ProPack Pro August 2023

People Technology Business

www.propack.pro August 2023

A FOCUS ON:

Labelexpo Europe 2023 preview

Some of the innovations that will be on display at the upcoming show

Building on Label Line’s success

BRUSSELS EXPO 11 - 14 SEPTEMBER 2023

Label Line builds on its momentum with the hire of Jason Brown

HALL 7 | STAND #7C45

Pride in Print NZ awards industry

LABEL OPEN HOUSE DURST HQ, BRIXEN, ITALY SATURDAY 9 & FRIDAY 15 SEPTEMBER 2023

Labels and packaging companies were put in the spotlight at the recent awards ceremony ALSO INSIDE...

‘Outside of the box’ design

My client and I both say YOU’RE A LEGEND !!!

The cards arrived this morning - which was perfect timing as they are being used today.

Thank you so very much.

Phil

Client has received their 8pp A5 brochure this morning, way earlier than expected (thank you!!!), and they are delighted.

Mel

I really appreciate how quickly the books arrived and loved your notification system.

The quality is gorgeous.

Just wanted to say a big thank you to you for rushing the booklet job through and dropping off to the client.

:)

I know it was a huge ask and again you did not let me down.

Marie

Angela

The books have arrived and are amazing!

You do a fantastic job.

We received the business cards they look great!

Everyone was surprised at the quick turnaround.

I am so happy to be working with you because I can trust we are in good hands and it will be a quality result.

Luke

Xheantelle

OF OUR NEW CLIENTS ARE REFERRALS YOU CAN SEE WHY...

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EDITOR’S LETTER

Gearing up for the biggest labels event The excitement around the first Labelexpo show in Europe since 2019 is building, and with the tradeshow just a few weeks away, the industry is getting more eager to find out about the new technologies and innovations that will be on display.

Labelexpo Europe will take place on 11 to 14 September at Brussels Expo in Belgium, promising demonstrations of the latest printing and converting equipment, masterclasses and special events focused on automation and flexible packaging.

In addition to the new product launches and live demonstrations, the show will also feature themed areas highlighting fast-growing areas of the industry.

The show will span across nine halls, showcasing cutting-edge technology launches – including everything from prepress to materials, and digital and conventional print and converting

technology. Key technology themes are already emerging from the snippets of previews that we are now getting from manufacturers.

Tarsus Group, organiser of the Labelexpo Global Series, said diversification across labels and flexible packaging technologies, digital embellishment, workflow and machine automation, real-time data collection over the Cloud and sustainability across multiple fronts from LED-UV to more new materials and adhesives choices are just some of the trends making headway.

With converters and brand owners facing growing legislative pressure to demonstrate the sustainability of the labels industry, the key theme of ‘sustainability’ is also expected to go mainstream at Labelexpo Europe.

With hundreds of product launches planned for the event, this issue of

Hafizah Osman

ProPack.pro keeps you up-to-date with some of the latest and greatest innovations that are planned for the event. There’s plenty to learn and takeaway from this issue, so I hope you enjoy the read.

The ProPack.pro team aims to bring you all the information about the latest launches from Labelexpo Europe as they come so keep an eye on the website for the news. We’ll also publish a detailed review from the show in the next issue of the magazine, in October.

On a side note, this will be my last ProPack.pro editor’s note to you for this year – fret not, I’ll be back next year following a few months of leave. The very capable ProPack team will continue to support you and their details are as below.

Hafizah Osman | Editor hosman@intermedia.com.au Ph: +61 431 466 140

Stay informed… visit www.propack.pro and subscribe to receive the latest packaging industry news and views

ProPack Industry Supporters

Managing Director & Publisher: James Wells Editor: Hafizah Osman News Editor: Piotr Wnuk

Sales Manager: Carmen Ciappara Production Manager: Jacqui Cooper Pre-Press Manager: Tony Willson

Design: Sarah Vella Printed by: Hero Print, Alexandria, NSW 2015 Mailed by: D&D Mailing Services

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4 ProPack.pro August 2023

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CONTENTS

IN THIS ISSUE...

P12-18

Unimax upgrades to Screen Truepress Jet L350UV SAI S

P6

Jet Technologies and Fujifilm NZ partner with Unimax for New Zealand’s first Screen Truepress Jet L350UV SAI S digital label press

Orora Beverage brings digital can decoration to the region P8

P24-27

P8

Innovation to shine at Labelexpo Europe 2023 in Brussels P12-18

Flexible mono-material plastic packaging segment growth P28

An exciting range of new conventional, digital and hybrid press technology will be on display at the upcoming Labelexpo Europe event in Belgium

A new Smithers report tracks growth segments for the mono-material flexible plastic packaging films market

Setting the foundations for Label Line’s success

P20

Orora Beverage has launched Helio by Orora, a “transformative packaging decoration and first-to-market high-speed digital printing technology” for can design and decoration

Label Line’s new managing director Jason Brown explains how he intends to build on the company’s momentum moving forward

From the brink of closure to getting NZ$70M in investment P9

Key considerations to take note of for label print quality P22-23

New Zealand’s Whakatāne Paper Mill has secured private investment of over NZ$70 million for further factory expansion

Mediapoint reviews the elements of label print quality using its new equipment to help you understand, compare and evaluate options

Labels and packaging shine at Pride in Print P10-11

Refining packaging by thinking ‘outside of the box’ P24-27

Labels and packaging companies were put in the spotlight at the recent Pride in Print Awards in New Zealand

‘Outside of the box’ thinking is one of the vital strategies to creating designs that stand out from the crowd

The future of paper vs plastic packaging markets to 2028 P29 In the next few years, brands will focus on developing smart designs and packaging solutions that improve packaging performance while minimising environmental impact

Sustainability trends boost wet glue label appeal P30-32 Labels & Labeling report: Glue-applied labels remain the dominant form of prime product labelling, providing key volume, sustainability and print quality benefits for end users

Pack diary

P34

A guide to the upcoming events globally

THIS ISSUE SUPPORTED BY

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August 2023 ProPack.pro 5

LABELS & PACKAGING

Unimax upgrades to Screen Truepress Jet L350UV SAI S Jet Technologies and Fujifilm New Zealand partner with Unimax for New Zealand’s first Screen Truepress Jet L350UV SAI S digital label press we receive from both Fujifilm New Zealand and Jet Technologies”.

The range of substrates available to Unimax has increased substantially with the new model, enabling the company to print on thinner synthetic stocks, as well as a thicker range of paper and hybrid products.

years ago when it invested in its first Screen Truepress, which helped take the business “from letterpress to the digital age”.

Kumar added, “Productivity has increased on all jobs and particularly for the work containing Screen’s high opacity white.

The Screen Truepress Jet L350UV SAI S digital label press has impressed everyone, and we are thrilled with the results, which are next level in quality and productivity. Another benefit is the addition of orange and blue, which has increased the colour gamut.”

Kumar said, “Our original press was extremely reliable over its five years with us.

It helped us to diversify our client base and grow our business in higher-value markets.

Upgrading to the L350UV SAI S was an easy decision, especially with the service

Fujifilm New Zealand director Stephen Hodson mentioned, “We are proud to partner with Screen and Jet Technologies to deliver this solution to Unimax and we look forward to continuing our support.”

(l-r) Stephen Hodson (Fujifilm New Zealand), Dinesh Kumar (Unimax) and Jason Jones (Jet Technologies) with the Screen Truepress Jet L350UV SAI S digital label press

F

rom its base in Avondale, Auckland, labels and packaging printer Unimax works with a diverse group of clients across the agriculture, transportation, health, food, and beverage sectors.

Recently, Unimax installed Screen’s most productive label inkjet press – the L350UV SAI S digital label press, supplied and supported by Jet Technologies and Fujifilm New Zealand. With an eye to the future, Unimax looked for a solution to support its growth and competitiveness with the capability to provide a broader variety of printing options for its customers.

Unimax director Dinesh Kumar said, “We were looking for a digital printing press that offered the highest quality print product and consistency. The solution we chose has those two qualities and was the most cost-effective of the options we considered.

“We feel particularly pleased to bring the first L350UV SAI S into the country.

We have always been huge fans of inkjet and what it can do. In fact, we were the first to bring the L350UV into New Zealand and can proudly say that we are now the first with the new SAI model.”

Increasingly, industry sectors such as liquor, cosmetics, food, and beverage employ UV inkjet-based digital printing as a substitute for silk-screen printing. Digital printing provides these industry customers with several benefits, including shorter turnaround times, lower costs and reduced environmental impact. Demand for quality label and packaging printing continues to grow. Unimax recognised this trend five

6 ProPack.pro August 2023

New press broadens the options for label production Introduced in 2020, the Screen Truepress Jet L350UV SAI S digital label press builds on the success of the popular Plus (+) range, as a high-productivity, highquality and versatile UV inkjet label press.

Screen developed the SAI series to help printers produce a wider range of spot colours to meet brand owners’ challenging demands. The machine prints on media widths of up to 350mm wide, with a print speed of up to 60 metres per minute. Using white ink, it can still achieve 50 metres per minute.

As a compact and configurable platform, the SAI series can accommodate the full range of label printing requirements. For example, the four-colour CMYK standard ink set and can easily upgrade to seven colours, as Unimax has done. to include white, orange, and a vivid blue.

Another option for the Truepress Jet L350UV SAI S digital label press is the recently introduced high opacity white mode. When used with clear film or similar labels, this new printing mode provides more opaque white, preventing the colour of bottles or package contents, from showing through. This helps to maintain rich colour saturation, ensuring high-quality labels with eye-catching visual appeal, even when applied to translucent base materials.

The printer has already taken out the EDP (European Digital Press) Best Label Printer Award for its “its ease-of-use, thanks to its advanced software, as well as for its improved colour quality and increased speed”.

It is the third time Screen’s digital inkjet label press technology has an EDP award for its digital inkjet technology.

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Versatile Printing.

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• Extra wide colour gamut including Orange, Green & Opaque white inks • Improved turn-around times • Proven Epson technology • Non-contact Epson micro-piezo printhead array delivers high quality results even on textured and uncoated materials

Learn more, visit www.epson.com.au/surepress

*Product shown includes Epson SureSpectro AS-4000 option

LATEST NEWS

Orora Beverage brings digital can decoration to the region Orora Beverage has launched Helio by Orora, a “transformative packaging decoration and first-to-market high-speed digital printing technology” for can design and decoration

O

Helio by Orora introduces digital printing technology in the can decoration sector

rora has partnered with Velox Digital, an Israel-based global developer and manufacturer of industrial-grade direct-to-shape digital decoration solutions, to install the first digital printer in Oceania at the company’s can production facility in Dandenong, Victoria.

Orora said the name Helio, derived from the ancient Greek god of sunlight and colour Helios, symbolises the brand owners’ ability to realise their colour, texture and finish imagination and inspiration to engage consumers through a means currently unavailable.

“With Helio, the can becomes the canvas for leading marketing communication, innovation and infinitely unique promotional execution,” Orora said.

By adding the new advanced digital printing technology, the company, which currently decorates cans with traditional high-speed offset processes, is aiming to provide its customers with a quick turnaround by eliminating with the lead time required for the development of printing plates.

Moreover, the Velox Digital technology is expected to provide greater operational flexibility, catering to smaller minimum quantities and reduced inventory overproduction as well as complement

8 ProPack.pro August 2023

and capitalise on the new multi-size can line investment at Dandenong.

Orora beverage can general manager Chris Smith said, “We have been assessing the development of direct-to-shape digital decoration technology for cans for some time – we’re thrilled about our new technology choice and the introduction of Helio enabled by new high-speed digital decoration capability.

