Greg Hrinya, Editor03.03.22
Flexography has historically been the dominant process when it comes to label and package printing, but suppliers are looking to the future when designing their newest products. They are not resting on their laurels as they envision the next generation of these pivotal machines. Flexo press manufacturers have a keen eye on automation, connectivity, utilizing data and simplifying the printing process. Meanwhile, suppliers of inks, plates, materials and the like are going all-in to further shape the future of flexo.
Flexo presses have been designed with robotics and newer CNC machining technologies in mind. Production workflows and quality control procedures have been enhanced, as Industry 4.0 technologies continue to play a prominent role.
“Flexo is a truly beautiful process that continues to evolve and has made significant advancements over the past few years,” says Keith Nagle, sales manager, MPS Systems North America. “I can’t remember a time where every contributing part has made such strides to improve the process for the converter. The technical advancements in inks, anilox rolls, doctor blades, plates, tapes, sleeves, curing technology, embellishments (foil, tactile, embossing) and the actual flexo press have all improved the process.”
The continued impact of the Covid-19 pandemic has even influenced product development. As converters struggle to find skilled press operators, doing more with less will emerge as a mantra for many. Automation will allow converters to accomplish that goal while also promoting process improvements to the next-generation workforce.
“In recent years, flexo technology has advanced greatly, mainly through improvements in automation,” states Andrea Pasquinelli, product marketing manager, narrow and mid web, Bobst. “All Bobst inline flexo presses can be equipped with a high level of automation, which means that even less skilled operators can run them properly and profitably. More automation also helps to eliminate waste in the entire process by reducing job setups, changeovers and machine downtime, thereby improving the sustainability of flexo and meeting brand owners’ requirements for greener production methods.”
“It’s pretty straightforward: increased automation means that operators are required in fewer numbers and can operate more efficiently, effectively and with less knowledge than operators traditionally need with more mechanical equipment,” states Steve Schulte, vice president of sales, Mark Andy. “The use of software enhances the automation possibilities for flexography. Simple user interfaces, greater flexibility and increased control are just some of the reasons why flexo machines are having a major impact on productivity.”
According to companies throughout the industry, the quality produced on flexo presses has never been better. “With servo technology and better tension control, flexographic presses compete closely with offset and gravure due to higher print quality and tighter registration,” explains Chris Baldwin, sales and marketing director, Omet Americas. “With the improvement in electronic technology, presses are very easy to operate, set up faster with minimal waste, and have less downtime.”
With quality comes the need for speed. The two work in tandem, as converters strive for greater throughput, but speed is meaningless if it cannot match the quality demanded by discerning brands. “Profitability is higher in today’s production because a stable production is ensured even at high running speeds,” comments Claudio Nagel, product manager, Conventional Systems, Gallus.
Nilpeter, meanwhile, has optimized its equipment to meet the latest industry trends. “Many machine manufacturers have gone the economic route and provided the industry with commodity presses – entry level – to fight back on the digital offerings with lower priced investments,” comments Jakob Landberg, sales and marketing director, Nilpeter. “We have gone the route of vertical standardization and automatization of the originally manual conventional presses, thus improving the features to compete in shorter and shorter runs. We use these elements across our product program and manufacturing sites in Europe, the USA and India. This fight goes hand-in-hand with the focus on sustainability – saving waste and setup time both for our customers and ourselves.”
The flexographic improvements are not limited to the presses, either. The requisite supplies have improved, as well, which has led to a more robust process.
“The flexographic printing process has improved greatly over the years due to newer technologies in inks, anilox rolls, mounting tapes, photopolymer plates, UV and LED curing and so on,” adds Baldwin.
As converters are increasingly looking to expand their book of business, flexible packaging will continue to emerge as a trend for label printers. Flexo press manufacturers have engineered wider presses intended to accommodate more printing applications.
“Flexo is perfect for shorter runs of flexible packaging when produced with highly automated presses that are suitable for multiple substrates, can run ECG printing, and are fully connected,” notes Pasquinelli. “By creating only low waste and offering a faster time to market combined with high quality, inline flexo can be very competitive in this particular market.”
“Flexible packing is one of the fastest growing markets, especially in the mid-web widths of 26"-33",” adds Baldwin. “With servo-driven presses and tension controls, inline flexo presses can print a wide range of packaging applications, from shrink sleeves, roll-feed wrap around labels, pouches and sachets, etc.”
