FPT 3:2021

Elif Plastik choose Fast Bridge Adaptors developed by Rossini Evaluation of Expanded Gamut Printing in Flexography

The global flexible plastic pouches market size is rojected to grow by 6.5%.

Martin Automatic about the company’s solutions to this perennial problem

Neuefeind unlocks the full potential of the KODAK FLEXCEL NX System

4

There is a great need in the packaging industry to produce increasingly smaller lots in a more cost-effective and sustainable way, where the spot color accuracy of the brand elements is critical. Traditional flexography is spot color printing or four-color process printing supported by spot colors that consume a lot of time, effort, and materials.

10

The global flexible plastic pouches market size is estimated at USD 53.7 billion in 2021 and is projected to reach USD 73.5 billion by 2026, at a CAGR of 6.5%. The flexible plastic pouches market is witnessing high growth owing to the increase in demand for lightweight, convenient, and cost-effective packaging products & solutions for food and beverage applications.

18

Printers and converters know that controlling tension in a web is essential to the quality of the finished product. Web tension problems can arise from several issues with the unwinding roll. These include deceleration, the action of splicing, and acceleration of a new roll.

Out-of-round or unbalanced rolls also cause tension disturbances, even during steady state unwinding.

22

Elif Plastik, one of the global companies of the flexible packaging industry, closely follows the technology for trouble-free printing processes and high quality prints. Elif Plastik prefers its choices for printing materials and machines with the latest technology.

24

Neuefeind GmbH of Ochtendung, Germany, provides flexographic technology services encompassing all aspects of the packaging process, not just prepress and platemaking. The family-run firm employs 20 specialists, with its business roughly breaking down to 60% for direct printing on corrugated board, 20% for preprint corrugated and 20% for flexible packaging.

2

3

Evaluation of Expanded Gamut Printing in Flexography There is a great need in the packaging industry to produce increasingly smaller lots in a more cost-effective and sustainable way, where the spot color accuracy of the brand elements is critical. Traditional flexography is spot color printing or four-color process printing supported by spot colors that consume a lot of time, effort, and materials. This study evaluates the transition from spot color printing to Expanded Gamut Printing, EGP, i.e., a multicolor process in solvent-based wide web flexography, which reduces the complexity of the printing process and produces spot color simulations in a simpler, more effective, and more sustainable way.

The packaging printing industry has traditionally been a conservative one and new methods are usually trialled without a deep systematic and scientific approach.

Therefore, there has not been a comprehensive and scientific investigation of the multicolor process in flexography and it is relatively unknown in detail; thus EGP is considered a niche process. Printers

and brand owners lack concrete evidence to support its implementation. This thesis aims to fill the scientific gap and provide data and test results to facilitate the transition to EGP in flexography.

available are mainly proprietary marketing materials, various articles, user manuals, college-level studies, and seminar presentations.

The available test results typically only apply to narrow web printing, while the availabilCurrently, there is very ity of empirical produclittle scientific peertion data is almost nonreviewed literature or existent.

PhD studies on multicolor printing in flexog- This study provides exraphy. The materials amples and data to

www.packagingnewsletter.com 4

show the potential of multicolor printing.

The main questions are whether and how multicolor process printing can replace conventional spot color printing.

The purpose is to describe and calculate the achievable benefits of EGP in figures, since economy and ecology are also significant market drivers.

The study collects and supplemens materials from various sources. A novel EGP calculator is developed to describe and evaluate the potential of the method.

The study investigates and evaluates the possibilities of color gamut expansion in wide web flexography and describes and calculates the potential of the gang-run printing.

Finally, a legacy

job printed with spot colors is converted into EGP and the results evaluated.

Several key findings are made in the tudy and the calculations show great potential for efficiency and cost savings in various areas.

The improvement in the press setup is clear, but one of the most interesting findings is the effect of cleaning solvent distillation. In addition, the influence of the amount of stock ink is low and the savings potential on the substrate high. It is also a novelty to link these calculations with Overall Equipment Effectiveness (OEE) and CO2 values.

