FPT 1:2022

70 years of K in Düsseldorf – a world career made in Germany!

Benefits of Expanded Color Gamut Printing Highlighted in New Video from Hamillroad

Innovation increasingly important as flexo print market grows

Packaging Films Market To Reach USD 164.11 Billion By 2028

ECG and KODAK FLEXCEL NX Technology power Mega Embalagens to Award success

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Hamillroad Software, creators of the multi-award-winning Bellissima DMS screening technology for Flexographic printing, released a new video explaining what Expanded Color Gamut (ECG) printing is and the sustainability benefits.

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The same year that saw Queen Elizabeth II ascend to the throne, the first artificial heart valve implanted in the USA and the musical “Singin’ in the Rain” inspire millions at the cinema, history was also made in Germany with the inaugural edition of K, hosted in Düsseldorf from 11 to 19 October 1952.

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Global demand for flexo printing will reach $172.2 billion in 2022, with a total of 6.80 trillion A4 print equivalents produced, according to exclusive new data from Smithers.

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The global packaging films market is expected to reach a market size of USD 164.11 Billion by 2028 and register a high CAGR during the forecast period, according to a latest report by Reports and Data. Rapid growth of the packaging films can be attributed to the rising demand for flexible packaging.

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“As soon as we saw what’s possible with extended color gamut production using KODAK FLEXCEL NX Plates, we knew we’d found the perfect tool to improve manufacturing time and reduce costs, without compromising on quality.”

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Benefits of Expanded Color Gamut (ECG) Printing Highlighted in New Video from Hamillroad Hamillroad Software, creators of the multi-award-winning Bellissima DMS screening technology for Flexographic printing, released a new video explaining what Expanded Color Gamut (ECG) printing is and the sustainability benefits.

The video highlights how brands and retailers can benefit by switching from using spot or PMS colors in label and packaging design to using ECG. ECG printing brings many positive benefits over conventional spot color use. The wider color space enabled by ECG delivers more vibrant-looking print output, enhancing the onshelf ‘wow’ factor. It is also a greener process that reduces the number of environmentally unfriendly chemicals used in print production, including inks and solvents that need to be disposed of in landfills.

Commenting on the new video, Danielle Kinsella, Marketing Director for Hamillroad, said, “ECG isn’t a new concept, in fact, many printers are already utilizing it; however, there has been a reluctance to adopt ECG, mainly from brands who want to see like for like reproduction of graphical brand assets that use spot colors.

Historically these have been difficult to reproduce due to limitations with screening technol-

ogy, but with Bellissima DM screening, we have increased the level of image fidelity possible and are making ECG a reality for brands and printers globally.”

“As the video explains, image quality is only one part of the story.

The most important takeaway from ECG is the sustainability advantage. By adopting ECG and moving away from using spot or PMS colors, a printer can reduce the number of

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CMYK chemicals and solvents used, which results in less waste and fewer chemicals going into landfills.

We hope our video highlights these benefits to brands and encourages them to explore how they, and the planet, can benefit from ECG,” concludes Danielle.

What is ECG printing?

Expanded Color Gamut printing (ECG) is the practice of using a set of 4 or more inks (typically 7): Cyan, Magenta, Yellow, and Black (CMYK) plus Orange, Green, and Violet (OGV) to achieve a larger color gamut than that of CMYK. It is also used as a solution to replace spot colors.

ECG Current Flexo

creases registration problems; as you have Conventional AM-based up to 7 colors to regisscreening is the current ter, the chance of waste standard of screening from misregistration inused for flexographic crease. printing, however, it has its limitations and chal- Stage 1: Bellissima lenges in an ECG envi- CMYK ronment: To print high lpi AM Moving to a Bellissima screens, printers typiDM Screen for flexo, a cally have to reduce the printer immediately running speed of the benefits from increased printing press in order printed image fidelity to print the high-fidelity. and is able to match, This lengthens the time and in some cases exthat a job will run on ceed, the quality of jobs press and reduces its printed offset and graproductivity to produce vure. sellable output.

Unlike an AM screen, To register 4 colors can Bellissima doesn't have be challenging, and screen angles, instead, when misregistration its patented stochastic occurs on the press, rosette interleaves the color shifts which cause screens in the separawaste. Moving to an tions to eliminate noise ECG environment with and moiré. In addition, AM-based screening in- the stochastic rosette

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maximizes the ink-onpaper area and minimizes the amount of ink-on -ink to expand the available color gamut while eliminating color shifts due to misregistration.