“Our role in primary packaging is to help our brand owners engage the shopper at the point of purchase. Helio and the Velox solution will transform our ability to do this for our customer’s brands.

“Once commissioned, what this means for our customers is that wait time will be significantly reduced in delivering a specific can size or label design for activities such as promotions, new products and limited-edition retail events.

“With no label set-up required and nearimmediate supply, shorter, faster minimum runs can be accommodated, providing greater flexibility in product and campaign planning.”

Expansion into the can market Orora also mentioned that the introduction of Helio adds to the company’s significant investment

Orora’s multi-size can line Dandenong

in cans capacity expansion, uniquely positioning it to meet the strong outlook for growth in the cans market.

In June, construction of the company’s new $80 million multi-size can line at Dandenong was completed to plan, increasing production capacity by 10 per cent and allowing for varying can sizes and formats.

A $30 million project to expand can ends capacity at Ballarat was completed in March, and a new $85 million can line at Revesby, NSW, is underway and expected to come online by Q1 2025.

Smith added, “We are seeing the demand for aluminium cans continue to grow, with particularly exciting developments across a number of categories including craft beer, soft drinks, RTDs and seltzers.

“Cans are a terrific sustainable, packaging option, convenient for many occasions and most importantly, produced from aluminium containing recycled content, with the can itself being infinitely recyclable.

“We know that can graphic design and decoration is a critical tool for engaging consumers – with strong in-house can decoration capability, the Helio solution enabled by high-speed, direct-to-shape digital printing, adds even greater value to Orora’s service offering for its customers.”

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LATEST NEWS

From the brink of closure to getting NZ$70M in investment New Zealand’s Whakatāne Paper Mill, which was on a brink of closure in early 2021, has secured private investment of over NZ$70 million for further factory expansion Whakatāne Mill was on a brink of closure in February 2021

Additionally, WML will eliminate plastic consumption by transitioning from plastic to paper wrap for packaging of its finished products.

Construction commenced in the last week of June and will continue until mid-late August with full production expected to be achieved by November.

W

hakatāne Paper Mill (WML) is New Zealand’s only paperboard mill located on the North Island, where since 1939 it has been a big part and one of the significant employers in the Bay of Plenty. The mill employs approximately 210 personnel, the vast majority from the local Whakatāne area.

The company started the production of paper over 80 years ago to turn the nearby Central North Island Pine forests into export paperboard for New Zealand’s growing economy. Since then, the company has been owned by NZ Forest Products in the early days, Carter Holt Harvey and Rank Group and more recently SIG Combibloc.

However, its Swiss owner SIG announced plans to close the facility in February 2021, attributing the move to the loss of its biggest customer that resulted in its operations becoming uneconomical.

Under the closure proposal, all staff at the mill were to be made redundant, the plant decommissioned and the site remediated.

The situation then changed a few months later, when the Irish paper and packaging tycoon Dermot Smurfit and New Zealand private equity chief Ross George expressed their interest in the mill.

They struck a deal in May 2021, when SIG Combibloc agreed to sell it to a consortium of investors led by Smurfit who, together with other European consortium members,

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have extensive experience in owning and operating paper packaging businesses. They also brought a number of New Zealand investors alongside them.

The company most recently announced securing a substantial private investment of over NZ$70 million from its shareholders, signalling its robust health and promising future.

This investment marks the most significant capital expenditure for WML since 2004 and the infusion of funds will facilitate a major upgrade, elevating it to industry-leading standards.

The upgrade will deliver an additional 50,000 tonnes of premium folding box boards, increasing WML’s production from 150,000 to 200,000 tonnes.

Customers will enjoy the advantages of higher quality board, while the production process will be more environmentallyfriendly, utilising less raw materials and operating with improved energy efficiency.

The upgrade is paving the way for WML to potentially produce up to 300,000 tonnes of premium folding box board in the future.

The upgrade will also present significant sustainability improvements. Per tonne of board, the energy efficiency will be approximately 30 per cent better, gas consumption will be reduced by more than 30 per cent, and WML’s water consumption from the local river will also see a significant decrease.

The equipment for the upgrade has been sourced from highly specialised manufacturers in Europe. The core equipment for the board machine, specifically the water removal/drying section, has been imported from Germany, while the fully automated paper wrap line originates from Finland, and the crucial heat recovery system has been acquired from Italy.

Fifty contracting companies from across the Bay of Plenty are involved in the upgrade with over 400 contractors on site to install approximately 45km of cable and 5.5km of piping.

WML executive chairman Ian Halliday

WML executive chairman Ian Halliday expressed his pride in this achievement, not only for the WML’s workforce but also for their commercial partners, customers and the local community.

“As the largest private employer in Whakatāne, with an 80-year history of exporting, this moment is a significant step towards a bright, positive, and sustainable future for WML,” Halliday said.

As the sole folding box board producer in Australasia, WML’s advancements offer main brand owners such as DB Breweries, McDonalds, and Griffins the chance to reduce their carbon footprint and avoid importing packaging from countries like Finland, Korea, China, and Chile.

August 2023 ProPack.pro 9

PRIDE IN PRINT

Labels and packaging shine at Pride in Print in New Zealand Labels and packaging companies were put in the spotlight at the recent Pride in Print Awards in New Zealand, as they won several gongs in their categories

The Pride in Print Awards recognise the best of the best in New Zealand’s visual communications industry

T

he 30th annual Pride in Print Awards recently took place in Auckland, New Zealand, recognising the best in visual print communication products produced in the country.

According to the judges Kāpiti Caramel and Almonds flexible packaging is an outstanding example of technical excellence from a demanding print process.

Innovative Taco Truck brings recognition to APC Innovate

Labels and packaging winners shared the spotlight with their print counterparts as they took home some of the most coveted awards within their categories.

Here are some of the labels and packaging winners from the evening: Amcor Flexibles bags two awards for flexible packaging job

Amcor’s printing manager Brent Watson with the Flexible Packaging category award

New Zealand Original Kāpiti Caramel and Almonds ice cream packaging produced

by Amcor Flexibles Christchurch won in the flexible packaging category.

Judges appreciated this work as a great demonstration of achievable quality

10 ProPack.pro August 2023

Judges appreciated this work as a great demonstration of the quality achievable when all the correct technical attributes are utilised to produce work as good as any other printed media.

The same job has been also recognised with the award in the flexographic process.

Judges described this work as a standout example of excellence in point of sale

Auckland-based brand display and packaging solutions business, APC Innovate has been praised by Pride In Print judges for producing a “standout example of excellence in point of sale” in taking out this year’s Structural Design Packaging Category award.

Judges awarded this work, which “won out in a closely contested category, for its job features functionality, good

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PRIDE IN PRINT Chemistry is a modern London-Dry gin infused with Sichuan peppercorns, sage and seaweed. Born from a love of science and nature, the company explored botanicals at a molecular level to bring out the best of each flavour for a perfectly balanced New Zealand gin.

Judges commented, “As well as being a beautifully printed job, featuring fantastic foiling and other enhancements, this double-acting label has been innovatively devised to enable the printer’s customers to seamlessly regift their bottles of wine, if so desired.”

Judges thought it was a great example of a creative concept combined with high-quality digital print and finishing.

The second entry by Rapid Labels, Rapid Remix, has also grabbed the award in the Print Industry Promotion category with its concept utilising a mini turntable with “playable” sleeved records demonstrating a wide range of print processes.

“This label has expertly drawn together a silver foil, high-build varnish and beautiful colours to deliver an amazing effect,” said the judging panel.

APC Innovate’s creative manager Zane Barclay collected the award

Rapid Labels cheers double category win

attention to detail, good print work and robustness, executed at large size.

Gravure Packaging scores with Ajax Hospital Disinfectant

“Instead of resorting to the ‘same old, same old’, it is obvious they’ve had a hard think about the modular design structure – the shelving is well made, everything fits as it should, and all components are removable to assist transportation to stores around the country. Additionally, they’ve demonstrated significant attention to detail – for example, printing inside the taco element. It’s all there.”

Multi-Color wins label category by adding chemistry to gin

Rapid Remix was appreciated by the judges as an amazing concept utilising a mini turntable with “playable” sleeved records to demonstrate a wide range of printing processes and techniques has delivered an outstanding piece of selfpromotion for the printer.

Gravure Packaging, a privately owned flexible packaging and shrink sleeve manufacturer, headquartered in Wellington, scored gold in the Gravure category with its Ajax Hospital Disinfectant job.

Rapid Labels entered the competition with a concept utilising a mini turntable with playable sleeved records

MCC’s senior account manager Phoebe Rudge collected the award on the night

Gravure Packaging technical director Grant Amelung enthuses that being bestowed with the Pride In Print Gravure Process award “enshrines the competitiveness and relevancy of rotogravure”.

Judges commented, “This job has been very well printed with crisp and vibrant graphic elements. The background vignette is very clean and effective. There has also been clever use of software to distort the image to ensure perfect reproduction when applied to the final product. A very welldesigned and well-executed example of gravure print work.”

Alex Straight, technical director and Dale Bamford, general manager of Rapid Labels collected the awards at the Gala Dinner

The winning label drew together silver foil, high-build varnish and beautiful colours

La Montée Champagne label and packaging printed by Rapid Labels has been names the winner of the Industry Development and Creativity category.

Multi-embellished, colourful Chemistry Gin label brought a win for the East Tāmaki-based Multi-Color New Zealand in the label category.

Designed to be re-gifted, La Montée Champagne, which translates as “The Rise” is a beautifully designed comment on the soaring cost of living and a little something to help ease the pain.

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Judges were impressed with the well-executed example of gravure print

August 2023 ProPack.pro 11

LABELEXPO EUROPE PREVIEW

Innovation to shine at Labelexpo Europe 2023 in Brussels An exciting range of new conventional, digital and hybrid press technology will be on display at the upcoming Labelexpo Europe event in Brussels

Labelexpo Europe will be a showcase of the latest innovations and technologies

L

abelexpo Europe 2023 is expected to be a landmark event, unleashing four years of pent-up technology development for visitors to the Brussels Expo. The event, which will soon take place from 11 to 14 September, will focus on the key themes of automation, sustainability and diversification.

Over 600 confirmed exhibitors will be taking part in Labelexpo Europe 2023, including ABG, Avery Dennison, Bobst, Canon, Domino, Durst, Epson, Fujifilm, Gallus, HP, Kocher & Beck, Konica Minolta, Lombardi, Mark Andy, Nilpeter, OMET, RotoMetrics, and Xeikon.

Between them, they will be demonstrating their latest innovations and technology including: digital and conventional printing presses; high tech label and packaging materials; finishing and converting systems; inspection, overprinting and label application equipment; inks and coatings; RFID and security solutions; as well as software and interactive technology.

With just a few weeks to go until the event, many manufacturers have already announced what they will be showing

12 ProPack.pro August 2023

at the tradeshow. Here is a round-up of some of them: A B Graphic International (ABG) ABG is preparing for its biggest presence yet at this year’s Labelexpo Europe event, where it will unveil its automation technology and showcase its latest product innovations. The company said its primary focus will be unveiling its new automation technology – ABG Connect – and showcasing its latest product innovations.

ABG Connect is an automated workflow solution that streamlines the print and finishing process by connecting all stages into one automated workflow.

ABG will also showcase its latest new product innovations, which will include advancements in non-stop winding technology and the new turret rewinder model. It will introduce the Converter – a new fully modular converting line that boasts higher speeds, new flexo technology and a smaller footprint.

Other products include a Digicon with screen and Ecoleaf unit for sustainable foiling, DigiLase 4.0, DigiJet 330, DigiLite, SRI3 430 with monochrome inkjet, shrink sleeve seaming, doctoring solutions and an entry-level SRI. ABG’s stand will also feature a booklet module and its partner Maan Engineering’s module for laminate and linerless label solutions.

