Greg Hrinya, Editor06.04.20
With label converters facing greater demand than ever before, there is never a bad time to evaluate options for diversifying their portfolios. One of the most popular applications finding its place in the label printer’s book of business is flexible packaging.
Suppliers are developing new materials to meet demand, and converters are increasingly exploring this option.
“Flexible packaging has been on the rise for quite a few years, as we’re educating our customers on how to expand their technical knowledge,” says David Parsio, vice president of sales and marketing, Multi-Plastics. “We work closely with the narrow web label industry to broaden their reach in this space, which is a daily goal for our sales professionals. In a very competitive business climate, label converters will continue to try to grow their product offerings by expanding into flexible packaging.”
The Flexible Packaging Association (FPA) has conducted and researched in-depth studies on the market, and in 2018, flexible packaging was valued at $31.8 billion in sales. This packaging type accounted for 19% of the total US packaging industry, which was valued at $170 billion. The 10-year CAGR, evaluating the period from 2008-2018, was approximately 2%.
Growth is expected to flatten in the near future. For example, flexible packaging utilized for baby foods grew at a CAGR of 5.7% from 2013-2018, but a 1.4% CAGR growth rate is expected for 2018-2023, Euromonitor data shows. Growth is anticipated to remain strong for flexible packaging used for processed foods and vegetables. From 2013-18, this segment grew at a CAGR of 4.5%, and it is expected to see continued growth of a 4.6% CAGR in the next five-year phase.
HP Indigo is envisioning a bright future, as the company has developed digital press technology to handle flexible packaging specifically. Alon Bar-Shany, general manager of HP Indigo, stated in a recent interview with Label & Narrow Web that HP is seeing an annual growth of almost 50% in flexible packaging, which has been emphasized by the emergence of ePac. However, HP still sees massive room for growth, as its flexible packaging output accounts for just 0.2% of the global output.
“For flexible packaging, we can quadruple the business and still be only 1% of the global output,” says Bar-Shany. “Theoretically, there’s no reason one day flexible packaging won’t be at least as big as labels. We have to develop all the solutions, the capabilities and the business model. It’s a great business.”
L&NW recently sat down with AB Graphic International’s Matt Burton, global sales director, and Josep Orozco, managing director and flexible packaging expert at Enprom Solutions. We discussed the latest trends and how ABG and Enprom can fill the market need for flexible packaging.
What trends are you seeing in our industry concerning flexible packaging?
Burton: From an ABG perspective we are seeing a lot of traditional label printing companies expanding into new market segments to offer their customers more than just a label. Predominantly, this includes packaging solutions such as stand up pouches and shrink sleeves. Digital printing is helping customers to easily diversify as the press can often print a wide range of substrates. The label printer only needs to invest in different finishing solutions.
Orozco: The main interest in the flexible packaging and the shrink sleeve industry is in finding new materials and products that are more sustainable and recyclable. The environmental point of view is one of the most interesting, and many new proposals will feature it in the future. It is a trend that is growing thanks to the demands on different products, the most prominent being the development of technologies for the heat shrink sleeve market and flexible packaging.
How are Enprom and ABG providing equipment to help flexible packaging producers?
Burton: ABG can offer narrow web solutions for lamination at 350mm wide web, but now with the Enprom acquisition, we can offer the option to go wider and expand, and grow our business in the future. We have customers running shrink sleeves on our Digicon and Omega machines today and have for some time. However, we can now offer seaming, inspection and sheeting for shrink sleeves, thereby providing an end-to-end solution.
Orozco: Enprom has been manufacturing a full range of converting products for flexible packaging since 2012, from standard entry level slitters to the more advanced. We can design and manufacture a complete line adapted to the needs and process of each product or customer. From folding machines to complete multi-process lines and hybrid converting solutions, we can help add inline processes for circular economy solutions.