As a result, you get a reduction of ink and waste and achieve stable, repeatable color over the print run.

es its press capacity by +40%.

You can learn more about ECG and watch the video here: http:// www.hamillroad.com/ expanded-color-gamut/

Stage 2: Bellissima ECG A flexo printer can achieve further cost reductions and benefits by adopting Expanded Color Gamut printing with Bellissima DMS. A printer will reduce the amount of labour and resource requirements needed to wash up the press by using ECG. The press capacity and utilization of the machine is optimized by combining or 'ganging' multiple jobs.

Less waste is reported due to color shifts, and further cost savings are made by reducing the amount of ink and solvents used in the process.

Bellissima ECG enables a flexo printer to increase its sustainability credentials and increas-

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70 years of K in Düsseldorf – a world career made in Germany!

The same year that saw Queen Elizabeth II ascend to the throne, the first artificial heart valve implanted in the USA and the musical “Singin’ in the Rain” inspire millions at the cinema, history was also made in Germany with the inaugural edition of K, hosted in Düsseldorf from 11 to 19 October 1952. At that time nobody suspected this event only just taking off would develop into the world’s leading trade fair for the plastics and rubber industry.

Today, K in Düsseldorf can look back on a success story of 70 years.

It is the most relevant information and business platform of the plastics and rubber industry worldwide. Its position as the leading trade show for the entire industry, where theme leadership and innovation go hand in hand to pave the way for visions for the future, is undisputed.

For K 2022 from 19 to 26 October around 3,000 exhibitors from 61 nations are expected and the Düsseldorf Exhibition Centre is completely booked.

square metres of net exhibition space.

At the premiere 165,000 visitors marvelled especially at the colourful consumer goods exhibited by How it all started plastics processors. Because from 1952 to However, K in Düssel1959 K Düsseldorf was dorf also started small purely a showcase of once: the debut event the German industry.

“Wunder der Kunststof- Any interested visitor, fe” (Miracles of Plastics) be it a layman or spein 1952 registered 270 cialist, was admitted to exhibiting companies – visit the trade fair. MaOn no other platform is exclusively from Gerjor attractions on show the internationality as many. They occupied were products designed high as in Düsseldorf. approximately 14,000 to make life more beau-

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tiful and convenient. Today, we smile at the advertising of that time, which was also aimed at the "modern housewife" and introduced her to such post-war achievements as trendy PVC raincoats or sheer nylon stockings - aesthetic epitomes of the economic miracle.

The more the plastics industry specialized and high-tech plastics for special solutions in electronics, medicine, automotive or aerospace attracted attention beyond standard polymers, the more specialists visited the trade fair. In 1963 the break was made: K in Düsseldorf became a specialinterest only trade fair of international standing. Since then it has maintained its position as a leading global trade fair for the entire industry. 2019 saw over 220,000 trade visitors

from almost 170 nations travel to K on the Rhine River.

The international origin and composition of exhibitors will also guarantee the completeness of the product ranges and a comprehensive overview of the world market at the upcoming K in autumn. Nowhere else will they find such a wealth of innovations, and no other trade show will provide such a variety of impulses for the future of the global plastics and rubber industry.

smile and marvel at historical photos and stories. Embark on a travel through time with us at https://70years.konline.de/en

Event’s own microsite: immerse yourself in 70 years of K in Düsseldorf Before K 2022 even opens its doors, there is already an opportunity to get in the mood for the trade show's anniversary. We are celebrating K with its own microsite, inviting you to delve into seven decades of K history and to

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Innovation increasingly important as flexo print market grows to $188.9 billion in 2027, Smithers analysis finds Global demand for flexographic printing will reach USD 172.2 billion in 2022 according to exclusive new data from Smithers.

Comprehensive forecasts published today in The Future of Flexographic Printing to 2027 are that a compound annual growth rate (CAGR) of 1.9% will increase demand to $188.9 billion over the next five years (at constant prices). Across the same period volume growth will increase at a faster 2.5% CAGR seeing output reach 7.68 trillion A4 print equivalents in As the market evolves flexo will benefit from continuing growth in demand for packaging print and labels. Its commercial position is as an increasingly costcompetitive alternative to gravure and offset litho in these applications; but does also face the risk of losing some market share to higher throughput inkjet presses, in narrow web and corrugated segments over the Smithers forecast period. Corrugated print will

remain the largest segment of the flexo print market – with a 36.8% share by volume in 2022. Flexible packaging print is becoming increasingly significant, and will be the fastest growing of the nine major applications tracked in Smithers’ analysis.

ing regimes implemented to control Covid-19 infections, and the shift away from alternative polymer cleaning materials prompted by single -use plastics legislation.

