicker and cheaper to produce than their flexo counterparts, let alone the time and cost of prepress with gravure. The result is less
The 850mm Thallo at Vuye Flexible Packaging in Belgium is the company's third VSOP press
NC: What’s driving the demand for being fast to market? RK: Simply put, the internet and social media, both of which have had significant effect on consumer buying habits and revolutionised logistics and the supply chain. In today’s competitive environment you need to be ‘lean’ to survive, and we believe that offset is peerless in its ability to hit targets for quality, cost, and time. That’s why we see our Thallo press setting new standards in food packaging, where ink migration is an ongoing consideration, and the use of UV or EB curing offers a greater degree of security. Offset is also VOC free, so we can keep the ‘green lobby’ happy too! NC: Where do you see Thallo fitting into the market? RK: For sure it’s a very congested marketplace with narrow web flexo manufacturers offering wider web widths, and CI flexo and gravure manufacturers going narrower. We are all chasing the same jobs, namely 50,000 to 200,000 sqm. But we offer Thallo in three web widths, 520mm, 850mm
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68 and 1050mm, and with the capability of handling a wide substrate range from 12-micron film up to 762-micron board at speeds up to 400m/min, so we feel we have all bases covered as far as demand is concerned. It’s also a very flexible and responsive technology that meets the demands of the ‘just enough’ and ‘just in time’ supply chain that we have to cater for, making even short runs cost-effective. NC: Why did you choose to make Thallo a sleeve press? RK: We had years of experience with roll to roll offset and used it to develop what is in effect the second generation of VSOP technology, which offers the facility to work with variable repeats by allowing size changes, without having to change the complete unit or print cartridge. The sleeves are light and easy to handle so can be changed in seconds which is essential for the fast makeready and quick job change that are fundamental to ‘lean’ manufacturing. It’s also possible to have what we call the ‘Pro-Arm’ unit, which allows the sleeves to be fitted to the mandrel with only finger and thumb pressure required to slide the sleeve in and out. NC: A number of manufacturers are offering hybrid lines – what’s your take on this? RK: Thallo is available as a hybrid. Its modular design allows converters to choose the configuration that best suits their own production requirements, whether it be a mix of offset with flexo, or gravure or digital. This allows them to meet today’s demands from their customers and also enjoy a high degree of futureproofing with their investment. You can also specify a range of options including non-stop splicers, corona treaters, insetting, any combination of EB/UV/hot air and IR drying/curing, closed loop control, 100% inspection monitoring, automatic blanket washing, die cutting, and laminating – and that’s
not the complete list! NC: What’s the key to being able to process a wide variety of substrates? RK: It’s all about tension control. Web transport on the press is independent of the ink train, and with no need for warm up, the Thallo can be ramped straight up to production speed - and to conserve expensive substrate, it can rewind a machine’s length of material for use as make-ready on the next job. Operator control is straightforward via the touchscreen control panel. It uses sophisticated motion control, which provides the human machine interface (HMI) and safety in one system and gives detailed feedback on production performance and machine operation, making first line maintenance very simple. The print units are also generously spaced to make cleaning and access easy. They can be fitted with stainless steel covers as an option, if required by the working environment. NC: Much of this technology is available on other presses – what sets the Thallo apart from the competition? RK: Total cost of ownership. If you look at the TCO and compare the same job across typical flexo and gravure presses and the Thallo, you come up with a figure that puts it around 17.5% ahead of flexo and 22.5% ahead of gravure based on cost per square metre delivered. It’s a complex calculation but we have a well-researched cost model that we are more than happy to share with any converter interested in our technology. Of course, each company is different in its requirements and working practices, not to mention customer portfolio and job profiles, but the fundamental principles remain the same – and each converter can key in his or her own
numbers to the model to see what comes out. NC: How has the VSOP principle performed in practice with customers? RK: We have two users in Europe that have multiple presses, Vuye Packaging in Belgium and NovaPrint in Germany. No company invests in multiples if it’s dissatisfied with the performance of the first machine, so your question is best put to the people who operate those presses in daily commercial production, but from numerous conversations I have had with Lieven Vuye and Ingo Pauw respectively I can tell you that while not without their issues, both companies are well pleased with their investments, albeit that both were familiar with the offset process. At this point I directed my questions to the two users, Lieven Vuye (LV) and Ingo Pauw (IP) NC: Which presses do you have and what type of work are you doing? LV: We began with one of the first Drent Goebel VSOP presses to roll off
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69 NC: How has the package print market changed since you first started with VSOP technology? LV: We’ve moved from PVC to PET, OPP and foil substrates, which with low migration inks provide good barriers for the food industry. These mono structures require lower temperatures so slower running speeds, but that’s what the market wants. The question is, whether brand owners are prepared to pay the price that environmental protection requires? Typically, we now look at running around 5,000 metres per job, batched four or five designs up for the Belgian chocolate industry, as an example.