Additionally, in conjunction with ABG, we have been developing new solutions for the market, especially to adapt to the digital printing process, such as our thermo-laminating machine, which has been a great step in a rapidly growing market. The machine provides a fast lamination process for flexible packaging products, such as pouches or sleeves, which is perfect for digital printing that requires fast time-to-market and short runs.
Are there any specific types of flexible packaging you’re seeing more from your customers?
Burton: We are seeing an increase in pouches, shrink and easy open. As stated in the recent Market Research Future study, sleeve label production is increasing and expected to increase to an annual composite growth rate of more than 6% by the end of 2022. Also, we’re seeing short runs and fast delivery – digital and thermal lamination – for different markets, while long runs continue with traditional processes, again in different markets.
Orozco: We are seeing an increase in value-added products. The traditional market for the sale of flexible packaging has always been in reel format – this in recent times has been changing with the proliferation of pouches and materials with label inserts for better dispensing. In this transformation, Enprom has been offering new processes to meet demand.
What is the learning curve like for label converters looking to expand into these new segments?
Burton: There is a lot to learn, but we have many customers who have made the transition successfully. While the vocabulary, terminology and processes (especially around lamination) are new to label printers, the processes themselves, such as printing, are similar. Over the last 20 years, the label market has adopted and embraced digital technology, and in some ways this makes it easier for label printers to transition into flexible packaging. However, at the moment, digital is still very new to packaging companies. According to the report and analysis from FINAT, the growth of label procurement among all digital labels and labels is projected to grow 3% and 7.8%, respectively, this year.
Orozco: Flexible packaging is an extensive market with a variety of products and processes to learn. For a label producer close to the beverage market, sleeve products complement their product portfolio, which makes it easier to know the demands of this market and with it the learning curve is shorter. The great advantage that we can offer from Enprom is the ease and repeatability in the sealing process, with simple machines to use through the incorporation of technology. The same occurs in the formation of the pouch through our thermo-laminator.
What do you anticipate in the future as more converters expand into new markets like flexible packaging and shrink sleeves?
Burton: We are incredibly confident and excited about the future of the flexible packaging sector and the opportunity for label companies to diversify. Furthermore, with Enprom’s engineering expertise and ability to quickly react to changing consumer demands, the future looks good.
Orozco: The new revolution in flexible packaging will come from the materials, as players look for more recyclable products and with a clear environmental point of view. We believe that caring for the environment plays and will play a very important role in market demands. Increasingly, more and more customers will not only value that the packaging is attractive and novel, but they prefer and will prefer that it be sustainable. They will be interested in technologies with minimal impact on the environment.
Label converters are buying into this philosophy, too. Mepco Label Systems, based in Lodi, CA, USA, has expanded its digital labels and packaging production capacity with the installation of an HP Indigo 20000 digital press. The press will allow Mepco to expand its services into digital flexible packaging, with the 30" format capturing a vast array of applications such as stand-up pouches, zipper pouches and other flexible packaging.
“The press will enable our company to offer small and medium brands flexible packaging products at an economical price to test out the market and get on the shelves fast. In addition, the press will improve our company’s economics by cutting out setup and setting us apart from our competitors,” says Jennifer Tracy, president of Mepco.
According to Parsio, the flexible packaging market is gaining steam with label converters for numerous reasons. Narrow web converters boast high end, multi-process print capabilities to succeed in this market, and there is a low cost of entry without large tooling expenditures.
“Label converters’ superior speed-to-market allows brand owners the versatility to bring multiple marketing campaigns swiftly on the same budgets brand owners would typically need to commit to only one campaign,” adds Parsio. “Expanding both the regional brand owners’ reach nationally, as well as adding greater margin to the narrow web converter, is a mutually beneficial marketplace that attracts interest from the label industry.”
Shelf appeal and speed to shelf are critical for brand owners, but there are other reasons for this application’s popularity. Consumers are demanding longer shelf life, brand connection and convenience in their packaging, notes Leslie Kozar, senior marketing manager, Rapid-Roll, Avery Dennison.