ABG’s primary focus will be unveiling its new automation technology, ABG Connect

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LABELEXPO EUROPE PREVIEW To complete its extensive showcase, ABG will also collaborate with HP to demonstrate its non-stop unwind and rewind system, seamlessly integrated into the HP Indigo V12 line.

Asahi Photoproducts Asahi’s new water recycling unit for the plate processor

The Bobst Digital Master 340 All-in-One modular and upgradable label press

At Labelexpo Europe, visitors to the Asahi Photoproducts stand will be able to learn how switching from solvent-wash to waterwash plates can not only make their operations more sustainable, but also reduce waste, improve print quality, and speed time to market.

The company has developed a specific roadmap towards a Solvent ZERO solution that will help platemaking operations not only be more sustainable, but create a safer, more enjoyable work environment for their employees as they migrate to a Solvent ZERO operation.

Durst’s Tau RSCi range is designed to take over mid-to long-run jobs

At Labelexpo Europe, the company will be unveiling this roadmap and helping visitors understand their best pathway to a Solvent ZERO future.

The company said it is spearheading digitalisation, automation, connectivity and sustainability in packaging production with a portfolio that includes flexo, digital and all-in-one presses for the widest variety of applications.

At Labelexpo Europe 2023, Asahi Photoproducts will also be introducing its updated AWP wastewater recycling unit for use with AWP plate processing systems.

The Bobst Digital Master 340 All-in-One modular and upgradable label press, equipped with the latest UV inkjet technology, will be running live at 100 m/min.

The Asahi Photoproducts water-washable AWP-DEW CleanPrint flexographic plates have been certified Carbon Neutral by the Carbon Trust.

Visitors will be able to see how Bobst’s AccuCheck system, which comes as standard on this machine, performs 100 per cent inline at full speed. The full configuration will also include flexo modules and a highly automated diecutting unit to showcase true end-toend label production.

In addition, to increase sustainability of its platemaking solutions even more, Asahi has developed this innovative water recycling system for AWP plate processing equipment.

The unit features proprietary filtering technology developed by Asahi Kasei – Asahi Photoproducts’ parent company – that reduces wastewater by 75 per cent, and detergent usage by 40 per cent.

Bobst Under the motto “Simplifying label production”, Bobst will be demonstrating its innovation in labels and flexible packaging production with two main production lines in focus.

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As converters face manpower shortages and demands for more sustainable solutions, Bobst said it will highlight unique automation features that can alleviate these issues.

The high-end Bobst Master M6 flexo press will demonstrate how oneECG technology for extended colour gamut printing and V-Flower printing units enable fast, automatic changeovers of the printing cylinders without stopping the press and with only very minimal waste.

Durst The spotlight on the Durst booth will be on three primary themes – more applications, more automation and less waste.

At Labelexpo Europe, Durst Group will again be setting the benchmark in digital printing with the introduction of its Durst Hawk Eye technology. This innovative technology utilises camera vision systems with the aim of automating print quality, resulting in significantly reduced waste and overall improved print quality. The Durst Hawk Eye is not only an inspection system – it goes one step further as it is correcting print mistakes, such as missing nozzles, inline and in real-time, without any setup needed and without any operator intervention. Additionally, it aims to significantly reduce setup time and waste, resulting in enhanced efficiency and an even more competitive total cost of ownership for the Tau RSC platform printers.

“The Durst Hawk Eye is revolutionary for the digital printing industry. This technology will greatly increase productivity and efficiency, but more importantly, it will reduce waste and the carbon footprint of our customers.

We are thrilled to introduce this innovative solution to the market and provide exclusive information during Labelexpo,”

August 2023 ProPack.pro 13

LABELEXPO EUROPE PREVIEW Durst Group product manager Martin Leitner said.

Durst Group will also unveil the next generation of the Tau RSC UV ink set at Labelexpo. This new ink set, available in the colours CMYK OVG and white, will meet the latest regulatory requirements and expands the converters’ application range even further.

On the showfloor, alongside a new digital printing press, the successful Tau 510 RSCi will be showcased. This press will demonstrate its capabilities in real-time, printing at a remarkable speed of 80m/min at a printing width of 510mm, leading to productivity of over 3000 square metres per hour. The Tau 510 RSCi brings powerful advantages to production: material and application versatility and excellent print quality even at highest productivity and extremely aggressive TCO. These are a few reasons why label converters are using the Tau 510 RSCi to switch their flexo production to digital.

Durst has equipped the Tau 510 RSCi with new automation features, making the life of the operator easier and increasing the overall high efficiency of the machine.

The press on the showfloor will be equipped with the new, powerful double white feature, as well as inline flexo stations, adding an extra option for customers that need just a little bit more for challenging applications. Visit the Durst booth to see these technologies and for other surprises.

are helping the packaging industry achieve consistent performance from concept to market,” Esko director of marketing, industry relations and strategy Jan De Roeck said.

“Using demonstrations of the latest technology, displays and expert discussions, we will highlight how an end-to-end ecosystem of new colour management software and measurement solutions supports digital workflows to increase efficiency, enhance sustainability and drive growth opportunities.”

•

•

•

•

•

Esko and X-Rite Pantone will join forces at Labelexpo Europe to spotlight one connected workflow across the label and packaging supply chain.

Visitors will see first-hand how a connected Esko and X-Rite Pantone ecosystem of automated workflow, colour management, flexo platemaking, digital printing and print inspection tools can deliver consistent performance and accelerate business growth. The companies will lead a deep dive into all facets of labelling and packaging.

“Visitors to our combined booth will discover how Esko and X-Rite Pantone

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Gallus

Esko and X-Rite Pantone will showcase their entire range of digital workflow solutions – from design through production. Highlights include:

Esko

Esko will demonstrate its latest technology at Labelexpo Europe

on the environment. With sustainability and digitalisation fundamentally altering how the industry operates, it is imperative that today’s label and packaging companies invest in digital workflow technology that enables them to boost efficiency, reduce costs and improve their overall productivity.”

•

•

Phoenix, Esko’s AI-based tool that unlocks planning and imposition productivity improvements, with a seamless interface between prepress data and production data in Esko applications.

The award-winning CDI Crystal XPS 4835, utilising UV main and back exposure to produce highly consistent digital flexo plates while minimising waste.

AVT Helios System, which automatically inspects printed labels or packages for defects and imperfections, delivering exceptional quality results and eliminating customer rejections.

The latest Esko Software version, which delivers a combination of prepress editing and cloud-based workflow automation solutions, now more integrated and connected throughout the entire pre-press workflow.

X-Rite eXact 2, a connected and easyto-use handheld spectrophotometer that can measure colour across various substrates – including flexible film and paper – in a single device, while also verifying customer standards.

X-Rite ColorCert Suite, which works with Esko WebCenter, AVT’s Spectralab, and eXact 2 to provide printers an overall view of print quality and colour performance in a single number score to confirm compliance with brand specifications.

PantoneLIVE digital colour libraries for the creation and sharing of accurate brand colour standards that are achievable across printing technology and substrates.

“Error and waste reduction has a direct impact on the environmental footprint of a packaging businesses,” De Roeck said.

“As we are all looking to protect the environment in which we live and to safeguard it for future generations, we must reduce the impact of our operations

Built on the Gallus Labelmaster press platform is the Gallus One

At Labelexpo Europe, Gallus, a subsidiary of Heidelberg, will celebrate its 100 years in business as well as the opening of its landmark facility, the Gallus Experience Center.

It will showcase unique digital solutions developed with parent company Heidelberg, to support increased automation of the entire eco system.

The objective of these solutions is to facilitate ‘Smart, Connected, Printing’ to support skilled labour shortages, increase productivity and reduce waste.

In line with this theme, the company will be showcasing its Gallus One digital label press. Launched in August 2022, it was specifically designed to remove the Total Cost of Ownership (TCO) barrier for the adoption of reel-to-reel digital labels with the highest level of automation and cloud-based technologies. In doing so, Gallus One provides brands, for the first time, with access to cost effective and sustainable, high quality digital labels.

Built on the Gallus Labelmaster press platform, Gallus One is a 340mm wide rollto-roll UV inkjet digital inline labels press.

It utilises a host of impressive features to achieve high levels of automation and press efficiency, with unrivalled UV inkjet print quality and stand-out print speeds of up to 70 metres per minute.

HP Indigo HP Indigo will be showcasing end-to-end digital production at Labelexpo. With the first presentation in Europe, both the HP Indigo V12 Digital Press and the recently launched HP Indigo 200K Digital Press will be on the show floor, demonstrating digital efficiency, sustainability, and profitability for the labels and packaging industry.

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TAU RSCi INNOVATES YOUR BUSINESS

REACH & SVHC COMPLIANT HEAVY METAL FREE VOC FREE BS5609 SECTION 3 COMPLIANT

BEST IN CLASS

COMPETITIVE EDGE

SCALABILITY

Print quality

Flexo-like productivity

Industrial scalability

1200 x 1200 dpi @ 2 pl Up to 95 % Pantone coverage

Competitive ink pricing Low ink consumption

330 / 420 / 510 mm print width Jumbo winders

For more information, please visit durst-group.com/label

LABELEXPO EUROPE PREVIEW narrow web market will showcase its latest space-saving technology at the upcoming Brussels trade fair in September.

On working display will be two of its most popular machines in the narrow web sector, an MBS automatic unwind butt splicer and an LRD transfer rewinder.

The HP Indigo V12 Digital Press

Alongside the popular HP Indigo 6K Digital Press, converters will be able to learn how Indigo’s LEP and LEPX technologies can help them grow their business.

The HP Indigo V12 Digital Press ensures non-stop production and earning power.

A narrow-web label press, it prints at 120 linear metres per min with all the capabilities of HP Indigo’s technology for label production. HP said it is a versatile digital press with offset- and gravurematching print quality for commercial and labels and packaging jobs.

The HP Indigo 200K Digital Press delivers a 30 per cent improvement in speed and 45 per cent increase in productivity, opening the door to more flexible packaging converters who want to enter the digital market. It provides an entire production line in a small footprint and prints up to 56 metres a minute.

As for the HP Indigo 6K, it is a versatile, narrow-web printing solution for digital labels and packaging production, delivering high productivity, wide versatility and intelligent colour automation.

The Digital Pouch Factory, featuring the HP Indigo 200K Digital Press, will also be demonstrated at the booth with pre-press and finishing equipment. An elaborate application showcase will invite visitors to examine samples of unique and sustainable labels, shrink sleeves and flexible packages.

Konica Minolta

and packaging production by igniting creativity on its stand at Labelexpo Europe.

Seeing the potential by stepping into a world of digital label production will be a major theme on the stand where Konica Minolta will demonstrate its unwavering commitment to customers and growing importance within industrial printing markets.

As well as its toner-based AccurioLabel 400 digital press, Konica Minolta will demonstrate its entry-level AccurioLabel 230 configured with a DC 330 Mini finisher with an integrated inkjet module supplied

by Industrial Inkjet Ltd (IIJ). This unit can be used for a wide range of applications from white, to security inks and digital varnishes.

Konica Minolta will also be sharing the booth with partner MGI Digital Technology, to showcase the latest trends and the full label production cycle as well as packaging solutions.

16 ProPack.pro August 2023

Furthermore, these machines can be installed directly against walls at either end of the press and still allow access for the maintenance and roll loading and unloading, without the use of carts.

In addition to the innovative machinery on display, Martin Automatic said it looks forward to welcoming visitors to its newly designed stand and serving up some true American hospitality with its renowned hotdogs.