the line in Holland. It was a 520mm machine and shortly afterwards we added a second seven-colour press. This was specified with a flexo unit for water based or UV varnish and intermediate drying between units 5 and 6 to allow reverse side printing. The second press was also subsequently fitted with Martin Automatic unwind and rewind units to allow us to run it non-stop. Initially we used the technology to tap into the IML market, but the principal work on these presses today is filmic labels, shrink sleeves and pouches. These are traditional flexo and gravure markets but offset provides significant cost and time benefits on the short to medium runs that now typify this sector. In 2015 we installed a Thallo press – this is the 850mm wide press with seven offset and one flexo unit that prints mostly whites and lacquers. It’s around 50m/min faster than the older presses as well as being 30% wider, and importantly, it carries a range of improvements in control for better consistency. We use it mostly for IML and wraps on white or clear 30-micron OPP.
The presses’ hybrid capabilities are useful because they offer a degree of production flexibility, and we are about to add flexo and hot air capability to the second VSOP. One of the key factors is regular maintenance if you want to keep them running at their best. We operate a day shift pattern here, five days per week, although the Thallo did run a triple shift for four months back in 2019 to cope with a surge in demand – and ran very well too. We have worked closely with DG press over the years and developed a mutual understanding based on trust. NC: What about NovaPrint? How do you view VSOP technology in your markets? IP: I’m the Technical Director here in Oldenburg, where we have two VSOP 850 lines – the first was installed in 2006 and has eight offset units, and the second, which is the only 10-colour in Europe, includes two convertible offset/flexo units and was commissioned in 2014. We found the switch from sheet fed offset to web offset straightforward as we knew the technology and it was within our comfort zone. We also appreciate the flexibility that these presses offer us and our customers. Offset print quality is still a preference for the larger players in the market, and it’s good to have confirmation that the decision we made not to switch to flexo back in 2006 is still valid today. NC: Are you finding it’s all about substrate choice now, or are there other influences? IP: To a degree yes, we are. The green lobby has done a great job alerting
the public to the perils of plastic in the environment, but in many cases, there are no alternatives, and it’s more about disposal and re-use than initial production. We’re working with a number of soft drink manufacturers who are weighing up the relative merits of OPP and paper for their labels. We’re currently around 85% – 90% film and foil here, but I can see that changing as a number of customers look into new ways of recycling. Away from substrates, the growth of low-cost supermarkets is driving prices down, and with run lengths shortening, we are batching our work. A 40,000-metre run might be made up of 5,000 metres for eight different jobs, and this is where we benefit from the VSOP concept and its flexibility, to say nothing of the lower cost of offset inks when compared with flexo. In a constantly changing market you need to have confidence in your suppliers, and we view DG press as more of a partner than just a technology manufacturer. We both understand offset very well and this has been a huge benefit to both parties over the years. Looking ahead, I’d say the future for Thallo is in the 850mm size – it’s the best allrounder and gives you all the flexibility you need. The final word is with Remko Koolbergen. NC: Where do you see VSOP technology in the future? RK: What began as a rescue plan 10 years ago, when the collapse of the business forms market left Drent Goebel without new customers, has developed to become a valuable alternative to established practices in the package print market. Offset is a well-known and well proven technique, and in sheet fed form has been the mainstay of the folding carton industry for years. Now in web fed VSOP form it is a serious challenger across the entire package print market and that’s the reason why we sold the IP to Contiweb in 2016 because they have the resources to fund the ongoing technological development that every press needs. Since then six more Thallo presses have been delivered to customers around the world, so the future looks very bright.
