FPT 3 2023

Wipak strengthens gravure division and supports sustainability pledge with BOBST oneECG

Analysis of Dot Gain Produced by Interactions of Flexo Plate and Anilox Roll Screen

The EREMA Group drives a new era in plastics recycling

Labelexpo Europe 2023 showcases vibrant industry

Understanding the performance of sustainable consumer goods packaging

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Flexography prints on non-absorbent as well as absorbent substrates using liquid ink. With developments in photopolymer plate and anilox roll manufacturing technology, we can print half tone with screen frequencies exceeding 150 LPI (Lines per Inch) where the print quality can be comparable with offset printing results.

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Interview with Manfred Hackl , CEO of Erema Group

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The first edition of Labelexpo Europe since 2019 has closed on a high note, with a total of 637 exhibitors taking part in the show, which took place between 11-14 September at Brussels Expo in Belgium.

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In recent years, the world has witnessed a shift in demand for more sustainable packaging designs, particularly for consumer goods packaging. Legislation – particularly variations on a plastic tax – has driven this change in the packaging industry.

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Driven by its vision to become the most sustainable company in the flexible packaging sector, Wipak Walsrode, together with BOBST, has set out to take its gravure printing division to a new level with BOBST’s oneECG technology. The company is thus continuing its long-standing partnership with BOBST.

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Analysis of Dot Gain Produced by Interactionsof Flexographic Plate and Anilox Roll Screen Frequencies Flexography prints on non-absorbent as well as absorbent substrates using liquid ink. With developments in photopolymer plate and anilox roll manufacturing technology, we can print half tone with screen frequencies exceeding 150 LPI (Lines per Inch) where the print quality can be comparable with offset printing results. This has helped flexographic printer to reproduce the blackand- white, single colour tone and full colour graphic original, satisfying the printing and packaging needs of many customers.

But unlike other printing technologies in flexographic printing screen frequency of plate i.e. image carrier and engraving line frequency of anilox roll collectively affect the smoothness and uniformity of reproduced half tone image. Furthermore, the LPI of the screen used in plate making also adds to variation in tonal reproduction. In the presented work 3 line frequencies expressed in CPI (Cells per Inch) of anilox roll and 5 screen frequency of image carrier are selected and their effect on print characteristics is studied using the plot of theoretical dot area against apparent dot area. Given the sizable capital investment involved in manufacturing of anilox roll, this work is directed at finding the optimum combination of screen frequency and line frequency required to achieve tonal balance.

Flexography’s applica- ing technology repro- per Inch) of 150 and tion area label, flexible duces colour in line and above [1]. It represents and rigid package print- half-tone form. It is ca- 75% of the $440 billion ing and industrial print- pable of producing half printed packaging maring application areas. tone print at screen fre- ket. 92% of its global Flexography as a print- quency i.e. LPI (Lines volume is packaging,

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h 8% divided among tions are 55, 65, 70, 85, being the costliest part pharmaceutical, security 100, 120, 133, and 150 of the flexographic printing, printed elec- with increasing screen printing unit; for small tronics and similar mar- frequency officering and medium scale printkets [2]. smoothened print. The ers this requirement line frequencies of adds to the procureIn flexography ink anilox roll available ment and carrying cost transfer and print qualirange between 250 and of the anilox roll inventy is controlled by an 1200 [3]-[4]. The flexo- tory. This general situaanilox roll that transfers graphic printers follow tion prevails in the laink to half tone image the industry standard bel, flexible and rigid on a flexographic image that the line frequency package printing and incarrier i.e., plate. The of anilox roll should be dustrial printing applicaanilox roll has a helical at least 3- 4 times that tion areas of flexogrow of tiny cells enof printing plate screen raphy. The use of regraved at regular spacfrequency so that 3% duced anilox inventory ing and angle. The finehalf tone dot can be has other advantages ness of an anilox roll is printed. Even in some like the benefit of indedefined by a number of situations printers pendence on the suppliengraved cells per linear maintain this ratio at 4 - er for providing specific inch often called line 5. With this yardstick type roll, less lead time frequency expressed in printer for a screen fre- in case of breakdown, CPI. Therefore, the regquency of 70 LPI can less storage space reular geometrical patselect an anilox roll line quired to maintain interns of half tone image frequency between 280 ventory, no more downscreen frequency in and 550 CPI [5]. Of time in changing the question and the anilox course, the print re- anilox roll at the time of roll of identified line frequirement of the small- change in product or quency interact with est halt tone dot area application, improved each other and decides demands a finer anilox productivity, reduction the ultimate half tone roll but still, the printer in consumption of print quality of half tone has a choice of anilox cleaning solvents used and process colour flexline frequencies. There- during each changeover ographic printing [3]. fore printer is required and reduced operating The screen frequencies to keep an inventory of cost. The tiny cells are employed in a label, anilox roll with multiple engraved at 300, 450, flexible and rigid packline frequency for the 600, and 900 angles to age printing and indusintended screen fre- the axis of the metallic trial printing applicaquency. The anilox roll anilox roll. The hexago-