The EGP calculator estimate in this study shows an improvement in the OEE of 42% to 85% and 5

a total cost savings of around 0,6 to 1,3 million euros per printing press per year, while the CO2 equivalent is reduced by 34% to 51% compared to spot color printing, the results will be different case by

case. The studied tests show the capability to expand the color gamut with additional process colors, up to 91% of the Pantone Color Matching System (PMS) colors for the studied 7-color system of less than 3,0

ΔE2000, as expected.

However, against expectations, high-pigmented inks also expands the color gamut by 14% for the studied 4-color inks.

The Total Area Coverage (TAC) calculations of the

www.packagingnewsletter.com 6

tests show that EGP can transition from spot colsave ink. ors to multicolor designs for greater flexibility, efThe benefit of gang-run ficiency, and better susprinting is generally tainability. mentioned by many sources. This study also AUTHOR’S CONTRIdefines the increased BUTIONS efficiency in numbers as This study evaluates the test showed the and examines the usaability to eliminate 30% bility of Expanded Gamof the total number of ut Printing in replacing inks. The calculated inspot color printing with dividual ink consumpsimulated multicolor tion based on TAC is reprocess printing in flexduced by 15% to 69%, ography. Since the rewhile the number of search area is a very printing plates is also specific part of packagreduced by 9%. The ing printing and this legacy job test proves doctoral thesis is the the possibility of a realfirst of a kind, and there world EGP implementais hardly any previous tion with improved effiscientific reference maciency, quality, and susterial available about tainability.

The total this topic in flexographic number of colors is reprinting, the author has duced by 33% and ink carried out work to deconsumption is reduced velop this area. while the quality was acceptable to the brand This work included owner. the following:

The results show that the use of EGP enables accurate spot color simulations in a simplified way. Therefore, the proposed method offers the basis for the industrial

New methods of increasing color intensity and contrast were investigated in order to achieve an expanded color gamut.

CMYK and CMYKOGV multicolor process print profiles were printed and measured, analyzed, and compared, and a color transformation lookup table was created to examine the accuracy of simulated EGP spot colors. The calculations revealed also the potential for ink savings with this method.

Information was collected to describe the average production values of modern multicolor process printing compared to traditional spot color printing.

A great effort was invested in developing the EGP eco-efficiency calculator to model the printing results to derive novel ROI and sustainability calculations.

Scattered data were collected and completed to combine theories, and previous work and to illustrate the differences between various sys- Since very limited infortems. mation was available on

www.packagingnewsletter.com 7

the Global Warming Potential of flexography, a literature search of CO2 equivalents was conducted and a calculation model was created to describe the sustainability in flexography.

Since there were very few reference implementations of expanded gamut printing for flexography in Europe, a consumer-level test was

conducted with a brand owner to determine and prove the usability and acceptance of simulated spot colors printed using multicolor process printing on flexible packaging.

to convert brand spot colors into simulated spot colors with improved eco-efficiency.

The author’s investigations about the potential of increased sustainability in flexography has This research has prov- raised sustainability as a en that the EGP system global topic in packagworks in practice, and ing printing. the analysis shows that Download the entire the proposed method study here. can be successfully used

www.packagingnewsletter.com 8

9

Flexible Plastic Pouches Market Global Forecasts to 2026 The global flexible plastic pouches market size is estimated at USD 53.7 billion in 2021 and is projected to reach USD 73.5 billion by 2026, at a CAGR of 6.5%. The flexible plastic pouches market is witnessing high growth owing to the increase in demand for lightweight, convenient, and cost-effective packaging products & solutions for food and beverage applications. The aesthetic appeal, increased shelf life of product, rising demand from end-use sectors, and increasing e-commerce sales are key factors driving the demand for flexible plastic pouches during the forecast period.

The demand for various flexible plastic pouch types has increased during the lockdown and created more demand for the future.

The pandemic has also increased the use of single-use plastics in terms of pouches; this has created more demand for the market.

Consumer behavior has changed owing to the safety concerns due to

the pandemic. Consumers, right now, prefer to buy packed food & beverage rather than going to restaurants.