Simultaneously the longer term impact of widespread social distancing and shifts in consumer preferences There will be new demand across 2022-2027 for media means defor more printed paper mand from graphic aptowels, and other sani- plications (envelopes, greeting wrap, etc) and tary and kitchenware. publications (mainly This is a consequence both of increased clean- newspapers) will trend

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downwards.

Markets in Western Europe are essentially mature. There is new demand for flexo equipment emerging in the Americas. Demand for flexo output is accelerating across much of Asia, led by China and India – potentially the world’s two largest markets for purchases of printed FMCGs. Sales for new equipment will be muted across the region, however.

Instead the Americas will provide the best new sales opportunities for flexo press manufacturers through to 2027.

The need to produce shorter print runs, and manage new demands for variable data print, will stimulate further development of hybrid (flexo inkjet) configurations, and the adoption of computer to plate

(CtP) and other automation features, and inline finishing to improve order turnaround. Another important development for press OEMs is the demand for medium web-width flexo machinery, with specialists in both narrow web label and wideformat central impression (CI) facing different challenges to adapt to this. Another focus for R&D is the effective integration of electron beam (EB) curing stations and inks for flexo print, which especially suited for high speed print on newly popular monomaterial flexible plastics substrates.

moves towards stabilisation across 2022, interest in a lower environmental profile for print jobs will foster wider interest in water wash flexo plates, and improvements in anilox roller technology on press.

The Future of Flexographic Printing to 2027 provides unparalleled detail on this major print market as it negotiates pressing contemporary challenges and adapts to longer term changes in print market dynamics. Contextualised by expert profiles of the latest technology trends, Smithers historic data analysis and forecasts In the short term (2017-2027) are the flexo market quantified in an is having to adapt exclusive data set to rising raw ma- with over 100 daterial prices, ta tables and figwhich are affect- ures segmenting ing the cost of this market by inks, other conend-use applicasumables, and tion, geographic printing plates. As region and naplate supply tional market.

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Packaging Films Market To Reach USD 164.11 Billion By 2028 The global packaging films market is expected to reach a market size of USD 164.11 Billion by 2028 and register a high CAGR during the forecast period, according to a latest report by Reports and Data. Rapid growth of the packaging films can be attributed to the rising demand for flexible packaging. The food and beverage product manufacturers are increasingly adopting flexible films based on polyethylene as they have distinct barrier properties that help with better protection or longer shelf life.

The manufacturers are increasingly investing for the production of enhanced flexible packaging films that prioritize durability and resistance to tearing, food safety and freshness, safe distribution and storage, and protection from environmental elements like light, moisture, temperature, and gas.

The flexible packaging films helps in maximizing the shelf life of perishable items and conceal the smells of the contents in packaging.

The elimination of the cost of labeling or capping with the utilization of flexible packaging films is expected to drive the market growth during the forecast period. Companies like UFlex are investing in

the domestic and international expansion for packaging films business. The companies are also investing in the collaboration and mergers and acquisition, such as Berry plastics acquired AEP Industries Inc., which is contributing to the growth of the global packaging films markets.

Rising demand for antimicrobial and antioxi-

dant active food packaging is expected to support the advancement of packaging films market during the forecast period. The packaging films manufacturers are investing in the development of new antimicrobial and antioxidant active food packaging in order to reduce the oxygen content inside packaging and prevent microbial growth.

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Further key findings in the report suggest In April 2021, Amcor entered into a partnership with Nestle in order to bring sustainable packaging to shelves.

Amcor, with the help of its global research and development resources, supported Nestle by making Smarties the first confectionery brand to move to recyclable paper packaging in Australia. Amcor is developing this new next-generation packaging solution in order to maintain the sustainability and ensure product protection.

Based on application, the food and beverage packaging segment is expected to account for the largest market share during the forecast period. Sustainability concerns, technological innovations, and attractive economics are key factors that are driving the demand for packaging films among the food and beverage manufacturers. The FMCG companies are increasingly adopting sustainable packaging films to ensure recycling of packaging materials and minimize packaging cost.