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nal cell geometry en- troubles arising on ac- image, halo effect or graved at 600 increases count of the use of squeezed edges on the the resolution of the anilox roll with too low half tone dot moiré efanilox roll and is widely line frequency are fect, High color used in flexographic bleeding-smudging, strength. On the other printing. The ink stor- blocking, bridging, ink side too high line freage capacity of an build up on edges of the quency results in a anilox roll is expressed in BCM (Billion Cubic Micron) per square inch of engraved surface. Typical values of anilox roll ink volume range from 9-4 BCM for heavy lines and solids to 2.8 to 0.9 for process colour printing [5]. Higher volume translates to higher solid ink density, more colour or a heavier coating thickness. Lower volumes apply thinner ink films directly associated with higher print quality and process efficiency.

The higher the line frequency of the anilox roll the lower its ink volume and vice versa. Multiple choices of anilox roll line frequencies for a given half tone print resolution i.e., screen frequency can result in the use of anilox roll with too low or too high line frequencies and limits print quality in half tone printing. The printing

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transfer of lower ink maintaining inventory of used in identifying comvolume ghosting effect multiple anilox line fre- mon screen angles for low colour strength [6]. quencies. At present, multiple screen frequenIt is also observed that the selection of anilox cies involved in half the higher line screen rolls during half tone tone screen printing. anilox rollers tend to printing for various ap- This approach provided become more clogged plications is governed a tool to reduce secondmore and lose their ad- by industry standard ary moiré problems in vantage of introducing recommendations given printing [8]. The charhigher LPI counts if not by technical services of acteristics curve is cleaned properly [7]. anilox roll manufactur- largely used in colour The proposed work in- ers. Such recommenda- control during lithovolves identifying an tions presented in terms graphic offset printing in anilox roll line frequency of the range of multiply- process optimization that is capable of half ing factors to get anilox and identification of sigtone printing at different roll line frequency from nificant variables. Also, screen frequencies lead- a given screen frequen- the effects of laser ening to a reduction in in- cy are observed to take graving settings on etch ventory of anilox rolls place from 3 to 5.5. The depth of polymer clichés with varying line fre- approach of plotting was carried out for difquencies.

Half tone characteristics curves, a ferent screen frequency printing performance in useful element in de- and screen angles to term of characteristics scribing half tone print study pad printing qualicurves is compared for performance, has been ty [9]. But the applicavariation at identified anilox roll. The anilox roll line frequency showing overlapping or close characteristics curves with reduced dot gain can be preferred over others. This systematic approach eliminates the reliance on industry standard of selecting anilox roll line frequency with 4- 5 multiple of screen frequency and the need of

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tion of such a subjective inking the excess ink is strate producing print. approach in identifying scraped off the surface Flexographic printing an anilox rolls line fre- of the anilox troll by a technology uses liquid quency that can accom- metallic doctor blade ink with a viscosity modate has not been [9]. The resolution of range of 50-500 mPas suggested by authors anilox engraving is ex- and offers an ink film and anilox roll manufac- pressed in cells per line- thickness of 10-15 miturers. ar inch i.e. CPI. The ink crons [10]. The remainfrom anilox is received ing paper is structured 2.

FLEXOGRAPHIC by the relief parts, that to discuss the materials, PRINTING TECHNOLis, image areas of the parameters and reOGY plate and finally trans- quired trials run in secThe printing unit of the ferred onto the sub- tion 3, results and disflexographic press and principle is shown in figure 1 and 2. The flexographic press is a roll-to -roll, direct rotary technology using wrongreading flexible relief image carriers called plate. The inking system of the flexographic printing unit consists of an ink fountain and an anilox roll. The anilox roll has a pattern introduced by engraving on its surface to hold and transfer ink to the substrate in question. The structure of the anilox roll surface is shown in figure 2. Anilox roll is a mild steel cylinder with a finely engraved chromium or ceramic surface and is dipped in the ink reservoir. During

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cussion is considered in section 4.