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Creating better consume The COVID-19 pandemic has caused a significant increase in online sales. One survey has recorded an 80% increase in the number of people now buying 50% or more of their shopping online. It is believed this trend will continue. While COVID-19 is not responsible for the move to online retailing it has amplified it and it has become the preferred choice for many consumers. The key to success for online retailers is robust packaging that allows the product to arrive at its destination in the same condition as they would if the consumer went to the store. At the same time, consumers are also keen to see companies address environmental concerns by reducing the amount of packaging their products arrive in. In 2019, the global online supplier Amazon delivered around 3.5 billion packages. Each package will go through several process stages on its journey,
meaning the potential for damage to the product is significant if the packaging does not perform correctly. Amazon launched its Frustration-Free Packaging (FFP) Certification in 2008, most recently updated in February 2020. This requires all packaging going through Amazon distribution channels to meet certain standards. Put simply, packaging must be: • Right sized • Easy to open • Made of recyclable packaging materials • Capable of protecting the product during transit
The goal for Amazon is that a product can be transported through their supply chain without requiring additional packaging. To push this further, on 19 September 2019, they made it clear that any incoming inventory arriving at their fulfilment centers had to go through a Packaging Performance Test. If a large product is not certified to at least its Ships in Own Container (SIOC) standard, or Tier 2, each unit will be liable to a chargeback fee of USD 1.99. There are exemptions – hazmat products, fresh pantry products, smaller products, and lower volume products that were listed at least eight months before the product was given its Amazon Standard Identification Number (ASIN).
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er product packaging
• Lost business • Tarnished reputations • Costly damage to products • Delays As more and more retailers move online, businesses are advised to ensure their packaging conforms to the right standards. Businesses that successfully adapt to industry and consumer requirements will find their reputation’s enhanced and their costs reduced.
To help online retailers and distributors, the International Safe Transit Association (ISTA) has established standardized transit packaging tests that fall into two types: • Performance tests – pass/fail assessment used to determine the viability of a packaged product to survive normal shipment • Development tests – compare relative performance between two or more packaging designs There are six different levels of performance testing, from 1-Series tests – non-simulation integrity performance tests – to 6-series, which tests the ability of packaging to meet the performance requirements of an
individual company. For example, ISTA 6-Amazon has been developed to test a package’s ability to conform to the company’s performance requirements. Testing can be undertaken against one or more of three tiers: • Tier 1 – Frustration-free Packaging (FFP) • Tier 2 – Ships in its Own Container (SIOC) • Tier 3 – Prep-free Packaging (PFP) Chargeback fees will be enforced on large product packaging that does not conform at least to Tier 2. It should be noted poor packaging can also result in:
SGS ISTA Certification SGS offers a range of solutions to help online retailers ensure their products arrive intact and undamaged while minimizing packaging costs, environmental impact and avoiding chargebacks and fees. SGS provides a comprehensive range of packaging services to help manufacturers and suppliers ensure their products are effectively protected during distribution. Their service includes environmental (temperature extremes, UV etc.), shock, vibration, compression, impact, moisture, and forklift and clamping testing to ensure packaging is robust enough to protect the product during transportation. In addition, they also provide testing against ISTA standards, including ISTA 6-Amazon, and can help guide customers through the Amazon FFP certification process.
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72 Vetaphone iCorona – the beating heart of surface treatment As with so many aspects of technology, the part that is on show is always the best known and attracts the greatest attention. Surface treatment is no different in that respect, but with Vetaphone, it’s the beating heart at the centre of the system that sets the Danish pioneer’s technology apart from all of its competitors – and that heart is known as the iCorona Generator. Modular in construction, iCorona is designed to be easy to be efficient, upgradable and easy to maintain to offer the high degree of future proofing that today’s changing market demands. All of the important electronic components are built into one easily accessible module that means servicing is quick and simple, which makes for smoother running and longer life, as all vital parts in the module are updated to the latest technology. And, all this comes within a very compact generator that has a small footprint to cater for today’s crowded production floor and is uniquely CE approved for Europe and UL listed for both the USA and Canada. The advantage of this is obvious – with approval across all continents, Vetaphone can build iCorona generators without needing to know their final destination, which means delivery is quicker and there are no