Ecommerce has also witnessed a positive impact due to the pandemic. Consumers are opting for online shopping for products instead of buying from brick & mortar stores, which is preferred for the purchase of a small

number of products or rapid fulfillment of the same. Moreover, consumers are buying onetime usable plastic pouches owing to hygiene issues. An increase in demand for FMCG products due to the pandemic is attributed to the growth of flexible plastic pouches.

www.packagingnewsletter.com 10

Driver: Rising de- rise in demand for packmand for packaged aged food subsequently food and beverages drives the demand for pouches.

Increasing health awareness and growing Restraint: Stringent per capita income has government regularesulted in the rise in tions demand for packaged Pouches are one of the food and beverages, fastest-growing segwhich, in turn, drives ments of the flexible the demand for pouchpackaging industry. es. According to ASHowever, stringent regSOCHAM (The Associatulations imposed reed Chambers of Comgarding flexible plastic merce & Industry of Inpackaging may pose a dia), an annual increase restraint to the market. of 22.5% has been witCompliance with regulanessed from 2010 to tions is necessary as the 2015 in the packaged smallest defect in packfood annual spending in aging may contaminate India.

The Growing the product; it may also westernization, along affect the manufacturwith an increase in the ers’ profit. Packaging for standard of living and food & beverage, perpreference for convensonal care, and ience food products, healthcare products recontributes toward the quires properties such rise in demand for packas moisture resistance, aged food products. The

barrier against light, and ease of transport.

Regulatory bodies for flexible plastic packaging include the Food and Drug Administration (FDA), the European Commission, and the US Environmental Protection Agency (EPA).

Opportunity: Growing popularity of pouches in alcohol packaging Alcohol packaging in pouches has recently started to gain popularity. Pouches are flexible, compact, lightweight, and cost-effective; they also contribute to aesthetic appeal and have the ability to preserve flavor & quality, which contribute to their increasing adoption in alcohol packaging. Furthermore, they also have oxygen & contami-

www.packagingnewsletter.com 11

nation barrier properties, which play a vital role in extending the freshness of the product. Currently, pouches are increasingly used for the packaging of wine, spirits, and beer.

This packaging format for alcohol is largely used in the US, Australia, and South Africa.

Challenges: Availability substitutes

of

The substitutes for pouches in the packaging industry include rigid containers and poly bags. Rigid containers include bottles, jars, cans, and containers and find wide application in the food & beverages, personal care, and pharmaceutical industries. The impact strength, high robustness, and barrier properties of rigid containers have contributed to its popularity across industries. Rigid containers are the most widely used and popular form of packaging in the food & beverages industry.

Polyethylene is the largest material segment of the flexible plastic pouches market The flexible plastic pouches market is segmented on the basis of material into polyethylene, polypropylene, and others. The polyethylene material segment accounted for a larger market share.

This is attributed to its unique flow properties such as propensity to stretch when strained, low production costs, high clarity, heat sealability, high elongation, and softness make it suitable for pouch packaging. Polypropylene is projected to be the fastest-growing material segment. This is attributed to its good resistance to almost all types of chemicals, including strong acids, alkalis, and most organic materials, and its high melting point makes it a superior material for boilable packages and sterilizable products.

Flat pouches is the largest type segment of the flexible plastic pouches market The flexible plastic pouches market is segmented on the basis of type into flat pouches and stand-up pouches.

The flat pouches segment led the market in terms of both value and volume.

Its costeffectiveness and aesthetic display in stores contribute toward its leading share in the flexible plastic pouches market.

Food is the largest application segment of the flexible plastic pouches market

The flexible plastic pouches market is segmented on the basis of application into food, beverage, and others.

Food application segment accounts for the largest market share in the market. Its malleability and low weight, along with the protection that it offers against contaminants make pouches an ideal

www.packagingnewsletter.com 12

packaging solution for food packaging products, leading to its large market share.

APAC is the largest market for flexible plastic pouches market The APAC region is projected to be the largest market and to grow at the highest CAGR during the forecast period.