Identified conclusions are communicated in section 5.

3. MATERIALS PARAMETERS

AND

The experimental set up includes varying and constant parameters as stated in tables 1 and 2.

The experimental model chosen covers a total of 15 trials. The printing was carried out on a narrow web flexographic printing machine. Fifty sheets were printed for each trial with strict control keeping over constant parameters.

The response variable identified is the dot area of each gradation expressed in percentage.

The test image identified for printing 15 trials as designed above has combined five half tone grey scales of five screen frequencies and three anilox roll engraving frequencies as shown in table 1. The grayscale helps facilitate the measurement of the dot area of each tone gradation from each trial print using an elec-

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tronic densitometer. The test image as used in the trials is shown in figure 3. During the measurement of percentage dot area five random prints of each trial were selected as samples wherein each sheet i. e. sample involved dot area measurement of 180 half tone steps. A round dot shape is typically used to counter the possibility of high dot gain [11]. The parameters shown in table 2 are process variables capable of affecting print quality and are held constant to get characteristics curve plots giving performance relationship between screen and anilox roll line frequency. The substrates have different ink absorption rates and give different ink film thicknesses. UV (Ultraviolet) inks have high colour strength with workable viscosity as that of water- and solvent-based inks [12]. Dot area measurement is carried out with a SpectroEye photodensitometer with

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D50 illuminant, 100 ob- 55, 70, 85, 100 and 133 whereas the 55 LPI is server angle, density LPI in appendices 1 and the minimum dot gain. standard T, and 45:0 2 respectively. Graphs Also, absolute dot gain measuring geometry are plotted with data decreases with increassetting. 100 observer tabulated in appendices ing anilox frequency if angle was preferred to 1 and 2. Figures 5, 6 the screen ruling is held 20 for a wider area of and 7 show the percent- constant. This behaviour view in the blue-green age dot area curves, is observed with print region of the spectrum. which is the tonal i.e. screen frequencies A standard calibration curves of the prints at 55, 70, 85, 100 and and operating procedure various screen frequen- 133. Also, figures 5 to is followed during meas- cies for the anilox roll 10 suggest that the aburement. All measure- line frequencies of 500, solute dot gain is not ments yielded 150 read- 700 and 1000 lines per varying much for 70, ings as data to be pro- inch. In these graphs x- 85, 100 and 133 LPI for cessed for getting infor- and y- axes are repre- anilox frequencies as mation about dot gain. sented by theoretical corresponding plots in dot area (%) and ob- figures 8, 9 and 10 4. RESULT AND DISserved area on print show that except 55 LPI CUSSION (%) respectively. Simi- screen curves of 70, 85, 150 gradations from 15 larly, figures 8, 9 and 10 100 and 133 LPI appear trials printed with offset show the absolute dot comparatively closer at press used for measure- gain curves at anilox roll higher anilox frequency ment of the response line frequencies of 500, that is 100 CPI. At 500 variable that is dot area 700 and 1000 lines per CPI the behaviour of dot percentage from indi- inch. In these graphs x- gain curves plotted for vidual grey scale wedge and y- axes are repre- 50, 70, 85, 100 and 133 for all combinations of sented by theoretical LPI are different, in this screen frequencies (LPI) dot area (%) and calcu- case, they are clearly and anilox screen rul- lated absolute dot gain distinct. In the case of ings (CPI). the percent- respectively Figures 5 to anilox frequency 700 age dot area values 10 show that at the CPI the dot gain curves were calculated. The same anilox frequency, plotted for 50, 70, 85, observed dot area and the absolute dot gain in- 100 and 133 LPI appear absolute dot gain values creases with screen rul- to be a little closer. The are tabulated for anilox ing (LPI). Therefore, in Anilox Line Frequency to rolls of 500, 700 and these trials screen, the Screen Ruling ratio for 1000 lines per inch with ruling of 133 LPI is 55, 0, 85, 100 and 133 screen frequencies of showing the maximum screen rulings and 500,