Martin Automatic vice-president of sales and marketing Gavin Rittmeyer said, “After a four-year break, we are looking forward to meeting friends old and new, and continuing our commitment to in-person working relationships with our longstanding sales team”.

OKI

The company said pooling both their knowledge and know-how, they will show how customers can increase profitability, as well as benefit from comprehensive software and global service capabilities delivered locally.

Martin Automatic The Martin Automatic MBS butt splicer with stacked festoon

The OKI Pro 10xx roll-to-roll label printer

OKI Europe has announced a key strategic partnership with Graphtec Europe to provide solutions that address the varying applications for creating ‘ready to use’ labels and packaging in the market. Labelexpo Europe will showcase this partnership.

As part of OKI’s continued expansion in the provision of solutions for printing labels in-house, it will be using Labelexpo Europe as a platform to highlight the increased demand for specialist finishing requirements.

Konica Minolta’s AccurioLabel 230

Konica Minolta has pledged to show firsthand how converters and brands can rethink end-to-end sustainable digital label

The company said creative use of the vertical festoon on the butt splicer and a proprietary roll unloading feature at the rewind saves users nearly one metre of overall space in the running direction.

Martin Automatic, a supplier of non-stop unwind and rewind technology for the

As customers want to make the most of media flexibility, the OKI Pro 10xx range of roll-to-roll label printers and the OKI Pro 9xx range of sheetfed package/label printers will be on display.

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www.hp.com/i

ndigo

www.curriegroup.

com.au

LABELEXPO EUROPE PREVIEW Their key features include being able to run blank media, which OKI said provides the freedom to create labels of constantly changing size, shape and durability.

As for the Graphtec range of cutting devices, they enable customers with flexibility to cut, perf, slit and rewind a variety of substrate types.

In addition, OMET will present its proven capability to print from 12 microns mono films such as PET, PVC/PET shrink, BOPP, IML and foils to 600 microns paper-based packaging such as cartons, paper cups and liquid packaging, covering the widest gamut of packaging materials on the market.

Xeikon

Screen

Being able to perform these functions on a separate device means customers can print the next job at full production speeds whilst finishing others at the same time.

“One minute, you can print silver paper labels and at the same time you can be cutting synthetic white labels, so regardless of whether your business is in beauty or beer, cosmetics or coffee, a joint print and finish solution from OKI and Graphtec gives your business a whole host more flexibility to print a huge range of labels in-house and on-demand,” OKI said.

OMET

OMET’s new KFlex flexo printing machine

OMET will be running live demonstrations of its new KFlex flexo printing machine at its stand.

The KFlex flexo printing machine is a modular platform press that can handle substrates from 12 microns up to aluminium lidding and light carton board.

It comes in two web widths – 16-inch and 20-inch – and boasts a maximum print speed of 200m/min.

The machine is targeted at end-use applications in markets including food and beverage, industrial, household, healthcare, cosmetics and wine and spirits.

The press is also designed to handle a range of jobs – from wraparound, shrink sleeve labels to lids, self-adhesive labels to wet glue and multi-layer.

With 60 years on the market and proudly serving market leaders across 100 countries, OMET said it will also take to Labelexpo Europe to demonstrate its ability to provide optimised solutions in the areas of flexo, digital, offset and gravure printing technologies with the capability to provide all these printing technologies in single pass combination printing solutions.

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The Xeikon CX500

The Screen Truepress L350UV SAI Label Digital Printing Press

At Labelexpo Europe, Screen and Nilpeter will present an innovative printing press for the digital hybrid printing segment.

The collaboration showcases a third generation press that combines Screen’s SAI inkjet digital printing technology with Nilpeter’s FA-Line flexo platform, delivering stable and high-quality combination printing.

This end-to-end solution is said to enable efficient production of value-added labels with expanded gamut printing and white imprinting capabilities.

A host of solutions will be on show when Xeikon sets up its stall at the 2023 edition of Labelexpo Europe. Xeikon will unveil important new advancements at Labelexpo Europe, taking its Cheetah technology to new heights with the introduction of Cheetah 3.0.

Leveraging the success of the Cheetah Series of toner presses, this latest iteration represents a leap forward in sustainable production. Cheetah 3.0 is poised to revolutionise the manufacturing of labels and packaging, playing a pivotal role in minimising the industry’s carbon footprint.

Upgrades include: •

A new Xeikon ECO toner that is formulated with over 60 per cent highgrade recycled PET. ECO toner will be available for the high-end presses in the Cheetah Series – the Xeikon CX300 and Xeikon CX500.

Xeikon has developed the Quality Measurement Module (QMM) which can be fitted on all Cheetah 3.0 CX Series presses as an option. The QMM will be responsible for the quality assurance of the printed output, closely monitoring the density and registration throughout the print run.

Additionally, Screen will be introducing an In-Line Digital Primer prototype for the Truepress L350UV SAI Label Digital Printing Press. The company said this feature addresses the challenge of poor ink adhesion on various substrates by incorporating a digital primer directly into the press.

•

In addition, it said this solution could deliver superior ink adhesion and better printing quality. Visitors at LabelExpo 2023 can witness this technology firsthand and experience its transformative impact on label printing.

Xeikon will also use Labelexpo 2023 as the European premiere for its new TITON toner technology, which has been developed to meet market demands for paper-based flexible packaging applications, such as stand-up pouches and sachets.

Finally, Screen will also showcase the Truepress PAC520P Inkjet Digital Printing Press for paper packaging, responding to the growing trend of replacing plastic packaging with environmentally friendly paper alternatives.

The first press presented with TITON technology will be the Xeikon TX-500 which prints in up to five colours at 30m/min in a resolution of 1200dpi. The 520mm-wide press will be instrumental in opening new market opportunities in paper-based labels and flexible packaging, helping converters to future-proof their businesses and respond to consumers’ concern for the environment.

This high-speed, water-based inkjet press offers label converters seamless entry into the profitable flexible packaging market. With its compact footprint, low environmental impact, and compliance with food-safety regulations, the Truepress PAC520P aims to provide a competitive edge and increased profitability.

As the next step in digitalising label production, Xeikon will be showing the Xeikon TX-500 press running live in-line with a digital embellishment module from Kurz.

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www.gd90.de

Q&A LABEL LINE

Setting up the strong foundations for Label Line’s success Label Line’s new managing director Jason Brown explains how he intends to build on the company’s momentum moving forward printing, we cater for just about every need possible.

We operate in several sectors as we’re supplying our products to a broad base of trade printers throughout Australia – we’re across various verticals including food and beverage and chemical.

Holistically, we want to broaden our service offer further. At the moment, we offer one of the best turnaround times in the market for blank die-cut labels, and the most options. We intend to broaden this service, while continuing to deliver the best turnaround times in the market.

We also intend to attract more clients.

Label Line managing director Jason Brown

J

ason Brown has been at the helm of Label Line, having taken on the newly-created role of managing director about three months ago.

He speaks to ProPack.pro about the company’s forward-looking plans and how he intends to lead them.

Q: You’ve recently taken on the role of managing director at Label Line.

Tell us more about your appointment.

Jason Brown (JB): Label Line is gearing up for future growth and to support its plans, the company created a new managing director role at the business.

I took on that role three months ago. This has resulted in the creation of a strong executive team that will bolster our plans and take the business forward, with my appointment being part of this strategy.

As the managing director, I have the responsibility for all of the operations within business, sales, finance and marketing. Linda Scott will continue in her role as general manager, running the day-to-day of the business.

Q: You were with ePac Flexible Packaging Australia as its managing director before taking on this role.

How has your experience equipped you with the necessary skills at Label Line?

JB: ePac was moving its business in a different direction. The opportunity at

20 ProPack.pro August 2023

Label Line presented itself and I found that to be one that is very exciting. ePac was just establishing itself in Australia, so it was operating in a way that start-ups do. And, as everyone who has ever been involved in a start-up knows, that requires a significant amount of hustling and setting up of things like infrastructure, processes, workforce and even brand awareness.

Having gone through all of that has equipped me well with skills across all sorts of functionalities in the business, which is great, as it is not something I always experienced in my previous roles.

It has made me a more well-rounded manager, which makes me better equipped to handle my current role.

Q: What do Label Line’s plans include and how do you intend to achieve them?

JB: Label Line has been in the market for 24 years. It is a trade supplier of pre die-cut labels, predominantly for the flat sheet offset and digital markets. In the last five years, it has added to its offerings roll-toroll printed colour labels as a trade printer, offering a range of trade label services to the print market.

We’ve had healthy growth patterns every year, servicing Australian and New Zealand-based customers. With over 21,000 options available in both an offset range (with optional side grip) and a fully centred range designed for digital

In the colour roll-to-roll side of the business, we want to expand our offering into new technologies. Currently, we use Konica Minolta’s roll-to-roll technology and have flexo and letterpress machines.

We intend to build on them further but at this stage, we’re still exploring and investigating what new technologies are available.

Q: What else can the industry expect from Label Line moving forward?

JB: The industry has already been receiving amazing service from Label Line for 24 years. They can only expect enhancements on the services that they’ve received in the past.

Our team works hard in its commitment to excellent service by employing three simple principles: •

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•

Saving customers time and money by offering an extensive range of label shapes, sizes and stocks on hand – without any waiting for stock or extra die costs.

Offering fast turnarounds due to an efficient team. We are proud to offer quick processing of orders. Customers can email or log into our website to place their order in the morning and we endeavour to despatch it on the same day.

Saving customers money by buying at the right price. We keep the prices low without sacrificing quality, and customers can take advantage of even lower prices when bulk purchasing.

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Supplier Profile Specialising in capital equipment sales, service, engineering solutions and consumables 72 Grady Crescent, Erskine Park, NSW, 2759 Call us toll free: 1300 885 550 | www.graph-pak.com.au YOSHINO – Perfect binders, PUR systems, 3 way trimmers and gathering machines.

Post Press – Bindery APR SOLUTIONS – Compact folder gluers for digital and offset, hot foil stamping machines, e commerce folder gluers and taping machinery.

BMATIC – Paper counting, tab inserters, friction feeders, batching machinery.

BOXWAY – The main products are on demand box making machinery for just in time packaging solutions, different box designs can be realised in seconds.

BUSCH – Pile turners, wate conveyors, table banding machinery, ink mixers and automatic punching machines.

Engineering, Maintenance & Rubber Rollers Services We provide a national footprint of service and support for our products. Our trusted and reputable partners are TRS, Merhone, Grafika Links, JTS Engineering, Print Repairs and NewTech Graphics.

We offer machinery and factory moves, preventative maintenance, breakdown and repair services, engineering and fabrication. Our rubber roller service offers a swap-out rubber roller service for products under our supplier banners as well as new roller sales and services, additionally, we supply the best rubber rejuvenator, rubber cleaners and washes.

TRS – Trim removal systems and bailers, conveyers, engineering solutions.

COL-TEC – Flatbed collating systems, inline finishing, fold-stitch-trim.

Compact Foilers

Ltd

COMPACT FOILERS – Our modules transform and bring a new dimension to your printing capabilities. They are suitable for both the application of cold foil and the creation of special 3D effects (cast & cure) using UV varnish on all makes of conventional and UV press.

INSIGNIA – The Insignia Series is a new class of sheet-fed rotary die cutter capable of diecutting, kiss-cutting, embossing, perforating, scoring, and cut-scoring a range of papers, plastics, magnetic material, PVC, styrene and polypropylenes. It is the only machine in its class capable of die cutting up to 30 pt. in thickness.

KOHMANN – Manufacturer of carton converting machinery and window patching machinery.