Growth in APAC is backed by the increase in disposable income of people in countries such as China and India, growing middle-class

population, rise in demand for packaged food, and the growth of the food & beverage industry. Moreover, the growth of the flexible plastic pouches market in the APAC region is attributed to the higher consumer spending and manufacturing of packaging materials in developing economies, such as China and India. China is projected to be the fastestgrowing market across the globe during the forecast period. This is attributed to the popu-

lation growth in the country, along with the high availability of packaging material coupled with technological development. This directly affects the growth of the flexible plastic pouches market in the APAC region.

Berry Global Inc. (US), Mondi (UK), Huhtamaki (Finland), Sealed Air Corp.

(US), Sonoco Products Company (US), Smurfit Kappa (Ireland), Amcor Plc (Switzerland), Gogllio SpA (Italy), Constantia

www.packagingnewsletter.com 13

Flexibles (Austria), and ProAmpac (US) are key players in flexible plastic pouches market.

Recent Developments In August 2020, Sealed Air Corp. announced that it had signed a collaboration agreement with Plastic Energy, an industry-leading company in advanced recycling technology. Additionally, Sealed Air has made an equity investment in Plastic Energy Global, the parent company of Plastic Energy.

In July 2020. Mondi partnered with Austrian meat producer Hütthaler to produce a fully recyclable thermoforming film made from a mono-material for their meat and sausage products. The film is made of a mono-material solution that can be fully recycled and provides a barrier to protect the food and extend its shelf life. The independent cyclos-HTP Institute for Recyclability and Product Responsibility has awarded this film the highest classification "AAA" for recyclability.

In July 2020, Mondi invested in its flexible packaging plants, in Aramil and Pereslavl in Russia, to provide customers with improved flexibility and a broader portfolio, including sustainable packaging solutions.

In May 2020, Berry Global Inc. announced its collaboration with the longtime customer, Mondelçz International, to supply packaging containing recycled plastic for Philadelphia, the world’s most popular cream cheese.

The package contains plastic material recovered using advanced recycling technology from Berry’s partnership with SABIC, announced earlier this year.

In May 2020, Huhtamaki and the international charity WasteAid announced a €900,000 (USD 1,011,330) partnership to drive communitylevel circular economy innovation in Vietnam, India, and South Africa for a two-year period. To mark its 100-year anniversary, Huhtamaki is donating €3 million (USD 3.4 million) to global sustainability initiatives.

In January 2020, Sealed Air Corp. launched a new version of its bubble wrap brand packaging made with at least 90% recycled content. The recycled content used to make this version of bubble wrap brand packaging is sourced from post-industrial materials that would otherwise end up in landfills.

www.packagingnewsletter.com 14

In January 2020, Huhtamaki completed the acquisition of Mohan Mutha Polytech Private Limited (India), a privately owned flexible packaging manufacturer. The transaction was complete for approximately USD 11 million.

In September 2019, Mondi, in a four-year effort with a customer Werner & Mertz GmbH (Germany), developed a fully recyclable, flexible, stand-up pouch for W&M’s Frosch-brand laundry detergent. The product is called StripPouch and has earned certifications from two independent bodies for being 100% recyclable.

•

In September 2019, Sonoco announced the introduction of EnviroFlex PE, which is a recyclable polyethylene flexible packaging. EnviroFlex PE can be dropped off at local retail stores for recycling with grocery bags as it is eligible to use the How2Recycle Store Drop-Off label. EnviroFlex PE is suitable for a variety of products, including cookies and crackers, confections, dry/ dehydrated foods, sweet and savory snacks, pet food and treats, and personal care items.

In August 2019, Sonoco announced the completion of its acquisition of Corenso Holdings America, Inc. (US) from a company owned by investment funds advised by Madison Dearborn Partners, LLC, and management for USD 110 million in cash.

In July 2019, Berry Global Inc. completed the acquisition of RPC Group Plc (UK) for a purchase price of USD 6.5 billion. The combination of Berry and RPC creates a leading global supplier of value-added protective solutions and one of the largest plastic packaging companies.

In April 2019, Huhtamaki launched Blueloop, a new range of recyclable flexible packaging made of mono-material PP, PE, and paper. Huhtamaki Blueloop solutions involve innovative polyolefin structures to pack coffee, snacks, dry food, personal care, and other fast-moving consumer products.