“We see an increasing number of label converters asking about flexible packaging as their business moves toward becoming a label and packaging solutions supplier,” says Kozar. “Studies and research reports agree that the growth in flexible packaging will continue to flourish over the coming several years.”
It is also worth noting, too, that the COVID-19 pandemic has increased demand for flexible packaging. Foods and home goods often utilize flexible packaging, which has seen an increase in production during the crisis.
Stand out on the shelf
Flexible packaging provides brands with a host of benefits, and chief among them is catching the consumer’s eye at the point of purchase.
Multi-Plastics’ Parsio cites powdered drink mixes, nutritional supplements, salty snacks, candy, single-serve foods and drinks, home products and pet foods as common end uses for flexible packaging. There is a financial benefit to using flexible packaging, as it provides reduced weights, which in turn saves costs during shipping. However, the main benefit is on-shelf.
The Flexible Packaging Association’s study shows that food makes up 49% ($15.6 billion) of the flexible packaging market. Beverages, consumer products, and medical and pharma applications account for 9% apiece.
“Flexible packaging provides increased shelf space for retailers and promotes flexibility in adding embellishments to promote branding,” says Parsio. “There are also reduced requirements for storing packaging prior to processing, all while adding recyclable and green options to promote a brand’s environmental stewardship.”
According to HP’s Bar-Shany, HP’s goal is to instill confidence in the brands and build solutions that go beyond printing capabilities. The ultimate product must entice the customer at the shelf. HP’s willingness to develop new flexible packaging products with its customers has spurred the company’s growth.
“We understand what it takes to be successful,” says Bar-Shany. “When we sell the press, we don’t disappear. We stay there and develop the market. We talk to the brands and bring in business, but we’re also very close and intimate with our customers. I think people trust us and they also see our ability to innovate.”
Product versatility
Various suppliers offer a wide range of products suitable for this market. For Multi-Plastics, popular materials include cosmetic webs, PPFP, BOPP, PET, and PE laminations.
According to the FPA, polyethylene is the material of choice when it comes to flexible packaging films and resins utilized by converters. Polyethylene comprises 50% of films and 85% of resins used, while polypropylene ranks second in both categories – 26% and 10%, respectively. The total industry value of materials earmarked for flexible packaging is $16.5 billion, with films accounting for 41% and resins making up 32% of those figures.
“Mono web films are used to create flexible packaging on-press, with and without high barrier options to extend shelf life, which can offer the lowest entry cost to a brand owner,” explains Multi-Plastics’ Parsio. “Adhesive and extrusion laminations offered as completed structures to the industry provide advantages of robust barrier properties and multi-use flexibility that limit the learning curve on-press, and provide immediate entry to the flexible packaging marketplace.”
Multi-Plastics has engineered a full line of mono web and high barrier coated films that can be used as single web overwrap films or in combination to create flexible packaging on-press. High and Medium Barrier Flexpack webs, cosmetic webs, paper-faced barrier laminations, stickpack structures and a full line of lidding films are also available.
Avery Dennison, on the other hand, sees the common materials including a film and foil combination that creates an excellent barrier, and film laminations that can be used in applications for wet and dry goods. Metalized films also provide effective barrier qualities. Paper foil structures are still very common for dry goods, says Avery Dennison’s Kozar.
“Flexible packaging can be a full package lamination or partial packaging such as shrink films and lidding,” she says. “Full package laminations take on several formats, including stickpacks, pillow packets and very popular stand-up packaging. The different formats each require different features and attributes in order to achieve optimum performance, depending on the contents and application. The demand for sustainable product offerings that provide the same barrier qualities continues to grow.”
Avery Dennison offers a wide range of stocked products available for narrow web converters. These include cosmetic webs, snackwebs, stickpacks, paper foil laminations and stand-up pouches. The company provides film and paper facestocks with a variety of sealants that are required to keep ingredients safe and provide longer shelf life. These products are part of Avery Dennison’s Rapid-Roll portfolio.