OSAKO – Established 1916, Osako is one of the world's most professional manufacturers of saddle stitching machinery, 3 knife trimmers, compensating stackers, section gatherers new and factory certified refurbished options.

ROLLEM – The leader in offset and digital print conversion for over 50 years, the most respected name for slitting, scoring, creasing, cutting, numbering, die cutting, inline with digital press finishing solutions.

THERMOTYPE – Digital finishing equipment – hot foil stampers, business card slitters from desktop to full industrial as well as the world's most flexible finishing machine the TSL2 which can die cut, kiss cut, perforate, score in cross directions, emboss, guillotine, drill holes, delivering endless capabilities.

TRANKSPAK – Manufacturer of strapping machines for the print media markets, inline and office solutions.

WINSHINE – Is a paper container making machine manufacturer with years of vast experience and expertise. Paper box-making machines we provide have a wide range such as paper lunch box machine, paper bowl making machine, and more.

WINPACK – Window patching machinery, easy nick grinders for removal of die cut waste.

MERHONE – Engineering services, mechanical, electrical, service & maintenance of all press & bindery equipment relocations and installations.

Environmental D.W.RENZMANN GROUP – RENZMANN’s core competency is the removal of stubborn residues and the handling of the flammable organic solvents or aggressive alkaline washing agents used for this purpose. The market is making higher and more diverse demands than ever on the cleaning of ink-carrying components that are removed from the press after a job change. And because print runs are becoming shorter, necessitating frequent job changes, there are also more parts that need to be washed.

That is why the efficient cleaning of anilox rollers, impression cylinders and press parts is becoming an increasingly important part of the process chain in print shops, paint and ink manufacturing and similar. We offer a powerful and robust systems for all cleaning tasks, washing machines for all cleaning requirements in the paint and ink producing industry, together with energy-efficient solvent distillation units.

Laminating & Spot UV & UV Varnishing AUTOBOND – World leaders in thermal and waterbased laminators, multi-purpose machiney, UV and spot UV. D&K EUROPE – High quality thermal laminating equipment.

Laminating Film Supplies Wide range of laminating films for offset and digital, high quality high tack bopp and PET films, glueable, stampable, printable.

We offer a diverse selection of pre-owned equipment that is available for purchase. We also buy used equipment.

FOCUS LABELS

Key considerations to take note of for label print quality Mediapoint reviews the elements of label print quality using its new equipment to help you understand, compare and evaluate options

By Mediapoint’s Jamie Xuereb

Mediapoint assesses the quality of print using its Durst Tau 330 RSC E

T

he quality of label printing significantly influences the overall appeal and effectiveness of the product.

For ourselves and our print resellers, it also has an effect on reputation and customer satisfaction. As such, label print quality should never be an afterthought.

Producing high quality stickers and labels, for whatever application a customer requires, can be a real boon for business.

When considering print quality for labels and stickers, several factors come to play.

We’ve addressed some key considerations in a sample print run on our new addition, the Durst Tau 330 RSC E to highlight these for you. So, let’s get into it…

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Resolution: The foundation of label print quality Perhaps the biggest consideration of any print job is resolution. Stickers and labels are no exception. Getting sharp imagery and legible text means using the right equipment and technology for the application.

When it comes to labels, you generally want a high dpi (dots per inch) count and small drop size. The higher the dpi the more nuance you can give designs, and the smaller drop size the less dot gain occurs – leading to crisp print details.

The Durst Tau 330 RSC E boasts a resolution of 1200dpi and a two-picoliter drop size.

That combination results in a marketleading label print quality. Just check out the quality sheet below. It’s an A4 paper showcasing ‘worst case’ scenarios, pushing a machine to its least effective print mode.

Design details still pop and the varying elements don’t bleed into each other.

Legibility of small text Small text has always been a tricky element to print clearly. On par with colour richness and image resolution, text issues are the most noticeable label print quality defects.

Naturally, a majority of label and sticker printing jobs require small text. You don’t want packaging and branding details

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FOCUS LABELS options, these elements really open up the range of applications.

Scannability of QR codes and barcodes

The smaller you can print text, the more you can play around with text on a design

being missed – especially in applications that fall under strict regulations.

The ability to produce legible, scannable QR codes is of great concern to printers.

It’s in high demand from the customers of print resellers post-2020. That’s thanks to the take-up of QR code functionality and how they can be used in packaging or marketing applications.

Again, when it comes to labels, these generally need to be printed at small sizes.

The clarity of the code print influences its scannability – you can’t have lines bleeding into each other.

The smaller you can print text, the more you can play around with text on a design.

Plus, the more peace-of-mind you’ll have of information being accessible to the end audience.

Taking this to the extreme, we’ve been able to print text on the Durst at one-point size. That’s text that requires a loupe to read. This text is illegible to the naked eye, but the legibility under magnification is a testament to the printer’s precision.

Even better, italicised text also comes out beautifully. Even ‘reversed out’ printing still yields good results. See the images below from our test outcomes:

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Colour richness is another instantly obvious aspect of label print quality that can significantly enhance overall appeal.

It’s a factor influenced by the printer’s colour reproduction capabilities, ink quality, and the interaction between the ink and the printing medium.

The Durst Tau 330 RSC E, leveraging the advanced inkjet tech we mentioned before, excels in this regard. Colours are both rich and vibrant, giving printed labels a high-end, premium look and feel.

Many of the applications of stickers and labels require the product to maintain quality label printing over a long-term.

Furthermore, the products are usually regularly handled, exposed to light, and outdoor conditions.

In the above example you can see that under a loupe, the clarity of a 5mm QR code remains impeccable

This is the smallest size QR code that we have seen scan through any of our presses.

Whilst not all applications will require such small sizing, it’s a testament to what’s possible using leading-edge tech. It opens up many options too for our print resellers and their customers.

This leads us to a quick note on something often overlooked – directionality of barcodes. Due to the setup of generic label printers, printing barcodes often requires a change in orientation to ensure scannability. That means compromising on design and often extra work for designers. This can lead to lower customer satisfaction and longer lead times.

‘Reversed out’ printing yields good results

When designing sticker and label printing or evaluating your printer

Rich solid colours

Durability and useful life

Barcodes in any direction

As shown in this picture, italicised text come out beautifully

With the Durst Tau 330 RSC E, we can print barcodes in any direction. That gives our customers the confidence to submit label and sticker designs knowing codes will scan perfectly.

Barcodes printed on different directions on the Durst Tau 330 RSC E

So printing equipment that utilises ink sets specifically for these purposes, in combination with durable stock, can greatly affect useful life. Our stickers and labels are printed with UV resistant ink sets that don’t require lamination and withstand outdoor conditions for up to two years. This, of course, isn’t necessary for every use case but it provides peaceof-mind to the end user.

It also unlocks a wide range of applications in combination with custom size options (stickers of up to 1m in length), a large die library, and the aforementioned label print quality.

Our aim for label print quality As you can see there are some clear pillars of label print quality when it comes to stickers and labels. Taking these into consideration when selecting a print partner for jobs can save you money and frustration.

At Mediapoint we’re not just addressing these concerns but pushing the boundaries of what’s possible in digital label and sticker printing. Whether it’s resolution, colour richness, readability of small text, scannability of QR codes and barcodes, or length of useful life. Our label and sticker solutions provide peace-of-mind and quality customers will love (at prices you’ll love). We’re not just improving the quality of our customer’s labels; we’re enabling them to elevate their brand and offer an enhanced experience and wider range to customers.

August 2023 ProPack.pro 23

FOCUS ‘OUTSIDE OF THE BOX’ DESIGN

Refining packaging by thinking ‘outside of the box’ ‘Out of the box’ thinking is one of the vital strategies to creating designs that stand out from the crowd, and is a necessary tool for today’s packaging companies A mix of creativity and boldness is required to create the best ‘out of the box’ solutions

P

ackaging is no longer just your usual square (or rectangular) box made of cardboard and held together by glue or tape. It is now a visually appealing package that performs based on form and function, in addition to being sturdy, having sustainable properties and having a purpose.

Box design ideas now inspire and excite, with some solving real-world problems even if they’re minimal. Many packaging companies are ‘thinking outside of the box’ when it comes to developing designs and aim to create unique, interactive experiences for customers.

We’ve rounded up some examples of how some companies have thought differently and found uncommon solutions to complex problems using packaging:

24 ProPack.pro August 2023

Close the Loop Group Close the Loop Group was awarded a high commendation for Lousy Ink within the Outside of the Box Design of the Year category of the 2022 Australasian Packaging Innovation & Design Awards (PIDAs), organised by the Australian Institute of Packaging (AIP).

Since 2000, Close the Loop has been involved in the reclaiming and recycling of hard-recycled print consumables – mostly ink and toner cartridges. Lousy Ink is made from ink sourced from discarded inkjet printer cartridges which have been sent to Close the Loop.

The brainchild of Oliver Ruskidd and Mike Eleven from Lousy Ink, the two Australian artists turned discarded printer ink into

Lousy Ink is made from ink sourced from discarded inkjet printer cartridges

sustainable art supplies, claiming it is the world’s first 100 per cent recycled ink for artists.

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FOCUS ‘OUTSIDE OF THE BOX’ DESIGN Before the partnership with Close the Loop came about, the ink would have been either collected and stored in 80,000L containers or burnt for energy, but after finding out about the massive amounts in storage Ruskidd and Eleven decided to see if it could be put to better use.

The end result was a high-quality ink made from recycled materials, and while each bottle can vary slightly in tone and consistency it provides artists with a truly unique medium to work with.

“It’s a great story as Lousy Ink was able to save over 85,000L of ink in 2022 itself. It’s a good circular story and a great initiative that shows that these products can be in use for as long as possible,” Close the Loop Group marketing manager Jessica Ansell said.

This product was also produced in conjunction with Cartridges 4 Planet Ark.

closure and windows etched into the chipboard using a debossing technique.

The packaging not only demonstrates a commitment to creativity – it also considers the environmental impact.

All materials used in the production are sustainably sourced with no plastics, no lamination (no celloglaze) and printed using soy-based inks.

For the manufacture of this product, sheets were printed using a Heidelberg five-colour offset printing machine.

They were die cut before going through the debossing machine, automatic rigid box making machine and gluing machine, all of which were best suited to produce high quality, premium packaging with a variety of special finishes.

Oji Fibre Solutions NZ

New Directions Packaging

Oji Fibre Solutions NZ’s gold-winning Coola Box The 2022 New Directions Australia Advent Calendar box

The 2022 New Directions Australia Advent Calendar box is more than just a box. The skincare manufacturer and wholesale supplier of essential/vegetable oils, cosmetic ingredients and skincare cosmetic bases wanted to showcase its product and service offering in a unique way which truly embodied the essence of its company.

Oji Fibre Solutions NZ’s silver-winning Snell Packaging – Mattress Corner Protector solution

The front and sides of the box simulate the actual front and sides of the building, including front doors recreated in the box design through the use of a magnetic flap

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The gold-winning Coola Box has an innovative design that allows for cool air to be contained inside the box, typically used for e-commerce deliveries. The structure of the box was designed to feature a snug fit with overlapping walls to help in better frozen and chilled ingredient arrangements that are packed with ice packs and required headspace.

According to the company, the design successfully achieves the requirement of temperature control needed for all delivery cycles.

This smart, sturdy box also achieves better space utilisation as more items can be safely packed within the area, resulting in lesser transit damages.

The box is also made from 100 per cent New Zealand recyclable corrugated board, meaning that the end user can easily dispose of the packaging with other recyclable items in their collection bins.

As for its silver-winning Snell Packaging – Mattress Corner Protector solution, its four corners were glued with trays snapped in half to make the perfect corner to protect a mattress.