The range also includes paper-based solutions to replace plastic packaging.

In April 2019, Huhtamaki started a new manufacturing plant for flexible packaging in Egypt, with an aim to enter into Africa’s flexible packaging market. The manufactured flexible packaging solutions are expected to serve the market in Egypt and will be exported to the African & European markets.

In March 2019, Sealed Air Corp. invested in increasing capacity at its Simpsonville, S.C. facility to produce plant-based food packaging. The facil-

www.packagingnewsletter.com 15

ity will produce materials from Plantic plant-based resin and postconsumer plastic and is the first such facility in North America.

In February 2019, Sealed Air Corp. acquired MGM Blendwell Corporation's (Philippines) flexible packaging business. The acquired company specializes in printing and laminating and offers flexible food packaging materials in Southeast Asia for the consumer-packaged goods market. This strategic initiative will help Sealed Air to leverage MGM’s expertise in lamination and printing capabilities.

In June 2017, Sonoco (US) expanded its ClearGuard flexible packaging portfolio to include pouches for viscous and liquid products. The added fea-

www.packagingnewsletter.com 16

ture holds the ability to withstand retort cooking processes and rigors of the hot fill.

In December 2016, Berry Global Inc. launched a new line of pouch packaging named ‘Entour.’ This product line includes non-laminated stand-up pouches for catering to the packaging needs of baking mixes, snacks, rice, pasta, granola, confections, and dry contents. This strategic initiative strengthened the company’s stand-up pouch product line.

www.packagingnewsletter.com 17

Maintaining good tension control Nick Coombes speaks with Gavin Rittmeyer of Martin Automatic about the company’s solutions to this perennial problem

NC: What are the basic NC: How can these isissues that cause the sues be countered? problem?

GR: Machine designers GR: Printers and con- need to consider the verters know that con- characteristics of the trolling tension in a web web, the weight of the is essential to the quali- roll, the mass of the ty of the finished prod- system, and the capauct. Web tension prob- bility of downstream lems can arise from equipment, often but several issues with the not always a printing unwinding roll. These press. They also have include deceleration, to allow for the set tenthe action of splicing, sion and tension control and acceleration of a requirements of the new roll. Out-of-round process, whatever it is. or unbalanced rolls also This can be done with a cause tension disturb- transducer or dancer ances, even during system. steady state unwinding.

NC: How transducer work?

does the system

GR: Typically, a transducer or load cell system relies on the principle of ‘sense and correct’. It uses a tensionsensing device, like a transducer roller and, through an appropriate control system, attempts to maintain the output of the sensor constant. This type of system has no ‘storage’, and its response-time limits its ability to adjust for rapid changes, so that tension transients are passed along to the process

www.packagingnewsletter.com 18

NC: And the dancer sys- tational (rotating dancer tem? motion) inertias.

So, unlike a typical load cell GR: This is our preor transducer system, it ferred way, with the actually ‘absorbs’ tendancer using the princision disturbances rather ple of inertia compensathan passing them tion that effectively abalong to the process. sorbs tension upsets The result is consistent and delivers constant web tension. web tension to the process. This method relies on the principle of NC: This sounds like a ‘establish and maintain’. simple principle of physTension is established ics? by the dancer, and strictly proportional GR: It is, and it typifies feedback from its travel Martin Automatic’s apis used to maintain the proach to engineering in dancer within its stroke. that we never seek to Inertia compensation is complicate that which achieved by engineering can be achieved simply the system components using fundamental printo balance the transla- ciples. Over the years, tional (up and down we have introduced indancer motion) and ro- ertia compensated ten-

sion control devices to the coating, printing, and converting industries, and made a major technical contribution in every case. The concept remains the simplest and most accurate means of delivering constant tension. On the market, and the principle is used for infeed and outfeed tension control systems, as well as Martin’s extensive line of unwinding and splicing systems.

NC: What makes it so special?