Shrink sleeves represent another opportunity for label converters, and flexo is ideally suited to serve this application, as well. “Flexible packaging and shrink sleeves are two applications that continue to be growth opportunities for flexo converters,” remarks Nagle. “Flexo is well positioned with the technical advancements that lend themselves to fast changeover times, shorter runs, and most importantly, a fully printed and decorated piece in a single pass.”
It is worth noting, too, that all major flexo press manufacturers have embraced digital as a complementary technology. “Today, many flexo presses share their frame and integrate digital processes like digital foiling, digital serialization and customization, and not to forget the full hybrid press that shares the best of both worlds,” states Nagle. “Flexo is the process that offers the most flexibility to the converter of multiple complex and highly decorated applications. If you are a standard label converter, whose customers are comfortable with the difference in graphic appearance (screens, spot color builds), then a full digital process or flexo hybrid process could suit your needs. If you are a converter with a complex product portfolio that covers all labels, sleeves and flexible packaging, the flexo process offers the most flexibility.”
“Bobst’s answer is to support production floor optimization,” says Pasquinelli. “By mastering digital, flexo and all-in-one printing, we offer converters exactly what they need. Rather than pitching one technology against another, it is important to understand that each has its strengths and that you must find the perfect fit according to your business model, the market and your customers’ needs. For this reason, we continue to promote all three technologies equally, as they are complementary to each other, not competing.”
According to Mark Andy’s Schulte, the next evolution of flexo printing will come from the ink delivery system. While the industry has strived to progress in this area, the applications have not been practical in daily use. “This will be a fertile area of development as we continue to strive for waste reduction, environmental sustainability, operator safety and even better print quality,” he concludes.
MacDermid Graphics Solutions has conceptualized The Flexo Xperience Center (The FXC) to “move flexo forward.” The Flexo Xperience Center is a partnership between MacDermid and Soma and is an expansion of their initial plans to install a Soma Optima2 printing press at MacDermid’s facility in Atlanta, GA, USA, announced in December 2020. The FXC will include multiple industry-leading partners providing software, equipment and consumables. The Flexo Xperience Center was a concept developed in late 2020 by the leadership, marketing, R&D, and sales teams at MacDermid and Soma. The goal is to develop products that will best serve flexo in the future.
“MacDermid is a customer-centric, innovative company looking to push creative boundaries and transform the industry,” says Brad Wills, global senior vice president at MacDermid Graphics Solutions. “The Flexo Xperience Center is one of the many ways we plan to do this.”
Press technology
For Bobst, its newest press technology has been categorized by improved automation. The company has ensured seamless integration between digital and flexo, specifically in the Bobst All-in-One press.
“Bobst has always offered high levels of automation on its inline flexo presses to bypass any human-related bottleneck and to deliver non-stop production with only minimal waste of time, substrate and ink,” says Pasquinelli.
The newest concept in the Bobst oneLABEL portfolio is the All-in-One platform, where digital printing has been integrated with the most advanced and automated flexo and converting modules for priming, printing, embellishing and cutting in one pass.
“Each module is digitally automated for on-the-fly changeovers, offering highest press uptime and outstanding repeatability, guaranteeing a fast time-to-market for most label applications,” adds Pasquinelli. “These are all technologies 100% developed and manufactured by Bobst to deliver a seamless integration. It also means that converters have only one point of contact for sales, service and support for both the digital and flexo parts.”
Gallus is currently working on two new flexo products. The first one is the Gallus Labelmaster 570, intended as an entry point into the flexible packaging market. According to Gallus’ Nagel, the Labelmaster 570 offers a machine that is ideally suited for a smooth entry into this profitable segment, with a width of 22.4". This iteration of the Labelmaster is suitable for short and medium runs in the sleeve sector and achieves excellent productivity in the label segment, the company says.
The second addition is the Gallus RCS 570, which offers print shops maximum customization and process flexibility. “The stable and modular design forms the base of this machine,” explains Nagel. “The Gallus RCS 570 is equipped with individual direct drives for operating flexographic, screen and hot foil printing units. The Gallus RCS 570 can be ideally adapted to the necessary requirements needed. Customized integration of processing modules and OEM equipment is carried out on the secondary rail system, thus offering the highest level of customization. A team of specialists stands behind every customer project and provides individual support.”
Mark Andy has multiple options for label converters looking at flexographic equipment. The Performance Series has seen more than 1,500 global installations, and the newest presses promote AI packages to support Industry 4.0 demands for enhanced automation. Plus, 360-degree registration adjustment and controlled ink densities allow for high-quality dots in a simple and repeatable fashion.