Based on packaging materials, polypropylene segment is expected to register faster revenue growth rate over the forecast period. The excellent strength, heat-sealing properties, softness, and clarity offered by the polypropylene are contributing to its growing demand among the food & beverage and pharmaceutical industries. Increasing consumption of fresh products is a key factor driving the utilization of BOPP and CPP packaging films.

The packaging films market in Asia Pacific accounted for the highest revenue share in 2020, owing to the presence of large processed food and beverage industries in countries like India and China.

Moreover, the growing organized retail sector in the region is helping in the growth of the food and beverage industries and packaging film market.

Key participants in the market include Amcor, ProAmpac, Berry Plastics Corporation, Char-

ter Next Generation, DuPont Teijin Films, Novolex, RKW Group, Jindal Poly Films Ltd, Graphic Packaging International, LLC, and Cosmo Films.

For the purpose of this report, Reports and Data has segmented the global packaging films on the basis of packaging materials, application, and region: Packaging Materials Outlook (Revenue, USD Billion; 2018-2028) Polypropylene Polyethylene Polyester PVC Others Application Vertical Outlook (Revenue, USD Billion; 2018-2028) Medical & pharmaceutical packaging Industrial packaging Food and Beverage packaging Consumer products packaging Others Buy Premium Research Report @ Regional Outlook (Revenue, USD Billion; 2018-2028) North America a. U.S. b. Canada c. Mexico Europe

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a. Germany b. UK c. France d. Italy e. Spain f. Sweden g. BENELUX h. Rest of Europe Asia Pacific a. China b. India c. Japan d. South Korea e. Rest of APAC Latin America a. Brazil b. Rest of LATAM MEA a. Saudi Arabia b. UAE c. South Africa d. Israel e. Rest of MEA

Explore Trending Research Reports by Reports and Data: Soft Magnetic Materials market is forecasted to grow at a rate of 7.8% in terms of value, from 2020 to reach USD 44.91 billion by 2027. Growing consumer interest in consumption of fresh products with extended shelf life and controlled quality is a significant factor driving growth of the packaging films Kraft Liner market is forecasted to grow at a rate of 6.1% from USD

38.55 billion in 2019 to USD 60.49 billion in 2027. The market of the Kraft liner will be driven by significant growth in the food and beverage industry worldwide Printed Tape market is forecasted to grow at a rate of 5.8% from USD 28.28 billion in 2019 to USD 44.56 billion in 2027. Increasing demand from various enduser industries is driving the growth of the market Metal Packaging market is forecasted to grow at a rate of 3.3% in terms of value, from USD 129.42 Billion in 2019 to reach USD 168.45 billion by 2027. Increasing consumption of canned food and rising demand for packaged food is driving the demand for the metal packaging market

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ECG and KODAK FLEXCEL NX Technology from Miraclon power Mega Embalagens to Global Award success “As soon as we saw what’s possible with extended color gamut production using KODAK FLEXCEL NX Plates, we knew we’d found the perfect tool to improve manufacturing time and reduce costs, without compromising on quality.”

Roberto Gräf, Sales Director of Brazilian flexible packaging producer Mega Embalagens, is looking back to 2018 and the start of a technology journey that culminated in a Silver Award at the Global Flexo Innovation Awards, sponsored by Miraclon, won for Creative Use of Graphic Design and an innovative Print Production Workflow — all thanks to its implementation of ECG using FLEXCEL NX Technology. The company was also one of only four entrants awarded Highest Honors by the judges to recognize companies that demonstrated the biggest impact on advancing the flexo printing process.

In 2018, after the initial testing yielded what he describes as “record production benefits and high-quality results”, the company decided to commit wholeheartedly to implementing ECG using FLEXCEL NX Plates. Four years on, the award-winning job showcases what Mega Embalagens can offer

clients using ECG. In this case, the client — a Uruguayan brand owner — wanted to relaunch its dried fruit line with a radical redesign of the packaging. Instead of a clear, unprinted package, the proposal was a printed stand-up doypack bag, representing a major step forward in on-shelf visual impact,

and offering these consumers a package they could easily open and reseal easily while also seeing the product through a window located on the back of the package.

A major challenge in the relaunch was producing short runs of the new pouch for test marketing at the lowest unit

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price. Mega Embalagens and its partners combined a unique approach to job-ganging (four separate images ganged two-by-two on a four-out form) with an ECG workflow using FLEXCEL NX Plates.