GR: Inertia tion can be any web and applications.

compensaapplied to virtually all It is espe-

www.packagingnewsletter.com 19

cially beneficial in processes that involve lower tensile strength substrates, such as nonwovens and extensible films, where an inertia compensated dancer absorbs tension spikes that could otherwise lead to neck down or permanent deformation of the web. In these instances, customers can easily control tension to within +/ - 0.25 pounds (1.1 Newtons) total variation, without the need for any complex control logic.

neers can select from sated dancer to provide tension several standard fes- infeed-quality toon configurations with control to the process. different web storage and acceleration profiles. Depending on the application, some accumulators include a separate inertia compen-

NC: What does the Martin solution entail?

GR: A Martin zerospeed splicer includes a festoon accumulator that not only supplies web to the process at full speed during the splice cycle, but also utilises inertia compensation to absorb tension upsets. When putting together splicer specifications, Martin engi-

www.packagingnewsletter.com 20

NC: Does this technolo- existing processes and gy have to be part of improving web handling of lighter or thinner mathe OEM installation? terials. Once again, by GR: No, it doesn’t! And using simple principles this is an important facof physics, we have tor because Martin fesdemonstrated how to toon and dancer sysimprove productivity tems are easy and ecoand become commernomical to retrofit, cially more successful. providing a means of increasing the speed of

www.packagingnewsletter.com 21

Elif Plastik choose Fast Bridge Adaptors developed by Rossini Elif Plastik, one of the global companies of the flexible packaging industry, closely follows the technology for trouble-free printing processes and high quality prints. Elif Plastik prefers its choices for printing materials and machines with the latest technology.

Elif Plastik is one of the leading flexible packaging companies in Turkey and also one of the customers of Rossini who has been using “Carbo Bridge Adapter” and “Starcoat Sleeve” products with satisfaction since many years.

chine of the W&H Novoflex II series to its machine park, Elif plastik preferred the newly developed “Fast Bridge Adapters” from Rossini brand in order to achieve better printing results.

Mr. Karim Hamdy, “Printing Executive” at Elif Plastik company, explained the reasons they preferred “Fast Bridge Adapters” developed by Rossini:

Elif invested recently a new technology of W&H Novoflex II series of Flexo Printing Machine which is equipped with new generation “Fast Bridge Adapters” from “We observed important Rossini. advantages while workWhile adding the new ing with Novoflex II technology printing ma-

machine equipped with Fast Bridge Adapters”.

We are able to run the machine with maximum speed (600 m/min) most of the time without having any problems.

With Fast Bridge adapters we are not facing Misprint problems .

Machine is very stable and we didn’t face any kind of pumping or (bouncing) effect .

Even at high speed we are not facing ink splash problems .

www.packagingnewsletter.com 22

We prefer to run the Novoflex II printing machine with Fast Bridge Adapters especially for long orders with high speed and difficult designs with misprint problems .

As Elif Plastik we are really happy about the performance .

Fast Bridge adapters are currently only available on our Novoflex II machine, but we foresee to equip also our other presses with these adapters.

Elif has a global reach, is a trusted partner worldwide and a global benchmark company for flexible packaging. In its two world-class plants with state-of-the -art machinery in Istanbul and Cairo, over 1,600 employees produce flexible packaging that is used in more than 200 productions sites in over 50 countries. Elif targets to be achieved by 2025, to develop packaging that is 100% recyclable, reusable or compostable.

Rossini, a family owned company founded in 1928 and is now managed by the 3rd generation. Rossini has a wide product range of sleeves and adaptors for flexo and rotogravure printing, offset, coating and lamination.

Rossini also manufactures equipments such as grinding machines, sleeve storage systems,

central cylinder cleaning systems. Rossini company is a pioneer in the development of many products in the sector,as well as a solution partner of many wellknown Printing Machine brands. Rossini brand is being represented by Almelek company in Turkey.

www.packagingnewsletter.com 23

Neuefeind unlocks the full potential of the KODAK FLEXCEL NX System from Miraclon to the benefit of packaging printers Neuefeind GmbH of Ochtendung, Germany, provides flexographic technology services encompassing all aspects of the packaging process, not just prepress and platemaking. The family-run firm employs 20 specialists, with its business roughly breaking down to 60% for direct printing on corrugated board, 20% for preprint corrugated and 20% for flexible packaging.