Ink technology can vary, too. “While label formulations can be complicated in nature, packaging inks tend to offer a much greater challenge due to the finishing and converting requirements done once they leave the printer,” says Jim Krstulic, national account manager - Envelopes, and Tag & Label product manager for INX International Ink Co. “As an ink manufacturer, we must have all the end-use information before any ink recommendation or formulation is considered.”
INX recently released its INXFlex UV Contour UVF and INXFlex UV Contour Dual energy curable ink systems for the narrow web shrink market, increasing its shrink capabilities both vertically and horizontally.
Contour UVF has been formulated for traditional UV curing systems while the Contour Dual exhibits curing capabilities for both the LED and traditional UV curing processes. INX has also upgraded its AquaTech ION S water-based shrink formulations for an improved shrink response.
In line with environmental endeavors, C-P Flexible Packaging has launched C-P GreenStream, a line of flexible packaging options designed for sustainability. This product line utilizes post-consumer recycled content, recyclable materials, compostable materials, downgauged materials, and/or materials derived from renewable resources. Created with the circular economy in mind, the C-P GreenStream line of flexible packaging includes options that reduce the amount of material entering the waste stream, as well as options that allow post-consumer recycled content to re-enter the stream of source materials. The C-P GreenStream portfolio includes flexible packaging materials with over 40% post-consumer recycled resin.
Digital printing has emerged as an asset for flexible packaging printers. Speed-to-market is a key benefit. As HP’s Bar-Shany notes, converters require slitting, lamination and pouch making – and it must all fall into place. If the printing occurs in a short timeframe but takes multiple days to convert into a pouch, then the process won’t be nearly as efficient.“Printing flexible packaging digitally is a way of driving supply chain efficiencies, lower inventories, track-and-trace and marketing campaigns,” he says. “These are the same trends we see in label, which is very consistent.”
Flexible packaging products extend to inspection, as well. Isra Vison recently launched PrintSTAR, a 100% inline inspection system that has been optimized for flexible pacakging. The product features continuous quality and process control of printed images, lamination and coatings. According to Isra Vision, a medium-sized packaging producer is now using 100% inspection technology to help with the application of cold seal adhesives to flexible packaging.
After printing, the flexible film is moved to the laminator, where a patterned adhesive is applied to the reverse side of the film. The application must then be aligned with the print on the front in the precise position in the register at a speed of up to 1,000 fpm.
Another challenge is that the various films are typically finished with reflective surfaces. The 100% inspection system detects all defects in the cold seal and monitors the process to ensure that the coating is even, free from voids, and aligns with the repeating print. Using high-resolution LCD cameras combined with ultra-bright LED lighting, the PrintSTAR system detects both individual and recurrent cold seal defects in real-time.
Label Traxx, a management software (MIS) specialist for the label converting industry, has announced that new features in Version 8.2 are tailored toward flexible packaging manufacturers. Version 8.2 of the software includes dedicated flexible packaging workflows for companies selling unsupported film, sachets and pouches by weight.
These new tools help with the accurate and consistent estimating of flexible packaging, along with features specifically for flexible packaging order processing. The system not only takes into consideration the weight of the raw material and inks but also considers other converting options such as additional machine passes to laminate or seal the packaging. In addition, Label Traxx Version 8.2 calculates the weight and cost of any other ancillary items such as spouts, zippers, seals or degassing valves.
The flexible packaging products are quoted in the MIS system in pounds/kilos and then carried through to manufacturing instructions, order confirmations, packing slips and, ultimately, the invoice. Purchase orders for flexible packaging materials can also be made in pounds/kilos.
“We have seen that flexible packaging is one of the fastest growth areas for our customers, and it’s an area showing tremendous growth worldwide,” says Ken Meinhardt, Label Traxx president. “Companies are moving to becoming a one-stop labels and packaging shop. We wanted to make sure those companies had no barriers to entering this lucrative market. While the converting process isn’t necessarily different – selling by the pound or kilo is unusual with labels. But now, our customers can be confident quoting and manufacturing these kinds of jobs right in Label Traxx.”