issues relating to type approval or power requirements, which typically sees 50Hz used in Europe and 60Hz in America. iCorona caters for both and its technology also includes a unique patented resonant feedback system that automatically matches the Corona to the substrate being treated. As befits market leading technology, Vetaphone’s iCorona generator is highly controllable. Its standard iCC7 panel is intuitive and compact, making it user-friendly for all operatives. There are plenty of interface options to provide centralised set-up and control from the main machine HMI. The benefit of centralised HMI is that it allows one operator to oversee production, including several lines at the same time. Vetaphone provides free software advice during implementation of the interface, which with graduated feedback provides the operator with only the information required at that stage – although full details are accessible at any time. A proud history of pioneering ensures that Vetaphone customers benefit from systems that are a perfect blend of innovation and proven technology. With iCorona generators in operation around the world, they can truly be said to be the ‘beating heart’ of surface treatment. ProPrint raises productivity to meet surge in demand -with Martin Automatic technology When the global pandemic prompted a nationwide lockdown in the UK, manufacturers of printed packaging found themselves under immediate pressure from customers to increase their output. With all restaurants, cafes, staff canteens and other food outlets being forced to close almost overnight, the pressure of increased demand at food retailers created a massive problem in the supply chain. One company, ProPrint Group based in Wellingborough, was able to respond quickly to the situation thanks in part to the timely installation of Martin Automatic technology on its latest Edale FL3 narrow web press. The FL3, which joins eight other Edale lines at the company, is a 430mm 10-colour flexo press devoted
entirely to the production of linerless labels and is currently working a double-day shift pattern. With increased demand on the newest Edale, the use of automation seemed a natural process to follow and after a visit to Labelexpo Europe in 2019 and a factory tour at Desmedt Labels, near Brussels, which is one of Martin Automatic’s best European showcase installations, ProPrint decided to place an order. Operations Manager for ProPrint Group, Bob Green, takes up the story: “We were seriously impressed with the Martin installations at Desmedt, which have effectively automated all of the company’s narrow web presses. The owner, Henri Köhler, was very open and helpful with production figures and we could see with our own eyes how smoothly the whole production process flowed.” The result of this visit was an order for a Martin Automatic MBS non-stop butt splicer, and a non-stop LRD rewinder. The MBS and LRD are two of Martin’s bestselling models from an extensive range that spans narrow to ultra-wide webs and substrates from self-adhesive and linerless labels and delicate films to sandpaper and roofing felt. With designs based on the principles of pure physics, all Martin technology is simple to operate, easy to maintain and reliable, matching the requirements of today’s production
the LRD has a short transition between winding positions that reduces the risk of web movement and changes in web tension. Speaking for ProPrint, Director Nigel Tollman commented: “Our continued focus on improving service levels and cutting down on waste, raw materials and time, means we are always looking at ways to streamline and improve our efficiencies. At ProPrint we believe in spending time ensuring we have the right supplier partners partners we can work with to make sure our business is always evolving and improving. The team at Martin Automatic were helpful, supportive and worked hard to give us the peace of mind that comes with certainty.” environments where JIT delivery leaves little margin for error. The MBS automatically shears and tapes the running web to the new reel while the press continues running at full production speed, which at ProPrint is typically around 140m/ min. It makes a perfect butt splice, that is with no overlap, and ‘irons’ the tape across the web to ensure good bonding. Other features include web tension control and automatic web alignment with an ultrasonic sensor. The LRD rewinds and unloads the finished rolls also at full production speed without the operator needing to be present. Unlike a conventional turret rewinder,
His words chimed especially well for Martin Automatic’s UK Sales Manager Chris Chappel, who together with Edale engineer Simon Coffin, was charged with installing the equipment when it was delivered during lockdown. Far from being flustered by the restrictions that prevented Martin sending technicians to start up the equipment, Chappel says the installation was carried out in a calm, steady, and professional manner. “There was no chance of an engineer flying in from the US or over from mainland Europe to commission the MBS and LRD, so Simon and I set to it. It’s the way we like to be there for our customers when they need us.” The result is a first-class installation, as Green acknowledges: “In the short
time since the machinery was installed we have found it easy to use, reliable and very efficient. I estimate that the Martin equipment is saving us around 30% of the time it took to change a roll manually and has also cut make ready waste significantly by between 50 – 100m per change. Overall, I’d say the Martins have boosted output by at least 20%, and that’s being conservative.” The investment package, which also included a Lundberg waste extraction system, is part of a larger programme to widen the Group’s range of printed packaging. Currently operating from modern facilities across two sites – one for cartons the other for labels, ProPrint offers digital and offset printing capability in addition to its narrow web flexo. Design and prepress are both handled in-house, and the company has invested heavily in streamlining all of its management and production processes to support and develop its staff. Miraclon’s solvent-free, waterbased flexo plate innovation improves sustainability, process efficiency and print quality Packaging prepress specialist U. Günther GmbH has a track record of exploring the potential of new technology. In the words of Thomas Pyssa, Operations Manager, “We’re always interested in testing the limits of what’s possible with innovative production solutions.” The company’s latest venture into new technology is the KODAK FLEXCEL NX Ultra Solution, for which Günther has been a pilot user since February 2019. Developed, manufactured and supplied by Miraclon, FLEXCEL NX Ultra combines the technological benefits of Miraclon’s well-established FLEXCEL Solutions with solventfree, water-based processing. Günther installed its first FLEXCEL NX Solution in 2013. Now, with sustainable, eco-friendly packaging production topping the list of demands from consumers, retailers and brand-owners, Pyssa says it’s a logical move to test the capabilities of the new FLEXCEL NX Ultra Solution.