Neuefeind operates a FLEXCEL NX Wide 5080 System from Miraclon, which allows flexo platemaking in formats of up to 1270 x 2032mm. Customers in various sectors of the packaging printing industry profit not only from the higher print quality that comes from production with FLEXCEL NX Plates but also from improved efficiency, productivity and stability on press.

Depending on the job and the printing application, Neuefeind can supply both press-ready FLEXCEL NXC Plates for printing on corrugated and FLEXCEL NXH Plates in different thicknesses for other uses.

According to Sven Neuefeind, Technical Director and Quality Management Officer, “customer feedback regarding the FLEXCEL NX Plates is invariably positive, and indeed many

clients are reluctant to accept anything else.

DIGICAP NX Patterning, which enables maximum control and stable ink transfer in combination with Advanced Edge Definition (AED), is a decisive criterion when it comes to getting the most out of the FLEXCEL NX Plates.”

Neuefeind confirms that “choosing the optimum DIGICAP NX Patterning really can make all the difference.” The compa-

www.packagingnewsletter.com 24

ny has its own selection strategy here, which was developed especially for this purpose and takes account of the press parameters.

FLEXCEL NX Solutions – much more than simply better quality

150 to 175lpi. The client is similarly impressed about the plates’ printing results, notably in the highlights.”

Numerous customers in the corrugated sector have testified to the FLEXCEL NX Plate technology’s other positive effects – the higher ink densities and better opacity on coated top liners, the improved ink laydown during overprinting (e.g. text on background graphics, particularly with metallic inks). DIGICAP NX Patterning also enables control of the ink volume transferred on press with only one set of anilox rollers but producing corrugated print jobs with varying types of top liner.

When asked where the advantages of the FLEXCEL NX Solutions lie for printing on corrugated, Peter Schreier, Customer Service Director, mentions the example of a longstanding customer who does most of their business in the premium segment with coated top liners: “Our FLEXCEL NXC Plates were the catalyst for the client’s tremendous leap in press productivity because they permitted significantly longer cleaning intervals, even Schreier, cites an examwith fine line screens of ple from a flexible pack-

aging customer: “By switching to FLEXCEL NX Plates, our customer realized a double-digit increase in productivity on an older press. Plate cleaning intervals have been all but eliminated, even during temporary print stoppages. We also found on-press behavior to be very stable in the highlights, which is good for print quality.”

The FLEXCEL NX System’s capabilities have repeatedly helped Neuefeind win orders for flexo from other printing processes, for instance from digital as illustrated by a recent example at a paper napkin production plant.

“The customer wanted a subject to be printed in digital-like quality. The challenge was that the

www.packagingnewsletter.com 25

image to be printed consisted simply of multi-colored rings with smooth gradients approaching a tonal value of 0%. The whole project was rendered even more difficult by the fact that, owing to the press configuration, it was not possible to exchange the anilox rollers in order to adjust the pick-up volume,”

Schreier explains.

“However, by applying our unique FLEXCEL NX Plate imaging strategy, we managed to print the application using Maxtone hybrid screening on FLEXCEL NX Plates, and no tonal breaks or ink build-up were visible.”

dispensable production tool for Neuefeind.

Forward-looking partner for packaging printers

Neuefeind GmbH was founded in 1993 by Dieter Neuefeind, who is still Managing Director today. Over the decades, the business has evolved from a small The KODAK FLEXCEL specialist agency to a NX Solution from Miratechnology-oriented clon has become an in-

www.packagingnewsletter.com 26

service provider with four separate divisions.

Neuefeind Prepress covers prepress, data organization and platemaking while Neuefeind Support assists users with all printing-related matters.

Neuefeind Academy caters to the printing and marketing sector’s growing demand for customized training and Neuefeind

Innovation focuses on future applications relevant for the printing and packaging trade, with the aim to formulate suitable solution strategies for the company and its clients.

Neuefeind has several industry certifications, including a quality management system certified to DIN EN ISO 9001.

www.packagingnewsletter.com 27