Suppliers are developing new materials to meet demand, and converters are increasingly exploring this option.
“Flexible packaging has been on the rise for quite a few years, as we’re educating our customers on how to expand their technical knowledge,” says David Parsio, vice president of sales and marketing, Multi-Plastics. “We work closely with the narrow web label industry to broaden their reach in this space, which is a daily goal for our sales professionals. In a very competitive business climate, label converters will continue to try to grow their product offerings by expanding into flexible packaging.”
The Flexible Packaging Association (FPA) has conducted and researched in-depth studies on the market, and in 2018, flexible packaging was valued at $31.8 billion in sales. This packaging type accounted for 19% of the total US packaging industry, which was valued at $170 billion. The 10-year CAGR, evaluating the period from 2008-2018, was approximately 2%.
Growth is expected to flatten in the near future. For example, flexible packaging utilized for baby foods grew at a CAGR of 5.7% from 2013-2018, but a 1.4% CAGR growth rate is expected for 2018-2023, Euromonitor data shows. Growth is anticipated to remain strong for flexible packaging used for processed foods and vegetables. From 2013-18, this segment grew at a CAGR of 4.5%, and it is expected to see continued growth of a 4.6% CAGR in the next five-year phase.
HP Indigo is envisioning a bright future, as the company has developed digital press technology to handle flexible packaging specifically. Alon Bar-Shany, general manager of HP Indigo, stated in a recent interview with Label & Narrow Web that HP is seeing an annual growth of almost 50% in flexible packaging, which has been emphasized by the emergence of ePac. However, HP still sees massive room for growth, as its flexible packaging output accounts for just 0.2% of the global output.
“For flexible packaging, we can quadruple the business and still be only 1% of the global output,” says Bar-Shany. “Theoretically, there’s no reason one day flexible packaging won’t be at least as big as labels. We have to develop all the solutions, the capabilities and the business model. It’s a great business.”
L&NW recently sat down with AB Graphic International’s Matt Burton, global sales director, and Josep Orozco, managing director and flexible packaging expert at Enprom Solutions. We discussed the latest trends and how ABG and Enprom can fill the market need for flexible packaging.
What trends are you seeing in our industry concerning flexible packaging?
Burton: From an ABG perspective we are seeing a lot of traditional label printing companies expanding into new market segments to offer their customers more than just a label. Predominantly, this includes packaging solutions such as stand up pouches and shrink sleeves. Digital printing is helping customers to easily diversify as the press can often print a wide range of substrates. The label printer only needs to invest in different finishing solutions.
Orozco: The main interest in the flexible packaging and the shrink sleeve industry is in finding new materials and products that are more sustainable and recyclable. The environmental point of view is one of the most interesting, and many new proposals will feature it in the future. It is a trend that is growing thanks to the demands on different products, the most prominent being the development of technologies for the heat shrink sleeve market and flexible packaging.
How are Enprom and ABG providing equipment to help flexible packaging producers?
Burton: ABG can offer narrow web solutions for lamination at 350mm wide web, but now with the Enprom acquisition, we can offer the option to go wider and expand, and grow our business in the future. We have customers running shrink sleeves on our Digicon and Omega machines today and have for some time. However, we can now offer seaming, inspection and sheeting for shrink sleeves, thereby providing an end-to-end solution.
Orozco: Enprom has been manufacturing a full range of converting products for flexible packaging since 2012, from standard entry level slitters to the more advanced. We can design and manufacture a complete line adapted to the needs and process of each product or customer. From folding machines to complete multi-process lines and hybrid converting solutions, we can help add inline processes for circular economy solutions.
Additionally, in conjunction with ABG, we have been developing new solutions for the market, especially to adapt to the digital printing process, such as our thermo-laminating machine, which has been a great step in a rapidly growing market. The machine provides a fast lamination process for flexible packaging products, such as pouches or sleeves, which is perfect for digital printing that requires fast time-to-market and short runs.