“Four sizes were required, and we developed one design that work for all. The slit in the design allows it to be adjustable, so the customer no longer needs to hold all the SKUs,” Oji Fibre Solutions NZ said.

Its bronze-winning Future Ecology – EmGuard solution is a robust product and proven solution to plastic debris entering waterways from plantings on or near riparian margins and waterways.

Operating in the industry for over 30 years and proudly Australian-owned and run, the company wanted to create an advent calendar and partnered with its specialty packaging division, New Directions Packaging, on a solution which needed to be both functional and fun. The advent calendar housed various skincare products whilst being visually striking with the incorporation of an exquisite illustration of its almost 100-year-old building by talented artist Aaron Favaloro.

The end result packaging is truly an experience – it allows the end user to open the ‘doors’ of the package in the same way that they are welcomed into the iconic art-deco style building.

Packaging Design of the Year category at the 2023 Australasian PIDAs. Its Coola Box won the gold award, while its Snell Packaging – Mattress Corner Protector and Future Ecology – EmGuard solutions won the silver and bronze awards respectively.

“In the past, green plastic corflute triangle guards were imported from overseas. We worked with our customer to create a more sustainable product that would break down after the tree is mature enough to thrive on its own,” Oji Fibre Solutions NZ added.

Omni Group The Omni Group was the silver award winner for the Outside of the Box Design of the Year category at the 2021 Australasian PIDAs for its VentX Unico solution.

Oji Fibre Solutions NZ’s bronze-winning Future Ecology – EmGuard solution

Oji Fibre Solutions NZ wiped out all the awards within the Outside of the Box

Omni Group said for several years, it had a focus to reduce the volume of plastic waste from discarded stretch film, which led the company to create the concept and eventual invention and rollout of VentX Unico.

August 2023 ProPack.pro 25

FOCUS ‘OUTSIDE OF THE BOX’ DESIGN “It generates impactful differentiation to drive greater sales in the retail environment. The design change helped to achieve multiple functions, including ease of displaying and sharing the chocolates, providing a sense of ‘premiumisation’ and creating a sense of occasion during the opening experience.

Omni Group’s VentX Unico solution

The JBS & Opal Dunnage solution

The company said the product is the world’s most innovative, effective, and sustainable ventilated pallet wrapping solution. The innovation guarantees optimum ventilation and superior load containment while halving stretch film usage.

Opal industrial regional sales manager Craig Madden said the gold-winning JBS & Opal Dunnage solution is a 100 per cent recyclable cardboard corrugated dunnage solution to replace non-recyclable Expanded Polystyrene (EPS) dunnage.

“End-of-line packaging plays a vital role in protecting and prolonging our farmer’s and supermarket’s perishable foods,” the company said.

“We developed the cardboard corrugated dunnage solution to limit product movement during container transportation for JBS Foods’ meat exports. Dunnage is usually constructed from EPS, which can’t be recycled and ends up in landfill. Opal’s cardboard dunnage offers a direct replacement for non-recyclable EPS dunnage,” Madden said.

“To keep produce fresh, meats, dairy, beverages and hot fill products from damage during transit and storage, they need to be ventilated quickly and adequately to avoid ripening gases, moisture build up and rust from occurring.

To assist with the cooling process, ventilated stretch wrap is used to extend the shelf life by allowing loads to breathe.”

The VentX Unico ventilated wrap is prestretched reinforced with ropers that act like cable stretch film bands, securing load and load-to-pallet bond.

The dunnage solution is 100 per cent recyclable and contributes to the achievement of the 2025 National Packaging Target of the phase out of problematic and unnecessary singleuse plastics packaging, by substituting single-use plastic packaging for recyclable packaging.

It has smart engineered ventilation which allows air to flow freely through the pallet, cools the load faster and maintains regular airflow during storage, and reduces freezer temperature allowance – which lowers energy consumption and electricity costs in chill rooms.

As for the unique and beautifully designed limited edition Cadbury Roses limited edition Mother’s Day chocolates box, Opal featured the artwork of First Nations Wiradjuri artist Karen Lee. The packaging was created in partnership with Mondelēz International.

In addition, with no loose tails, it meets supermarkets’ strict requirements for palletised loads.

The limited-edition box was made to be 70 per cent lighter than the traditional Roses tin and demonstrated Opal’s diecutting expertise as well as its use of colour contrast and tactile depth with the brand’s iconic rose.

The VentX Unico system’s highperformance stretch film of three mini rolls on one continuous core can be used in conjunction with an Omni pallet wrap machine, allowing for a complete customisation and control of load containment, ensuring each pallet is wrapped to a business’ unique needs.

Opal

The design also maximises functionality to ensure distribution efficiency and pallet optimisation. Mondelēz was able to add 25 per cent more shelf ready packaging per pallet – that is, 320 cartons per pallet versus 256 Cadbury Roses traditional 689g tins per pallet.

Opal was a multi-award winner for the Outside of the Box Design of the Year category within the 2022 Australasian PIDAs. The company took out a joint silver and a gold win, namely for its Cadbury Roses limited edition Mother’s Day chocolates and JBS & Opal Dunnage solutions.

“The Cadbury Roses box takes the brand from a flat standard chest style box instead featuring as a vertical style carton. It demonstrates Opal’s die-cutting expertise and takes advantage of colour contrast and tactile depth with the brand’s iconic rose,” Madden said.

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“Supplied as a one-piece tamper-evident box, upon opening, it becomes a two-piece box with a lid and a base. The box can then be accessed multiple times until all chocolates have been consumed.”

Pakko

Pakko’s Double Storey Holiday Hamper House design

Pakko founder and CEO Nina Nguyen started Pakko in 2017 with a vision to create a blueprint for Australian cardboard packaging manufacturing. Since then, together with her team, she has constantly challenged the status quo and encourages her team and customers to think outside the box.

One design from Pakko that stands out for its out of the box design is its Gift Hamper Card Package that Pakko designed to look like a house, created for use during the holidays. The lid of the packaging is incorporated into the roof design.

The team at Pakko designed two versions for customers to choose from – a single story created to mirror a gingerbread house and a double story option with side building that uses built-in locks to keep it attached.

The Pakko Holiday Hamper House was originally created for Pakko’s customers and trade partners. The team designed it and filled it with goodies before sending it out to its partners as an end-of-year thank you.

Apart from being used as a traditional Holiday Hamper gift box, the Pakko Holiday Hamper House is now being easily adapted for numerous uses including realestate marketing projects, housing development project marketing, new real estate development promotions and children’s promotional activities, just to name a few.

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FOCUS ‘OUTSIDE OF THE BOX’ DESIGN The inspiration behind the Single Storey Pakko Holiday Hamper House was to create a design that wasn’t a standard hamper design. It also had to be able to handle a wine bottle, plus additional items.

As for the Double Storey Pakko Holiday Hamper House, it had to do all the above in addition to providing more space and allowing for more unique building designs to be used.

In terms of materials, a corrugated board (E-Flute – 1.5mm thickness) was used to create the solution, which provides structural support. Additionally, as corrugated board is a sustainable material, it can be recycled even after it is digitally printed.

The solution is designed and made locally in Australia at Pakko.

Result Group

as process automation and scanning technologies, designed to collect endto-end shipping data.

The concept was to sell Australian table grapes by proving authenticity and provenance without disrupting the grape harvest and packing processes.

The traceability project started at the farm, where the polybags were given unique serialised GS1 Digital Link-enabled QR code labels. Labels also provided crucial traceability information about consumer pack units, cases, and pallet numbers, as well as time and temperature tracking information captured through the cloud database to combat all types of food fraud. The digital twin integrated into the QR code labels ensured that each one is unique and traceable.

“Collaboration with current system vendors and developing interoperable

Result Group’s ATGA Table Grapes Project

Result Group tied in a silver win with Opal within the Outside of the Box Design of the Year category of the 2022 Australasian PIDAs for its ATGA Table Grapes Project.

According to the company, the ATGA Table Grapes Projects was one of Australia’s largest traceability and authentication pilots. The achievement resulted from a collaboration between Australian Table Grape Association (ATGA), Agriculture Victoria, Perfection Fresh Australia, GS1 Australia, and Result Group.

that takes the Zipform composite pack to create a perfect combination of recyclable and reusable packaging utilising three components: 1. Primary Pack and Refill Pack – a curbside recyclable pack comprising of more than 90 per cent fibre and more than 60 per cent recycled content 2. Connecting Neck Assembly (PCT Patent Pending) designed to press fit and seal to the rim of the composite pack 3. A threaded Pump Assembly as would be found on existing pump packs.

protocols is always a challenge and requires trust and respect. The upside, it opens new opportunities in the traceability sector as we continue to strive to further innovative solutions in the Australian market,” Result Group general manager Michael Dossor said.

“We couldn’t have done it without our partners, the Australian Table Grape Association, Agriculture Victoria, Perfection Fresh Australia, and GS1 Australia, so this award was a joint triumph.”

More than 840,000 units of table grapes, including bunch bags, clamshells, and cartons, were labelled with a unique serialised QR code, enhanced with the use of GS1 Digital Link standards and exported to over 15 markets in the Asia-Pacific region.

Zipform Packaging

To assist grape growers in connecting with consumers and supply chains as well as consumer safety and quality standards, Result Group introduced a customised traceability platform, a label printing and management software, NiceLabel, as well

The company wanted to find a solution to the challenge of recycling problematic materials and products, while remaining true to its mantra of “more paper, less plastic”. As such, it created the Zipform Packaging rPump – a world first innovation

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Zipform Packaging’s rPump solution

Zipform Packaging was the gold award winner for the Outside of the Box Design of the Year category at the 2021 Australasian PIDAs for its rPump solution.

Zipform Packaging worked to design the rPump, which incorporates a reusable pump and connector. The reusable connector and pump assembly means that additional assembly processes are not required to utilise recyclable refill packs, whilst the removal of the pump assembly reduces carton sizing and weight for distribution.

In addition to this, the wide aperture of the pack can reduce end of use product waste with the consumer having easy access to any product not dispensed through the pump.

“The use of non-recyclable plastics has been increasingly in the spotlight since the announcement of the 2025 National Packaging Targets as brand owners and manufacturers alike grapple with the challenges of recycling problematic materials and products,” Zipform Packaging said.

“One such product which is widespread throughout retail shelves is the traditional pump style pack which typically consists of a plastic base and a screw-top pump assembly fitted for dispensing the product.

“The rPump solution addresses multiple outcomes, which are critical to achieving the 2025 Targets.”

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SMITHERS REPORT

Global flexible mono-material plastic packaging segment grows A new Smithers report tracks growth segments for the US$55.7 billion, mono-material flexible plastic packaging films market Polypropylene (PP) is the largest plastic type used for mono-material plastic polymer film, followed by polyethylene (PE). PVC and regenerated cellulose fibre (RCF) each account for very low market shares.

In 2023, the total consumption of monomaterial plastic packaging films globally will reach 24 million tonnes of material

PP mono-material packaging films are forecast to grow at the fastest rate, ahead of PE. One major advantage for PP is that it can be laminated with a PE film, and still be accepted as recyclable; as both are polyolefins.

T

he global flexible mono-material plastic packaging film market is projected to be worth US$55.7 billion in 2023 and is expected to grow at a steady compound annual growth rate (CAGR) of 4.1 per cent globally.

Central to future success in this segment is improving recyclability, replacing laminates and multi-layer constructions with easier to recover mono-material designs.

Data from the latest market report from Smithers, The Future of Mono-Material vs. Multi-Material Packaging to 2028, addresses this challenge directly. It shows that in 2023, the total consumption of mono-material plastic packaging films globally will reach 24 million tonnes of material.