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700 and 1000 CPI is selecting one anilox roll lection of an anilox roll shown in table 3 below. line frequency for multi- having a higher CPI As compared to table 1 ple screen frequencies count is always useful, of ISO 12647-6:2020 that optimizes that tonal the economy is also one instead of the tone val- loss in half tone printing of the important factor. ues on the printing form remains the best alter- Industrial houses assothe value on the printed native for the flexo- ciated with the manusheet are measured for graphic printer. The dot facturing of anilox roll 55, 70, 85, 100 and 133 gain curves at a given have proposed different LPI and the dot gain anilox frequency show anilox roll frequency-tovalues are observed to the same pattern that a LPI ratio for flexographic be +/- 2 and +/- 3 for higher CPI:LPI ration printers which varies ruling up to 120 LPI and produces the minimum between 4 and 6 inabove 120 LPI respec- dot gain and vice versa, stead of one anilox entively.

Furthermore, but these ratios offer graving frequency for measurement condition many distinct values the printer. Besides this is kept uniform and and suggest irregular significant variation in measured tone values deviation among the dot anilox frequency variaare considered for re- gain curves. Also, the tion; the flexographic sults and discussion. As extreme LPIs behave printers also have to per ISO 12647-6:2020 differently but the mid- consider the customer recommendation.

No dle three LPIs offer requirement of minimeasurement of tone comparable perfor- mum reproducible dot values on the printing mance in terms of dot percentage on print. A plate is carried out. gain as compared to the flexographic printer is, lowest and the highest therefore, required to 5. CONCLUSION LPIs that any printer keep cell opening smallIt can be concluded handle. Though the se- er than the minimum from these trials that in flexographic halftone printing the dot gain increases with increasing screen frequency and decreasing anilox roll line frequency.

The anilox frequency is responded to clearly by the lower and higher screen rulings. Hence,

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reproducible plate dot, ography is the secondand such a situation will ary or tertiary moire bedemand more finer cause of an anilox roll anilox roll. In identifying patterned surface. Bean anilox roll that sides flexography, matches with the plate screen printing also LPI printer may invaria- shows problems of secbly end up using too fin- ondary and tertiary er an anilox roll. Such moire because of patinstances can increase tern of screen mesh. the possibility of an in- This more problem can ventory which is more occur with both singlethan required and color half tone and problocking of funds. This cess colour printing. experiment has helped This work can be exflexographic printer to tended to design an exoptimize both engraving periment to optimize frequency and repro- screen angle for half ducible LPI. tone printing in flexography that involve the 6. FUTURE SCOPE use of multiple anilox The CPI:LPI ratio as a roll and screen frequenguide to select the cies. anilox roll for a screen frequency in question is actually a recommended value and every printer selects an anilox roll as per the economy he can afford to keep customer requirements in mind.

There cannot be the best CPI:LPI ratio in flexographic printing instead there is a range of anilox roll frequencies that printer can select from. Another issue that printer can face in flex-

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Understanding the performance of sustainable consumer goods packaging throughout the supply chain In recent years, the world has witnessed a shift in demand for more sustainable packaging designs, particularly for consumer goods. Legislation, particularly variations on a plastic tax – has driven this change in the packaging industry. This article examines the concept of a plastic tax for consumer goods packaging, challenges, and how you can ensure sustainable packaging performs as required throughout complex supply chains.

What is the plastic introduced per-tonne of tective layers to avoid tax? The plastic tax is packaging. This espe- having to pay fines.Not an initiative designed to cially impacts medium only is redesigning create economic incen- to large-sized, fast- packaging a costly protives for businesses and moving consumer cess in itself; it also consumers to reduce goods (FMCG) compa- brings about many untheir reliance on single- nies, where fines can knowns around pack use plastics. It encour- quickly amount to sig- performance, quality, ages manufacturers and nificant penalties. functionality and durabrand owners to explore bility. There are conChallenges for conalternative packaging cerns that should a sumer goods The inmaterials for their prodpack not be able to troduction of a plastic ucts. In the UK for excope with the rigours of tax drives manufacturample, you will have to the supply chains in ers and brand owners pay the Plastic Packagwhich it will need to to investigate redesigning Tax if you have function, then there is ing packs with new mamanufactured or imsevere risk to the integterial compositions, usported plastic packaging rity of the product and ing non-virgin plastics components which conan increased likelihood and other alternative tain less than 30% rethat the product would materials. This includes cycled plastic. Fines are not be saleable in a revoid fill and other pro-