Are there any specific types of flexible packaging you’re seeing more from your customers?
Burton: We are seeing an increase in pouches, shrink and easy open. As stated in the recent Market Research Future study, sleeve label production is increasing and expected to increase to an annual composite growth rate of more than 6% by the end of 2022. Also, we’re seeing short runs and fast delivery – digital and thermal lamination – for different markets, while long runs continue with traditional processes, again in different markets.
Orozco: We are seeing an increase in value-added products. The traditional market for the sale of flexible packaging has always been in reel format – this in recent times has been changing with the proliferation of pouches and materials with label inserts for better dispensing. In this transformation, Enprom has been offering new processes to meet demand.
What is the learning curve like for label converters looking to expand into these new segments?
Burton: There is a lot to learn, but we have many customers who have made the transition successfully. While the vocabulary, terminology and processes (especially around lamination) are new to label printers, the processes themselves, such as printing, are similar. Over the last 20 years, the label market has adopted and embraced digital technology, and in some ways this makes it easier for label printers to transition into flexible packaging. However, at the moment, digital is still very new to packaging companies. According to the report and analysis from FINAT, the growth of label procurement among all digital labels and labels is projected to grow 3% and 7.8%, respectively, this year.
Orozco: Flexible packaging is an extensive market with a variety of products and processes to learn. For a label producer close to the beverage market, sleeve products complement their product portfolio, which makes it easier to know the demands of this market and with it the learning curve is shorter. The great advantage that we can offer from Enprom is the ease and repeatability in the sealing process, with simple machines to use through the incorporation of technology. The same occurs in the formation of the pouch through our thermo-laminator.
What do you anticipate in the future as more converters expand into new markets like flexible packaging and shrink sleeves?
Burton: We are incredibly confident and excited about the future of the flexible packaging sector and the opportunity for label companies to diversify. Furthermore, with Enprom’s engineering expertise and ability to quickly react to changing consumer demands, the future looks good.
Orozco: The new revolution in flexible packaging will come from the materials, as players look for more recyclable products and with a clear environmental point of view. We believe that caring for the environment plays and will play a very important role in market demands. Increasingly, more and more customers will not only value that the packaging is attractive and novel, but they prefer and will prefer that it be sustainable. They will be interested in technologies with minimal impact on the environment.
Label converters are buying into this philosophy, too. Mepco Label Systems, based in Lodi, CA, USA, has expanded its digital labels and packaging production capacity with the installation of an HP Indigo 20000 digital press. The press will allow Mepco to expand its services into digital flexible packaging, with the 30" format capturing a vast array of applications such as stand-up pouches, zipper pouches and other flexible packaging.
“The press will enable our company to offer small and medium brands flexible packaging products at an economical price to test out the market and get on the shelves fast. In addition, the press will improve our company’s economics by cutting out setup and setting us apart from our competitors,” says Jennifer Tracy, president of Mepco.
According to Parsio, the flexible packaging market is gaining steam with label converters for numerous reasons. Narrow web converters boast high end, multi-process print capabilities to succeed in this market, and there is a low cost of entry without large tooling expenditures.
“Label converters’ superior speed-to-market allows brand owners the versatility to bring multiple marketing campaigns swiftly on the same budgets brand owners would typically need to commit to only one campaign,” adds Parsio. “Expanding both the regional brand owners’ reach nationally, as well as adding greater margin to the narrow web converter, is a mutually beneficial marketplace that attracts interest from the label industry.”
Shelf appeal and speed to shelf are critical for brand owners, but there are other reasons for this application’s popularity. Consumers are demanding longer shelf life, brand connection and convenience in their packaging, notes Leslie Kozar, senior marketing manager, Rapid-Roll, Avery Dennison.
“We see an increasing number of label converters asking about flexible packaging as their business moves toward becoming a label and packaging solutions supplier,” says Kozar. “Studies and research reports agree that the growth in flexible packaging will continue to flourish over the coming several years.”