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74 “without a hitch,” says Stephan Bühl, OMM’s CEO. “Today we regularly use them for jobs of various sizes and in runs that are typically between 10,000 and 100,000 meters. With FLEXCEL NX Ultra we can increase the screen ruling to 200 lpi for high-value jobs with up to eight or ten colors. That way, we achieve excellent printable densities and tonal reproduction as well as absolutely clean highlights.”
Stefan Schneider, Sales Coordinator with Günther, describes “a whole series of handling, quality and productivity benefits that FLEXCEL NX Ultra gives us. The plates deliver excellent print quality with high edge-definition and absolutely clean highlights. They also stay open longer during production, so longer cleaning intervals are longer and press downtime less. In the 21st century, sustainability begins with the plate, and with FLEXCEL NX Ultra we have an effective answer.”
Erol Yerlikaya, Printshop Manager, praises the plates’ properties on the press. “Ink stability is especially good, printing results are consistent, and edges are very sharp, even with wide formats.” He emphasizes the excellent ink transfer throughout the print run, quoting as an example a packaging job featuring an invisible Digimarc barcode integrated with the printed image. “When we printed an eightcolor subject on OPP film, with a 150-lpi screen and using solvent-based inks, the run was absolutely stable over 75,000 meters.”
Shorter platemaking time meets Pohl’s need for flexibility and fast plate delivery
Another major advantage of the FLEXCEL NX Ultra plates is evident on bigger jobs, he continues.
One of Günther’s customers benefitting from FLEXCEL NX Ultra Troisdorf-based packaging is Troisdorf-based printer Siegfried Pohl Verpackung Gmbh is. The foil and film packaging Pohl prints is characterized by short planning deadlines and lead times — two-day turnarounds are not uncommon — so flexibility and fast plate delivery are must-haves.
“We need to clean solvent-based plates every 6,000 to 12,000 meters, but with the NX Ultra Plates we get through at least 24,000 meters before the first clean.
Pohl’s eight-color Fischer & Krecke press was the first test platform for FLEXCEL NX Ultra. Set-up was simplified by using an existing color profile — for FLEXCEL NXH plates — and similarly no adaptations were needed to the existing ink systems or anilox rollers. Press operator Jürgen Braun says the benefits start before the plates are even on the press: “I like that they don’t smell of solvent because of the water-based processing, so they’re more pleasant to work with, and the plates are more flexible, so they’re very easy to mount.”
We also get the NX Ultra Plates clean in under two minutes because the ink that builds up comes off more easily. With solvent-based plates, we reckon on five or six minutes to clean each sleeve.” Paving the way for higher flexo quality For OMM Kunststofftechnik GmbH, Lindlar, FLEXCEL NX Ultra Plates deliver not only a major quality leap but also an environmentally-friendly production process that’s in line with the company’s sustainability-oriented business model, which includes packaging made from recycled or organic film. OMM manufactures film, flexible packaging and labels for a wide range of different industries, and introduced FLEXCEL NX Ultra in June 2019
Daniel Brochhagen, Sales Representative for OMM, adds: “This quality leap also means we can approach customers who are traditionally printing gravure. Since going over to FLEXCEL NX Ultra Plates we’ve increasingly succeeded in winning classic gravure jobs for flexo and can now target new customers. We’re totally convinced by these plates — they keep the promises that were made to us in every respect.” Sustainability is key message At LPF Flexible Packaging, a Dutch manufacturer of flexible packaging and part of the international Clondalkin Group, Sales Manager Henk Edzes says the FLEXCEL NX Ultra Plates are central to the company’s sustainability message: “If customers ask us what headway we’ve made in terms of sustainability, we point out that sustainable packaging can be extended into the prepress area using the new, solvent-free plate.” LPF’s first production runs using FLEXCEL NX Ultra Plates have been on flexible packaging films for sustainability-conscious customers in the confectionery business, in production volumes of between 15,000 and 50,000 meters. “The quality results have been excellent,” says Edzes, adding that “our printers are delighted with the plates. They don’t smell of solvent when they’re unpacked, they’re easier to mount and the edges don’t lift so much during production. On top of that, the plates don’t have to be washed as often and our printers can run the presses faster, so our productivity is higher.”
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Windmöller & Hölscher KG Lengerich / Germany Phone + 49 5481 14 - 0 · info@wuh-group.com www.wuh-group.com Local Contact: Dr. Mathew John +234 8028025787