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tail ment.

environ- which can vary it is important dramatically in to have confitemperature dence in its caManufacturers and humidity pabilities before want to ensure throughout a entering the that any redesingle journey. supply chain. signs have been Once the pack validated and How Smithers reaches land, it performance can help will likely travel levels are via lorry

by Smithers offers known before roads which can comprehensive new packaging vary in quality. packaging dedesigns enter The pack will sign support, the supply need to be able leveraging years chain. to endure vibra- of expertise to tion and harsh help clients creDifferent loads. ate and evaluate transit routes braking this new packaging require differ- Following ent considera- the pack would solutions. tions to pack- have to cope Through using with the associaging When a advanced equipteam develops ated drops and ment to simunew packaging impacts that can late various conduring ditions and realand utilises al- occur ternative mate- manual handling world scenarios, rials, particular when unloading their team asitems at their sists in ensuring consideration must be made end-destination. that new pack journey designs to the challeng- This can alone poses es the pack will withstand the many risks to a face throughout challenges of Other the entire supits service life. pack. routes ply For example, a supply chain, can be even premium conproviding assursumer item such more demand- ance of their as a new mobile ing for a pack, suitability and such as air phone will likely reliability in with their be shipped freight intended and applications. around the pressure globe on ship- temperature ping containers fluctuations, so 17

Labelexpo Europe 2023 showcases vibrant industry The first edition of Labelexpo Europe since 2019 has closed on a high note, with a total of 637 exhibitors taking part in the show, which took place between 11-14 September at Brussels Expo in Belgium.

Spread across nine halls sales across the four successor to the hugely and covering 36,588 days and an exhibitor successful HP Indigo sqm of floor place, this rebook rate of 96% was 20000. The company year’s show featured reported for Labelexpo also ran a ‘digital pouch over 250 product Europe 2025. factory’ ecosystem launches focused particdemonstrating pouch Demonstrating how Laularly on flexible packmanufacture and finishbelexpo Europe is aging, digitization and ing of other unsupportevolving into a package automation. ed films including shrink printing show, digital sleeve labels.

The unprecedented printing of paper-based heatwave in Brussels flexible packaging ma- Flexo made a major did not deter 35,889 terials was evident on comeback at this show, visitors from 138 coun- the show floor, with pa- with Nilpeter, Lombardi tries attending the four- per-based packaging and BOBST demonstrati day show. Countries printed by Xeikon on ng printing of flexible such as Germany, the new TX-500 Titon packaging and unsupFrance and Italy were toner press ported label film mateespecially well repre- and SCREEN on the rials on 26in/670mm sented, with large visi- Truepress Pac520P – mid-web UV flexo press tor delegations. seen for the first time lines on the show at a Labelexpo. floor. OMET made the Equipment manufacturHP launched the 200k show debut of its KFlex ers announced multiple mid-web digital press, modular flexo platform

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and Mark our exhibitors for your sociation partner of LaAndy launched the Pro partnership and com- belexpo Europe this Series flexo press, up- mitment in supporting year. In spite of the gradable to a hybrid the diverse and exciting heat at the beginning of machine. industry of labels and the show, there was a package printing, to- vibrant mood and genJade Grace, Managing gether with us. Thank eral state of pleasure Director, Labelexpo you to all who visited especially among the Global Series said: from 138 countries, and overseas visitors to re“We’ve just delivered to our association and connect with the global Labelexpo Europe 2023 media partners.” label community after after a four-year break such a long absence." and what a show it has “It has been the hardest been! The feedback we show yet for us to deliv- “For us, Labelexpo is alhave received from visi- er, but the most reward- ways an excellent optors and exhibitors alike ing. We are looking for- portunity to meet with has consistently shown ward to the next chap- members, potential the high quality of ter in 2025 where we members and other inleads, enquiries and will be bringing Labelex- terested parties and to contacts made at the po Europe to its new engage in conversations show, with an incredible home at the Fira in Bar- about our current and number of sales secured celona, with many plans future programmes, and on the exhibition floor. to stimulate growth and to recruit members and We have also secured a collaboration in the in- enlist volunteers for our rebook rate of 96% for dustry.” working groups and Labelexpo Europe 2025, taskforces. This year, Echoing this sentiment, which bodes well for our we featured our efforts Jules Lejeune, Managing first show in Barcelona." to facilitate value chain Director, FINAT said: collaboration on susContinued Grace: “I “FINAT was once again tainability such as would like to thank all proud to be the lead as-