It is also worth noting, too, that the COVID-19 pandemic has increased demand for flexible packaging. Foods and home goods often utilize flexible packaging, which has seen an increase in production during the crisis.
Stand out on the shelf
Flexible packaging provides brands with a host of benefits, and chief among them is catching the consumer’s eye at the point of purchase.
Multi-Plastics’ Parsio cites powdered drink mixes, nutritional supplements, salty snacks, candy, single-serve foods and drinks, home products and pet foods as common end uses for flexible packaging. There is a financial benefit to using flexible packaging, as it provides reduced weights, which in turn saves costs during shipping. However, the main benefit is on-shelf.
The Flexible Packaging Association’s study shows that food makes up 49% ($15.6 billion) of the flexible packaging market. Beverages, consumer products, and medical and pharma applications account for 9% apiece.
“Flexible packaging provides increased shelf space for retailers and promotes flexibility in adding embellishments to promote branding,” says Parsio. “There are also reduced requirements for storing packaging prior to processing, all while adding recyclable and green options to promote a brand’s environmental stewardship.”
According to HP’s Bar-Shany, HP’s goal is to instill confidence in the brands and build solutions that go beyond printing capabilities. The ultimate product must entice the customer at the shelf. HP’s willingness to develop new flexible packaging products with its customers has spurred the company’s growth.
“We understand what it takes to be successful,” says Bar-Shany. “When we sell the press, we don’t disappear. We stay there and develop the market. We talk to the brands and bring in business, but we’re also very close and intimate with our customers. I think people trust us and they also see our ability to innovate.”
Product versatility
Various suppliers offer a wide range of products suitable for this market. For Multi-Plastics, popular materials include cosmetic webs, PPFP, BOPP, PET, and PE laminations.
According to the FPA, polyethylene is the material of choice when it comes to flexible packaging films and resins utilized by converters. Polyethylene comprises 50% of films and 85% of resins used, while polypropylene ranks second in both categories – 26% and 10%, respectively. The total industry value of materials earmarked for flexible packaging is $16.5 billion, with films accounting for 41% and resins making up 32% of those figures.
“Mono web films are used to create flexible packaging on-press, with and without high barrier options to extend shelf life, which can offer the lowest entry cost to a brand owner,” explains Multi-Plastics’ Parsio. “Adhesive and extrusion laminations offered as completed structures to the industry provide advantages of robust barrier properties and multi-use flexibility that limit the learning curve on-press, and provide immediate entry to the flexible packaging marketplace.”
Multi-Plastics has engineered a full line of mono web and high barrier coated films that can be used as single web overwrap films or in combination to create flexible packaging on-press. High and Medium Barrier Flexpack webs, cosmetic webs, paper-faced barrier laminations, stickpack structures and a full line of lidding films are also available.
Avery Dennison, on the other hand, sees the common materials including a film and foil combination that creates an excellent barrier, and film laminations that can be used in applications for wet and dry goods. Metalized films also provide effective barrier qualities. Paper foil structures are still very common for dry goods, says Avery Dennison’s Kozar.
“Flexible packaging can be a full package lamination or partial packaging such as shrink films and lidding,” she says. “Full package laminations take on several formats, including stickpacks, pillow packets and very popular stand-up packaging. The different formats each require different features and attributes in order to achieve optimum performance, depending on the contents and application. The demand for sustainable product offerings that provide the same barrier qualities continues to grow.”
Avery Dennison offers a wide range of stocked products available for narrow web converters. These include cosmetic webs, snackwebs, stickpacks, paper foil laminations and stand-up pouches. The company provides film and paper facestocks with a variety of sealants that are required to keep ingredients safe and provide longer shelf life. These products are part of Avery Dennison’s Rapid-Roll portfolio.