Analysis of the designs showed they could be printed using five colors (CMYK + White) instead of the 28 colors (seven colors x four SKUs) required conventionally.

This approach optimized color while eliminating

three printing set-ups and a total of 23 plates.

From family operation to international business Mega Embalagens is a family business founded in 1993 initially to package animal proteins.

The company maintains its first-generation family management, but today the focus is on pet food, food, and personal care.

Currently, Mega Embalagens has considerable success in exports to both the United States and Europe, ac-

cording to Gustavo Gräf, commercial manager: “We have been operating in the US for a long time. The European market is very similar to the US; a competitive market that receives goods from all over the world, where competition with Chinese products and products made in Eastern Europe is strong. In Europe, but we win business not only because of our quality and technology, but also because we continuously strengthen our

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sustainability credentials. We also believe that customers abroad have the same expectations as our Brazilian clients, so we’ve invested in all the necessary logistics and technical support to provide an international service.”

Four pillars of sustainability The company’s sustainability investments are based on four pillars to differentiate Mega Embalagens from its competitors, explains Gustavo. “The first pillar is the use of postconsumer resins (PCR) in secondary packaging materials. Second, we produce 100% recyclable packaging that has the same protection barrier and appearance as conventional packaging, replacing multimaterial laminated structures and in line with the circular economy. Third, we replace fossil-based materials with renewable ones – one of the alternatives is green polyethylene from sugarcane, for example. Finally, we also work with biodegradable materials.”

The company’s main markets all share certain trends, Gustavo

continues. “Quality remains critical — so it’s our responsibility is to produce packaging that stands out in those few seconds in which the consumer decides to buy, or not.”

Mega Embalagens is one of only three Brazilian suppliers to have the BRC Packaging Materials Grade AA Certification, a globally recognized standard for packaging quality and the first recognized by the Global Food Safety Initiative.

As well as the trend for more SKUs produced in shorter runs, consumers’ consumption profiles are changing rapidly. “They want greater convenience in packaging, with more sophistication, so there’s an emphasis on features like seals and ‘easyopen-and-close’ options.

Because fast turnarounds are also critical, we installed indicators that analyze all our processes with the aim of finding places where we can cut time. So, the moment an order comes in, we have a clear idea of what has to happen in each department to meet the deadlines.”

ECG with FLEXCEL NX Plates — increased productivity, consistency and ink savings Currently, ECG jobs account for around 50% of production, and the share is growing.

“These jobs are all printed with FLEXCEL NX Plates,” says Roberto Auricchio, Prepress Manager, listing an impressive range of benefits that the technology delivers. “Our plate consumption is much lower, and with ECG we can reproduce special Pantone colors using a fixed ink palette of seven colors — CMYK + OGV. This reduces downtime between jobs, because we don’t change the inks, just the plates. We also get big productivity gains — press set-up is faster, and cleaning between jobs is significantly reduced. We can also gang together different jobs using the same stock.”

He adds: “The stable density ratio the FLEXCEL NX Plates provide allows us to transfer ink correctly and consistently, so we can take on more challenging jobs — for example, using smaller text, or replacing Pantone colors with

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more confidence in the ECG. And we use significantly less ink, of course.”

Huge quality and resolution improvements Roberto Gräf testifies to the huge improvement in quality and resolution since adopting FLEXCEL NX Plates: “A few years ago, we were working with 39 lines, but today many clients demand higher resolutions. So, we’ve standardized on 52 to 60 lines, regardless of the packaging size. But with FLEXCEL NX Technology we can go up to 120 lines of resolution in the matrix, so as demand keeps increasing, we can migrate work upwards without a problem.”

He acknowledges that converting brand owners to a radically different production solution such as ECG can be challenging. “At first, there were understandable concerns about whether we could convert their Pantones to ECG and ensure colors matched their expectations. But as they saw the results — both the production efficiencies and the quality achieved — any doubts went away.”

He adds that ECG also entails a culture change for the company’s press operators. “They have to understand it’s a new process, where jobs are no longer separated between process colors

and Pantones. So, we constantly invest in training, because any variation from process colors will impact the packaging. Attention to detail and knowledge is essential.”

Looking to the future, he sees bright prospects for ECG. “Once we convince clients to try the ECG approach, they tend to stay with the process because they see the tremendous advantages over conventional production. And word is getting around, too. We regularly get brand owners approaching us and asking ‘What’s this ECG I keep hearing about?’”

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