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CELAB-Europe, UV portunity to showcase linerless future, the FoodSafe and Product the leading LEPx-based benefits of EcoDesign, Carbon Footprint, and HP Indigo V12 and HP digital innovations and to act as spokesperson Indigo 200K digital so much more. Thanks of the label industry to- presses for the first for an amazing turnwards European legisla- time in Europe. This out!" tors and stakeholders.” was also a key moment Robert Rae, Managing for us to showcase the Continued, Lejeune: Director of Sales, GEW HP Indigo First mindset “We will miss the Atomisaid: “It was fantastic and how it can deliver um and the World Expo to return to Labelexpo flexibility at speed for 1958 building as the Europe for the first time converters.” background images for since 2019. The exhibimany selfies taken dur- Continued, Zilbershtain: tion was exceptional for ing the show, but we “It was also a pleasure GEW, with a record are convinced that the speaking with peers number of visitors to Fira and its Olympic within the print indus- our stand, and a very Montjuich will be a wor- try, discussing how we healthy order book to thy replacement in are committed to mak- show for it. We dis2025.” ing bold moves that played our full product push innovation bound- range but UV LED was Noam Zilbershtain, VP & aries and deliver value top of the agenda for General Manager of HP for customers. The label most of our visitors."

Indigo & Scitex said: Industry is now poised “It’s through trade “Our air-cooled AeroLED to become the first fully shows like Labelexpo, UV curing system was digital industry, and it is industry leaders have the subject of particular through digital print sothe opportunity to coninterest, and our ability lutions we will transform nect, network and disto demonstrate this businesses globally.” cuss the trends driving technology in action, our industry, such as Steve Flannery, SVP & live on OEM presses at digital innovation and GM Materials Group the show, meant that sustainability. I love be- EMENA, Avery Dennison we could clearly demoning in the thick of it all said: "We were thrilled strate the huge energy connecting with our to be back at Labelexpo and cost savings that customers and part- for the first time since printers can expect with ners." the pandemic and con- a switch to UV LED. We nect together.

Our measured and published “This year, we were booth was buzzing with our energy consumption thrilled to have the opconversations around a live, and were able to

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repeatedly demonstrate pack material construc- aging and sustainable a 77% saving when tions, coating, laminat- labels. compared to conven- ing, ink and curing rePierre Dogliani, R&D intional UV arc technolo- quirements, in-line and novation manager, NW gy." near-line decoration opEurope, Flint Group, tions, QC and migration “To see Malcolm Rae, who spoke at the sustesting. my father and GEW’s tainable labels and founder, being honoured Also well received was packaging master class at the Label Industry Flexo’s Future – ECG, a said: "Engaging in this Global Awards made it series of presentations educational platform the perfect end to the on Expanded Color has been a truly enrichBrussels era.”

Gamut (ECG) printing ing experience, and it's led by Dr Kai Lankinen. been very inspiring to Other major show feaThis was supported by observe the immense tures for Labelexpo Euguided tours across the enthusiasm among parrope 2023 included the showfloor. ticipants when exploring Automation Arena which the realm of sustainable drew in large crowds to A joint presentation by inks and coatings. I beevery one of its ten live Graphimecc and Avery lieve these insights ofdemonstrations. Visitors Dennison on setting up fered attendees a witnessed a fully auto- a track and trace operabroader and more inmated workflow from tion was also well atformed perspective on file creation to turret re- tended. sustainability in the lawind with automated inbel industry." spection and MIS integration, without any Two expert-led Label manual intervention. Academy-hosted master The participants includ- classes covered the hot ed CERM, Esko, Xeikon, topics of flexible packKURZ, Grafotronic and Fedrigo ni Self-Adhesive.

Another key show feature was the Flex Pack Trail, where visitors could deep dive into digital and conventional press technologies, flex

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The EREMA Group drives a new era in plastics recycling Printability Interview with Manfred Hackl, CEO of Erema Group.