Ink technology can vary, too. “While label formulations can be complicated in nature, packaging inks tend to offer a much greater challenge due to the finishing and converting requirements done once they leave the printer,” says Jim Krstulic, national account manager - Envelopes, and Tag & Label product manager for INX International Ink Co. “As an ink manufacturer, we must have all the end-use information before any ink recommendation or formulation is considered.”
INX recently released its INXFlex UV Contour UVF and INXFlex UV Contour Dual energy curable ink systems for the narrow web shrink market, increasing its shrink capabilities both vertically and horizontally.
Contour UVF has been formulated for traditional UV curing systems while the Contour Dual exhibits curing capabilities for both the LED and traditional UV curing processes. INX has also upgraded its AquaTech ION S water-based shrink formulations for an improved shrink response.
In line with environmental endeavors, C-P Flexible Packaging has launched C-P GreenStream, a line of flexible packaging options designed for sustainability. This product line utilizes post-consumer recycled content, recyclable materials, compostable materials, downgauged materials, and/or materials derived from renewable resources. Created with the circular economy in mind, the C-P GreenStream line of flexible packaging includes options that reduce the amount of material entering the waste stream, as well as options that allow post-consumer recycled content to re-enter the stream of source materials. The C-P GreenStream portfolio includes flexible packaging materials with over 40% post-consumer recycled resin.
Digital printing has emerged as an asset for flexible packaging printers. Speed-to-market is a key benefit. As HP’s Bar-Shany notes, converters require slitting, lamination and pouch making – and it must all fall into place. If the printing occurs in a short timeframe but takes multiple days to convert into a pouch, then the process won’t be nearly as efficient.“Printing flexible packaging digitally is a way of driving supply chain efficiencies, lower inventories, track-and-trace and marketing campaigns,” he says. “These are the same trends we see in label, which is very consistent.”
Flexible packaging products extend to inspection, as well. Isra Vison recently launched PrintSTAR, a 100% inline inspection system that has been optimized for flexible pacakging. The product features continuous quality and process control of printed images, lamination and coatings. According to Isra Vision, a medium-sized packaging producer is now using 100% inspection technology to help with the application of cold seal adhesives to flexible packaging.
After printing, the flexible film is moved to the laminator, where a patterned adhesive is applied to the reverse side of the film. The application must then be aligned with the print on the front in the precise position in the register at a speed of up to 1,000 fpm.
Another challenge is that the various films are typically finished with reflective surfaces. The 100% inspection system detects all defects in the cold seal and monitors the process to ensure that the coating is even, free from voids, and aligns with the repeating print. Using high-resolution LCD cameras combined with ultra-bright LED lighting, the PrintSTAR system detects both individual and recurrent cold seal defects in real-time.
Label Traxx, a management software (MIS) specialist for the label converting industry, has announced that new features in Version 8.2 are tailored toward flexible packaging manufacturers. Version 8.2 of the software includes dedicated flexible packaging workflows for companies selling unsupported film, sachets and pouches by weight.
These new tools help with the accurate and consistent estimating of flexible packaging, along with features specifically for flexible packaging order processing. The system not only takes into consideration the weight of the raw material and inks but also considers other converting options such as additional machine passes to laminate or seal the packaging. In addition, Label Traxx Version 8.2 calculates the weight and cost of any other ancillary items such as spouts, zippers, seals or degassing valves.
The flexible packaging products are quoted in the MIS system in pounds/kilos and then carried through to manufacturing instructions, order confirmations, packing slips and, ultimately, the invoice. Purchase orders for flexible packaging materials can also be made in pounds/kilos.
“We have seen that flexible packaging is one of the fastest growth areas for our customers, and it’s an area showing tremendous growth worldwide,” says Ken Meinhardt, Label Traxx president. “Companies are moving to becoming a one-stop labels and packaging shop. We wanted to make sure those companies had no barriers to entering this lucrative market. While the converting process isn’t necessarily different – selling by the pound or kilo is unusual with labels. But now, our customers can be confident quoting and manufacturing these kinds of jobs right in Label Traxx.”
