The FTA Flexography Awards honor companies that have created exceptional quality and precise consistency in their printed pieces.
The Vicious Styling Boost XTS Series shampoo tube stood out among other applicants due to its various effects and precise registration. Thanks to the capabilities of the Heidelberg-Gallus RCS 330, Berry Global was able to print the job directly on a laminate substrate as opposed to printing on film and then laminating to the substrate.
According to John Goddard, Laminate/Assembly manager at Berry Global, “When we were first looking for a new narrow web press, the RCS stood out due to its ability to print on laminate tube substrate as printing on it can be difficult due to the substrate’s variation in thickness and surface quality.”
In addition to the challenging substrate, the package’s design was another obstacle for Berry to overcome. According to Goddard, “The design included pale skin on a black background with intricate details in the tattoos, so precise registration and a clean print was crucial for this job. Luckily, with the RCS, we have a very wide color gamut and the latest HD technology, which allows us to achieve this.”
As a modular inline press with direct drive technology, the Gallus RCS 330 can be configured and extended at will. Individual printing methods can be replaced without needing to separate the web. Thanks to the high degree of automation in all of its modules, the press is able to minimize waste and reduce changeover times dramatically while still giving Berry Global the flexibility they need to grow.
“The Heidelberg-Gallus RCS 330 is an extremely flexible press that allows us to do everything in line and handles a wide range of substrates from extremely thin monofoils that are just a few micrometers to tube laminates up to 450 micrometers,” says Goddard. “We can do anything our customers are looking for all in one pass.”
According to Vali Braselton, brand marketing manager at Berry Global, “Since our customers are looking for brand differentiation, it’s very important to us to be able to do these special effects and unique packaging, which is exactly what the RCS 330 has helped us achieve. It’s key to being successful in the market.”