Q: How does the ERE- ers. central role in this, acMA Group see the fu- The whole industry is tively shaping the future? working on solutions, ture as a real driver in including a reduction in the new era of plastics MH: In the past busithe use of raw materi- recycling. ness year 2022/23 als, plastic packaging alone, the extruders Q: What do you mean that is designed for resupplied by the compaspecifically when you cycling, traceability nies within the EREMA talk about driving a standards for packagGroup deliver an addinew era of plastics ing, more efficient coltional 1.6 million tonnes recycling? lection and sorting proof recycling capacity. cesses, and innovative MH: Circular economy Our vision is that by technical solutions for and plastics recycling 2030 the circular econhigher recyclate quality. are key topics in poliomy in plastics is a reAs a result, people in tics, day-to-day life and ality. That is why the the value chain are business. Only once the recycling industry needs gaining an ever better circular economy has to continue developing overall understanding of been properly impleand evolving. This will the market. This is ac- mented will it be possirequire new technolocelerating the develop- ble to fully utilise all the gies and innovations to ments towards more re- positive properties of set positive signs for cycling and a better cir- plastics. And that is the future, even in the cular economy. With our what the EREMA Group current challenging group of companies, we has been striving for times for our customwould like to play a

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since it was founded 40 companies. Our next ly when high quality reyears ago. goal is to further in- cyclate and consistent crease the extent of stability as well as enerIn recent years, we added value with a clear gy efficiency are to be have become a pioneer focus on the polyolefin achieved. With our comin recycling technolosector and to set further pany KEYCYCLE GmbH, gies, and we have industry benchmarks. we already offer turnkey worked very hard to To get from waste ma- solutions for the entire bring together staketerial to recycled pel- recycling process inholders in the plastics lets, potential new raw cluding sorting, washing industry for discussion materials need to go and extrusion. We see and interaction. At the through several differ- the next step as an imEREMA Group we have ent recycling processes. portant stepping stone also broadened our The processes range in perfectly matching product portfolio for our from sorting, shredding, the washing process customers. We are well washing and drying to and the recycling exintegrated into networks extrusion including fil- truder. This will enable and can rely on longtration and compound- us to offer all-in-one term partnerships and ing as well as odour op- packages that are cusresearch cooperations. timisation. The chal- tom-built to meet the This means that we are lenge lies precisely in requirements of the able to understand even the optimum fine-tuning market and the needs better what it is that of all the individual re- of our customers. our customers need. At cycling steps - especialthe same time, however, it is essential that we take the entire value chain into consideration.

We need to include the whole picture to create better recycling technologies and optimum solutions for our customers.

Q: What does that involve?

MH: We will continue to expand our group of

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Wipak strengthens gravure division and supports sustainability pledge with BOBST oneECG Driven by its vision to become the most sustainable company in the flexible packaging sector, Wipak Walsrode, together with BOBST, has set out to take its gravure printing division to a new level with BOBST’s oneECG technology. The Lower Saxony company is thus continuing its longstanding partnership with BOBST. The multiple benefits of taining high and con- 50%, and work with Extended Color Gamut sistent quality through- fewer printing cylinders (ECG) printing will sup- out the entire print run. on press. All of which port Wipak’s sustainaallow the company to Make gravure printbility commitment to deliver its products to ing competitive again reduce its carbon emiscustomers faster. Flexiwith oneECG sions to zero by 2025. bility, speed, and delivWith oneECG from In combination, ery reliability with ever BOBST – the most de- BOBST’s expertise in smaller runs and freveloped technology for gravure printing and its quently changing deprinting with seven oneECG technology are signs are among the standardized colors in crucial for the industry most important degravure – the company and offer a variety of mands from customers. will be able to counter advantages. For Wipak, With ECG, these key remassive price pressure it was particularly im- quirements can be met, more effectively and portant to make better while at the same time enable brand owners use of its gravure press lowering manufacturing and retailers to achieve by being able to reduce costs, and reducing enshorter product launch ink consumption by vironmental impact. times, all while main- 30%, setup waste by