Out of 11 end-use applications examined in Smithers’ analysis, pharmaceuticals, personal care, and fresh food forecast to see the highest gains for mono-materials over the next five years.

Multiple manufacturers have successfully introduced higher barrier mono-material packaging substrates. These have already achieved good traction in dehydrated foods, detergents and dry pet food; barrier performance still needs to be refined to see better penetration into remaining segments, like liquid foods.

The same operators are making iterative improvements in heat sealing of monomaterial films to match the seal integrity and throughput of multi-material packs on high-speed filling lines.

Pressure for more sustainability in plastics is greatest in Europe, but many brand owners are galvanising the market, with commitments to make all their packaging recyclable, worldwide. This is manifesting in multiple new design for recycling initiatives – profiled in the report.

The ultimate goal is to create a circular economy for flexible plastics, with discarded pouches, sachets and films creating the feedstock for a new generation of packaging. This requires investment from plastic producers, closed loop collection schemes for consumer packs are already in operation, creating a nascent supply of recycled PP and PE for real-world trials.

True volume, however, will come from the commercialisation of chemical (advanced) recycling, which also promises to provide rPP and rPE grades suitable for food contact.

Demand by volume will increase at a 4.5 per cent CAGR to reach 30.0 million tonnes in 2028. Across the same period, volume demand for multi-material packaging will increase at a slower 3.6 per cent CAGR, driving consumption from 10.4 million tonnes (2023) to 12.4 million tonnes (2028).

The report’s expert analysis tracks the current state-of-the-art in mono-material flexibles design to identify which segments have the highest commercial potential. The principal technical challenges are to match the barrier performance and heat sealing of established multi-layer designs, delivering comparable shelf-life and protecting against spoilage.

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The breakdown of global mono-material plastic packaging film consumption – projected percentage share by end use sector

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SMITHERS REPORT

The future of paper vs plastic packaging markets to 2028 In the next few years, brands will focus on developing smart designs and packaging solutions that improve packaging performance while minimising environmental impact INFOGRAPHIC

legislators the most demonstrable method to achieve this is transitioning from harder to recycle plastics to paper packaging.

and their impact across supply chains.

PAPER vs PLASTIC packaging Smithers has also created an infographic

Market transitions to 2028below, which provides insight into the The study is framed by deeper critical strengths and limitations of both plastic consumer awareness and growing sustainability concerns studyMounting of current and future influencing and paper-based packaging solutions are driving major changes in the packaging industry. In the next five factors – including barrier and other for key market sectors, with expected years, brands will focus on developing smart designs and packaging performance enhancements, regulatory transition to 2028 and highlights the solutions that both improve packaging performance while minimizing targets, and brand owner strategies – major trends. environmental impact.

PL A

P

R PE A

PL A

P

R PE A

PL A

P

R PE A

R PE A

PL A

SINGLE-USE CONSUMABLES

P

PL A

P

PL A

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R PE A

R PE A

PL A IC ST

DAIRY Current pack formats HDPE and beverage cartons, paper alternatives are just paper shells.

Scope for refill in this sector.

R PE A

P

BREAD BAGS Plastic will retain market share, some moves to paper laminated with plastic less than 15%, flexible film recycling will ensure plastic remains.

PL A

IC ST

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STAND-UP POUCH Strong moves to mono material, some paper-based laminated alternatives for ambient dry food. Has strong refill take-up, negligible paper alternatives.

R PE A

IC ST

Sustainability will be the core driver for innovation in packaging across the decade.

For many consumers, brands, and

BEVERAGES Improved recycling facilities across Europe; moves to simpler laminates, i.e., paper and plastic layer only, easy to detach.

Bio-plastic layers.

IC ST

Some of the findings from the study include: • Within e-commerce, paper will see continued growth, however there will be innovation in plastic and bioplastic liners; reuse, and closed loop systems may affect this transition • Single-use plastic consumables will not be widely accepted going forward, there will be a continued transition to paper, bio-based, bioplastic and reusable materials.

PROTECTIVE PACKAGING Plastic, especially EPS, will lose share to paper, pulp and more recyclable alternatives.

Bio-based materials may make moves in this sector.

IC ST

A recently released dedicated Smithers study, The Future of Paper vs Plastic Packaging Markets to 2028, examined the competing advantages of plastic and fibre-based formats in 25 different packaging applications in the contemporary market, to identify where and when such a transition can be made.

FRESH PRODUCE TRAYS Moves towards laminated paper, retain plastic trays with lidding film, but make them mono plastic. Selling products loose, in bags.

IC ST

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ounting consumer awareness and growing sustainability concerns are driving major changes in the packaging industry. In the next five years, brands will focus on developing smart designs and packaging solutions that both improve packaging performance while minimising environmental impact.

IC ST

The use of paper packaging will continue to see growth in the industry

Single-use plastic consumables will not be accepted in many, if not any markets. There will be transitions to paper, bio-based, bio-plastic and reuse.

IC ST

E-COMMERCE Paper will see continued growth, with innovation in plastic and bio-plastic liners.

Reuse, and closed loop systems may affect transition.

TRANSITION TO 2028

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MARKET SECTOR

KEY DRIVERS Sustainability and consumer awareness will drive change between plastic and paper selection.

Design with the end in mind is now a fundamental part of the development process.

Regulation: higher taxes and fines on materials and pack format will result in shifting substrate selection.

Plastic tax should drive movement towards at least 30% recycled content, move away from virgin plastic use.

Single-use plastics and plastics that can not be easily recycled are being designed out, restricted, or banned.

Convenience: plastic plays a large part in this driver, there will be a lot of work to move into recyclable materials, and change consumer behaviour.

ABOUT THE REPORT

CONTACT US

The Future of Paper vs Plastic Packaging Markets to 2028 examines the competing advantages of plastic and fibrebased formats in 25 different packaging applications in the contemporary market, to identify where and when such a

Europe Bill AllenAugust 2023 ProPack.pro 29 ballen@smithers.com +44 (0) 1372 802086

FOCUS LABELS AND LABELING

Sustainability trends boost wet glue label appeal Glue-applied labels remain the dominant form of prime product labelling, providing key volume, sustainability and print quality benefits for end users

By Andy Thomas-Emans

The key end-use markets for glue-applied labels are in the labelling of drinks bottles and canned human and pet foods. Of the 25 billion sqm of glue-applied labels consumed annually, 70 per cent goes to the beverage market and 23 per cent to the food market. The remaining seven per cent is mainly used in the household chemicals and automotive segments.

Glue-applied labels have applications across a wide range of container types including cans, jars, bottles, composite tubes and boxes. As well as appearing as body and neck labels, glue-applied labels are also used as top straps over the closure as a tamper-evident or security feature.

Converting process

Glue-applied labels have applications across a wide range of container types including bottles

D

espite the consistently higher growth rates of pressure-sensitive and shrink sleeve labels, glueapplied labels remain, by far, the dominant method for prime product labelling.

How do we define a glue-applied label?

Wet glue labels are printed in sheets – or on rolls that are sheeted – then cut or die punched into single labels and stacked into a magazine, which is inserted into the label applicator. Glue is then applied to the reverse side of the label, either to the whole label or to the leading and trailing edges, and the label is applied to the container.

A second type of glue-applied label is the roll-fed wraparound label. These are delivered to the label applicator on a roll, then cut on the machine into single labels and adhesive (usually hot melt) is applied to the leading and trailing edges.

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According to figures compiled by the AWA consultancy, glue-applied labels account for just one-third of the 71 billion sqm of labels consumed annually, against 41 per cent for pressure-sensitive labels.

But when we consider only the primary (prime) label market, glue-applied represents 44 per cent of total label volume compared to only 23 per cent for pressure-sensitive. The remaining PS volume goes to industrial and VIP labelling.

The market share of glue-applied labels is markedly different in different regions of the globe, reflecting different levels of development. According to AWA’s figures, glue-applied has the highest market share in Asia, representing 46 per cent of all label consumption. In the Americas, glue-applied represents just 14 per cent of the market and in Europe 20 per cent.

Glue-applied labels are supplied by the converter in either traditional cut and stack wrapped bundles or on a reel. Cut and stack labels are either cut to shape or ram-punched into specific profile shapes compatible with the container profile.

These are also referred to as patch labels.

Cut labels are rectangular or square in shape, and this profile is suitable for 360-degree wrap-around decoration or patch labels.

Global distribution of glue-applied labels (source: AWA)

Glue-applied labels can also be supplied in reels for 360-degree wraparound decoration. These are not pre-cut to shape but cut singly from a reel at the point of application.

Cut and stack labels are manufactured in a multi-stage operation starting with the printing of label sheets on an offsetlitho press. If subsequent processing is required – for example over-varnishing, foil blocking, embossing or bronzing – the printed sheets are moved to different

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FOCUS LABELS AND LABELING workstations on the production floor.

The finished sheets of labels are then guillotined and square cut or profile punched, batched, packaged and palletised.

Manufacturing using this multi-pass process can have a production cycle of several days, or in some instances several weeks dependent on the quantities required, with perhaps 10 people involved as sheets pass through the printing, embellishing and converting processes.

High-volume wet-glue labels can also be printed on a web-fed gravure press.

The printed reels are transferred onto a sheeting unit which can be an in-line or off-line for further processing. The production of roll-fed wraparound labels is a simpler process involving high-speed printing on CI flexo, gravure, or mid-web inline presses, with or without lamination. The rolls are slit to width and delivered to the packer.

Materials A wide range of both paper and filmic label materials are available for glueapplied label applications. Wet glue label papers are available in a range of formats: standard, wet strength, humidity and alkali resistant, embossed, cast coated/high gloss and metalised, covering all the technical and marketing requirements of the enduser market. They are also suited to a wide variety of other applications like interleaving, lamination, box covering and food wrapping.

Wet glue papers are available in either coated or uncoated grades. Uncoated paper has a low gloss level, greater absorbency and is less suitable for quality image reproduction. Coated papers, available in matte coat, semi-gloss, gloss and castcoated grades, have a coated gloss/reflective surface, lower absorbency and are more suitable for quality image reproduction.

A range of specialist craft/antique papers are available specifically for wine labels and craft beverages.

When selecting papers for use in wet glue label applications, a range of performance factors must be considered: direction of the grain and the resulting effect on label curl in uncontrolled humidity; substrate moisture content during storage and transportation; humidity levels in the printing environment; and humidity levels in the filling and label application areas.

Films are available for both cut and stack and roll-fed wraparound applications.

Films are usually selected for performance reasons, typically for applications requiring durable moisture resistance, chemical resistance, wet strength and burst resistance on large PET bottles.

These films are available in transparent, opaque (white) and metallic grades and are supplied both for surface printing and for lamination.

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To run smoothly and efficiently on the applicator line, reel-fed wraparound films need to combine controlled stiffness with anti-static properties, web flatness and strong ink and adhesive compatibility.

A key trend is to downgauge the filmic material to get closer to the economics of paper labels.

Decorative effects Although cut and stack labels are targeted at low-cost, high-volume applications, there is a wide range of decoration options available to add value to each product category. Gloss lacquers, for example, are used on the face of glue-applied labels both for scuff resistance and increased shelf impact. For lithographic printing, the norm is UV lacquers, while photogravure printed labels use a range of solvent and water-based lacquers.

Embossing is used where a specific part of the design needs to be raised to enhance the label’s appearance. With gravure printing, in-line all-over or partial embossing is possible, producing a tactile feel to the label – particularly effective when used on metalised paper labels.

For metallic effects, foil-blocking is available as a separate process step on wet glue labels in a wide range of colours.

Foil laminate and metalised papers are also available, offering a reflective metallic finish that can be over-printed.

The superior transparency of offset inks allows high brilliance levels to be achieved in these applications. Holographic effect wet-glue label papers are also available.

Wet glue labels can be die punched in complex shapes, which, combined with embossing or other textural elements, delivers an effective promotional tool for high-end premium products.

Label applicators Cut and stack labelling machines operate by applying glue to the back of each label before applying it to the container. There are two main types of adhesive used. ‘Wet’ glue is water-soluble and liquid at room temperature, and is the most common type of cut and stack adhesive. The second

Global end-user markets for glue-applied labels (source: AWA)

adhesive type is hot melt, a solid glue that is heated to become a liquid.

The adhesive can be applied to either the full area of the reverse side of the label or by gluing the trailing and leading edges. The type of adhesive application can be selected from options such as skip, pattern or stripe, depending on adhesion, application speed or drying speed required.

When labelling cans, the adhesive is first applied as a stripe to the container and a second stripe of adhesive is applied to the trailing edge of the label as it rotates over the label magazine. Wraparound rollfed glue-applied labels typically use hot melt technology. Several kinds of hot melt adhesives are available to suit different purposes, such as particular packaging materials or the conditions within the factory environment.

A wraparound hot melt labelling system consists of two gluing units. The first applies a vertical strip of glue which adheres the label to the container, while a second unit applies glue to the trailing label edge as the label is wrapped around the container.

It should also be noted that there is a third type of wet glue labelling machine using pre-gummed labels. In the pregummed system, labels are pre-coated with glue, then water is applied either through dipping or spraying to activate the adhesive properties of the glue.

As techniques and materials have developed, however, the pre-gummed labelling method has waned in popularity in favour of wet glue and hot melt systems.

Wet glue vs self-adhesive The choice between wet glue, glue-applied roll-fed wraparound and self-adhesive can be a complex one when the Total Cost of Ownership (TCO) is considered. TCO includes a wide range of factors including material costs, printing and conversion costs, manufacturing window/lead time, application equipment investment, operational cost of application lines, application flexibility, application speed, application downtime, and logistics.

Wet glue labelling offers the lowest per-label cost of all methods of label decoration. This starts with the offset-litho provides itself, which provides excellent reproduction of photographic designs, tone-work and metallic colours with relatively low plate costs. Another press technology factor moving the TCO dial in favor of wet glue labels is the increasing use of in-line technologies on sheetfed offset presses, which can dramatically shorten lead times.

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FOCUS LABELS AND LABELING Offset-litho presses for wet glue labels are already equipped, pretty much as standard, with single or dual UV coaters or extended delivery hot air dryers for water-based coatings. And more processes are going in-line. Offset-litho technology also benefits from higher levels of industrialisation and automation than a typical PS label converting operation, along with a fully standardised colour management process from design and proofing to print. Some converters have their own in-house offset colour management systems as well.

Global label market by label technology in volumes (source: AWA)

Stages involved in labelling a can

Automation has also been happening on the cut and stack finishing line, both for square cut and die punched labels.

The ability of sheetfed offset presses to gang multiple jobs up on the same sheet, added to automated finishing, has allowed the economic production of shorter runs and smaller batches, as well as reduced cycle times.

Sustainable solution From a sustainability viewpoint, glue-applied labels have several key advantages. Most obviously there is no waste matrix or liner to dispose of. Wet glue labels applied with water-based adhesives can be easily removed from returnable bottles in a caustic wash bath, while a new generation of alkali-based washable hot-melt adhesives now allows these labels to be washed off cleanly as well. Modern conventional offset inks are non-bleeding, avoiding contamination on the alkaline water wash. Generally, UV offset inks are specified for one-way (non-returnable) containers.

Downsides of wet glue labels include the multi-stage sheetfed manufacturing process. Lead time becomes more of a factor when the specification requires multiple embellishment processes such as hot foil-stamping, embossing and lamination, all of which require separate steps in a sheet-fed workflow.

The ability of inline self-adhesive converting equipment to print and embellish in one pass considerably reduces the manufacturing time frame.

In addition, wet glue labels cannot be applied to highly shaped areas of containers, and paper labels have limited moisture resistance compared to plastic labels unless specially developed for ice bucket resistance. Wet glue applicators tend to require higher investment, including change parts and adhesive, while self-adhesive labels application equipment requires fewer resources to set up and does not require labels to be stacked in a magazine before application.

Against that, self-adhesive labels are more expensive, as they include the cost of the

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Global primary label market by label technology in volumes (source: AWA)

A typical patch label application sequence

liner and the ready-applied adhesive.

Label applicator speeds are not as wide apart as they once were, so this is not usually a factor differentiating wet glue from self-adhesive. Wet glue labelers typically operate at speeds around 600 units per minute, against around 500 per minute for PS applicators.

Paper investment Paper manufacturers are gearing up for increased production of added-value wet glue papers as the industry recovers from the intense paper shortages cause by a combination of forestry strikes and supply chain disruption.

Sappi, for example, is investing heavily in wet glue label production at its Gratkorn mill in Austria. The project includes a new embossing calendar, enabling the paper mill to produce high-quality wet-strength wet-glue label papers from Q4 this year.

Sappi has also been developing a new range of non-wet-strength, we-glue label papers. The Parade Label Pro is designed for applications including standard labels for bottles, tins and jars, as well as wrappers.

So, despite the continued inroads made by self-adhesive and shrink sleeve labels, particularly in the more developed markets, the usage of glue-applied labels continues to grow at a healthy rate.

Driven by moves towards sustainability and continued automation, Consultancy Research and Markets forecasts the glueapplied label market to grow by 5.94 billion sqm between 2022 and 2027, accelerating at a CAGR of 4.99 per cent.

Single label leading and trailing-edge gluing using a hot melt double head. Key: 1 Hot melt gluing head, 2 Pre-cut single labels in magazine, 3 Hot melt gluing head

Wrap round label featuring hot melt glue strips on leading and trailing edges

Typical reel fed wrap round applicator

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PACKAGING AND DISPLAY EQUIPMENT

The No. 1 solution for shortrun boxmaking BX200 BOXER  60 second, tool-less

 In-line printing solutions

auto set up  Extensive size range  Any run length upwards from a single box

 Converts single, double,

even triple wall  KOLBUS “360 ASSIST” 24/7 support

THE KOLBUS AUTOBOX RANGE OF BOXMAKING MACHINES

BOXMAKING

PRINTING

GLUING

For more information on how the BOXER BX200 can improve your in house boxmaking, call for details of your local agent on +49 (0)5771 710 or email info@kolbus.com.

HARNESS THE POWER OF THE BRAND NEW

BX Motion Pro

A ground up redesign is at the heart of this brand new generation modular boxmaker from KOLBUS. It allows custom specification for each module to meet your exact needs, including: ■

■

■

■

■

Heavy Duty box making In line digital or flexo printing In line gluing Single person operation Waste management system

In short, the BX Motion Pro is your very own personalised boxmaking solution.

Call your local agent now to arrange a demonstration.

THE HOME OF BOXMAKING Tel. +49 (0)5771 710 | info@kolbus.com | www.kolbus.com

Graffica Pty Ltd Phone +61 477 200 854 I Email grafficapl@bigpond.com I Visit Us www.graffica.com.au

PACK DIARY

UPCOMING INDUSTRY EVENTS Pack Expo Las Vegas

Australasia’s Processing and Packaging Expo

Labelexpo Europe 2023

ProPak Asia 2024

September 11-13, 2023 Las Vegas, US packexpolasvegas.com

March 12-15, 2024 Melbourne, Australia appex.com.au/

September 11-14, 2023 Brussels, Belgium labelexpo-europe.com

June 12-15, 2024 Bangkok, Thailand propakasia.com/

Foodtech Packtech

Labelexpo Asia 2023

Labelexpo Americas

Pack Print International

Sino-Pack

Pack Expo International

September 19-21, 2023 Auckland, New Zealand foodtech.packtech.co.nz

September 20-23, 2023 Bangkok, Thailand pack-print.de/

December 5-8, 2023 Shanghai, China labelexpo-asia.com/

March 4-6, 2024 Guangzhou, China chinasinopack.com/

September 10-12, 2024 Chicago, US labelexpo-americas.com/

November 3-6, 2024 Chicago, USA packexpointernational.com/

Got an event? Send an email to pwnuk@intermedia.com.au with all the details and we will put your event on the page.

34 ProPack.pro August 2023

www.propack.pro

Ignite the power of packaging with ProPack.pro Are you looking to spark your brand’s identity in the competitive market?

LOOK NO FURTHER! Our publication can put your message in front of label and packaging decision makers published in print six times a year, accompanied by our weekly eNewsletter.

To secure your advertising today, contact

Carmen Ciappara | 0410 582 450 | carmen@proprint.com.au

ON/OFF instant light source switching

* 91％

lower power consumption

15,000hr long life

Ozone free

Low heat

RMGT 1060TP-8 LED-UV

RMGT 1060ST-6+CC LED-UV

1,060mm Format 8-Colour Offset Press with LED-UV

Why LED-UV ?

No odor No Ozone No spray powder No set-off No loss time

• Instant dry • Instant ON/OFF irradiation

Reduce CO2 emission No large peripheral equipment No need for overprint varnishing Reduce electrical consumption

• Up to 91%

No VOC (Volatile Organic Compounds) Reduce heat generation Long life span

• Up to 15 times

Printing on film and cardboard Just like your conventional offset press ...without the cons.

Sydney

1,060mm Format 6-Colour Offset Press with LED-UV

NEW! LED-UV now available to all 2023 ushers in a new chapter to LED-UV dry-to-dry printing system. It is now made available to all makes and models of offset printing machines.

Starting from $90,000, come join the LED-UV revolution.

Energy-Saving & Environmentally-Friendly LED-UV dry-to-dry printing system.

Pioneering success, first introduced in Drupa 2008. Ryobi single-handedly led the industry in LED-UV printing. This revolutionary, award winning printing system offers impressive cost-savings by greatly reducing replacement frequency, power consumption, installation space and peripheral equipment space, while eliminating the odor of UV printing.

The defecto standard for small lot on-demand printing today, it is an important strategic advantage in being able to provide high-quality, small lot on-demand printing at low cost.

Now, 15 years later, Cyber is applying our wealth of expertise as an LED-UV pioneer to provide the printing industry with innovative solutions that meet your needs.

Rediscover the joy of printing…

Specifications

Singapore - Tel: (65) 6272 8936 Thailand - Tel: (66) 2 682 3411-4

Operating Temperature

25°C

Lifespan

15,000 hours

Additional Printing substrate

Yupo, foil, plastic and film

Irradiation

Patented optical design

Applications

Ink and varnish

Start-up time

0 seconds

Press size

52cm - 162cm

Shut down time

0 seconds

Printing Speed

18,000 sph

Sydney - Rob Crough 0423 337 788 Melbourne - Greg Knight 0411 338 855 Brisbane - Peter Erskine 0432 663 322 Perth - Alan Strugnell 0418 955 512 New Zealand - Paul Hilleard (64) 21 191 6548 Malaysia - Tel: (60) 3 7955 1668 (Kuala Lumpur) Indonesia - Tel: (62) 21 2555 8924 Tel: (60) 7 598 0771/2 (Senai, Johor) Vietnam - Tel: (84) 9 0938 9468

: 38 Victoria Street, Beaconsfield, NSW 2015 Australia Tel: (61) 2 9318 0099 Fax: (61) 2 9318 0399 New Zealand : Unit 22, Ground Floor, 6 Ken Browne Drive, Te Rapa, Hamilton 3200, New Zealand Tel: (64) 7 949 7722 sales@cyber1976.com www.cyber1976.com

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