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Thanks to the standard- leads to significantly entire production proization by oneECG, ma- higher productivity. In a cess, the ability to profchine downtimes are very competitive market itably print smaller significantly reduced, as where there is currently runs, and reductions in color changes are no extremely intense pres- waste during set-up and longer necessary with sure on prices, we have production changeoevery print job. In addi- to increase our efficien- vers. As a result, many tion, almost all color cy in gravure printing in brand owners and rematching processes order to compete sus- tailers have recognized take place in pre-press tainably with flexo the opportunity to save before the job goes to printing. BOBST oneECG costs by switching from print. The result is high- technology is the solu- gravure to flexographic er color stability and tion for us to this and printing. With oneECG long-term color con- many more challenges from BOBST, gravure sistency even over the in gravure.” printing technology can longest runs, as well as stand up to this develMany advances have accurate repeatability, opment and shine with been made in flexoregardless of whether its outstanding print graphic printing over repeat jobs are printed quality for both small the past decade, includon the same printing and medium-sized as ing significant improvepress or on a different well as large print runs. ments in print quality, press running oneECG greater control over the technology.

Stefan Bruns, Process & Quality Manager Converting and Project Manager ECG at Wipak Walsrode, explained, “oneECG from BOBST offers us the great advantage that we can work with fewer – completely standardized printing inks – and therefore significantly shorten the time when our machines are not producing. This in turn

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Bruns said, “Gravure ware from Esko, color ing cylinder costs that printing has a great measurement technolo- we can offer them chance of becoming gy from X-rite, printing thanks to oneECG. The ‘sexy’ again after being cylinder engraving from successful realization of pushed back by other ICR SpA, and process the oneECG project in printing processes for a inks from, among oth- gravure printing is not long time. At Wipak we ers, Sun Chemical and only based on the right call printing in the ECG Siegwerk. It is available technology, but also on color space ‘GCP – on BOBST gravure trust and support at all Green Choice Printing’. presses either on new levels.”

This Green Choice is machine installations or The close partnership embedded in our sus- as a retrofit option. In with BOBST, which tainability strategy as a both cases, BOBST and dates back more than very important building partners work closely 20 years, was also eviblock in overcoming the with printers to exploit dent in 2022 when challenge for the plastic the full potential of this Wipak supported the packaging industry.” technology.

Swiss company to win Partnerships built on “With its decades of the Golden Cylinder mutual trust and sup- practical experience and Award for technical inport the entire know-how of novation from the GAA the former Italian ma- (Gravure AIMCAL AlliBOBST’s oneECG is built chine manufacturers ance). Wipak’s glowing on major advances in (e.g., Schiavi, Cerutti) testimonial was instruprinting and pre-press that are now part of the mental in BOBST wintechnology. These enacompany, BOBST is the ning the trophy for ble more precise control gravure printing special- ‘Advanced Register Conof processes and allow ist par excellence,” says trol for Precision Printpackaging manufacturMr. Bruns. “Our long- ing and ECG in Gravure’ ers to work within sigstanding cooperation – a prestigious accolade nificantly tighter tolerwith BOBST is invalua- that represents the 14th ances. ble for Wipak, but it al- Golden Cylinder for The oneECG solution for so offers our customers BOBST in the history of gravure printing was enormous advantages. these awards. developed by BOBST in They appreciate the first Wipak Walsrode is curclose collaboration with -class print quality and rently developing a industry partners. It is a the cost advantage due oneECG future strategy complete system with to the sometimes signiftogether with its cuscolor management soft- icant reduction in printtomers in the branded

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goods industry and re- Wipak Walsrode GmbH minimizing its CO2 tail.

“In our view, & Co. KG is part of the emissions in accordance oneECG from BOBST Wipak Group, a global with GHG Protocol represents an enormous supplier of packaging Scope 1 and 2 and offopportunity to make solutions and services setting the remaining gravure printing in the for the food industry as emissions.

Central European mar- well as for medical deFurther information on ket for flexible packag- vices and pharmaceutithe oneECG project at ing more attractive cal products. The group Wipak Walsrode will be again – with the highest of companies, headavailable later in 2023 print quality across the quartered in Finland, when the company entire run, higher effi- employs more than takes part in an event ciency, and resource- 1,800 people at 11 prodedicated to innovation saving production while duction sites throughout in gravure printing at at the same time reduc- Europe and Asia as well BOBST’s Competence ing costs for all parties as in sales offices in 18 Center in San Giorgio involved, because fewer countries. Sustainability Monferrato, Italy. printing cylinders are is one of the core values needed,” said Bruns, of the group, which summarizing the cur- achieved carbon neurent position. trality in its operations at the end of 2022 by

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