Mark Andy’s Evolution Series has been designed to make full servo flexo attainable at a cost-effective price point. The new Evolution line, which was unveiled at Labelexpo Brussels 2019, is a perfect complement to Mark Andy’s award-winning Performance Series. Built around the fully servo driven P7 platform, the Evolution is a modular press that can adapt its configuration to current working circumstances and be modified later if necessary.
MPS recently unveiled its next generation EF flexo platform, which provides technology enhancements and new features in connectivity for better press performance and output. As a fully automated, multi-substrate flexo press ready for 24/7 operations, the EF has provided printers years of high-level automation, flexibility, connectivity and ease of operation. Based on the successful foundation of six previous EF platform generations, including MPS features such as Crisp.Dot Technology, Non-stop Print Change, and the Ultraflex Rail System, many enhancements were made to the next generation EF machine. These improved features include the MPS designed slide-out ink drawer for faster changeovers as standard on all machines, MPS E-sleeve with quick release, advanced job memory, M2M (Mark-to-Mark) register, extended web width to 580mm, and more.
“We recently launched and will show the EF7 press at Labelexpo Brussels and Labelexpo North America,” says MPS’ Nagle. “The EF7 press is part of the continuing evolution of the MPS EF flexo line that offers industry best automation and connectivity.”
Nilpeter’s FA-26 has been described as a “Swiss army knife for the production of packaging solutions.” This multi-process and multi-purpose flexo machine has been designed to take Lean printing to a new high, Landberg notes.
“Flexible packaging features a multitude of different substrates with very different characteristics and specifications – and the run lengths are shrinking,” he explains. “So more complex and more setups are required for every shift. We lean on the virtues from the innovative world of labeling: Our new solution for flexible packaging materials and constructions utilizes multi-process inline printing, laminating and converting, as well as UV LED, solvent and water-based flexo printing.”
Meanwhile, Omet has introduced a mid-web press (26") that is designed around flexible packaging. With a smaller footprint and short web path, the converter can be more efficient with faster job setups and minimal waste, all with a platform that’s simple to learn and operate.
Rotary screen, gravure and inline lamination are but a few of the additional options that can be added to the X7. “For label printers that are looking at expanding into the flexible packaging market, the X7 can still run their current pressure sensitive work as they grow into new markets,” says Baldwin.
Omet also offers a hybrid press solution called XJet. This allows customers to take advantage of digital inkjet printing for short-run jobs while adding the flexibility for one pass printing with diecutting, cold foil and other embellishments.
“For heavier ink coverage using whites, varnishes, etc. the addition of flexo printing stations helps reduce the cost of more expensive digital inks,” adds Baldwin. “In a hybrid configuration, the customer can take advantage of both technologies without sacrificing quality and efficiencies.”
Inks and materials
Substrate suppliers have worked in concert with flexo press manufacturers to ensure that their materials will deliver the highest quality print. For instance, converter trialing is part of the Avery Dennison innovation process, as it tests new materials on different presses, as well as testing different print methods and line speeds to validate the materials and gain insights into the products.
“Almost all of our materials can be printed flexo,” states Angel Harvey, senior product manager – paper, Avery Dennison Label and Packaging Materials. “One of the areas we see as particularly popular for flexo printing is our wine and spirits portfolio. These unique papers are often printed on flexo presses with high-quality graphics and decorative finishes.
“Avery Dennison has continued to innovate with flexo printing in mind,” she adds. “Our materials continue to see fast converting and increased productivity for converters, as well as maintaining the performance and aesthetic qualities expected.”
The most popular materials for flexo-printed PSL labels are paper and film, where the print surface is optimized for printing. Primary film types include PET, BOPP and PE.
“Paper facestocks were used primarily in the past, and quickly the market is growing in film demand because, in addition to it providing a good print surface, it also provides benefits for the final product such as strength, moisture impermeability, transparency, chemical resistance, and gloss,” explains Gabrielle Whittaker, director, Films & Specials SBU, UPM Raflatac, Americas.
One growing requirement of our customers is for third-party validation of the sustainability value these materials deliver to brands. “We have gone through extensive testing of our film materials and have received APR recognition for many of our products as meeting or exceeding APR’s critical guidance,” comments Anna Hunt, senior manager, Brand & Marketing, UPM Raflatac, Americas. “Our most recent APR recognition has been for our printed PP labels in the PET recycling process with UV flexo inks and varnish.”
According to Hunt, food safety continues to be top of mind, with many of UPM Raflatac’s customers, and performance, safety and third-party certification all playing a role. “When it comes to food applications, materials need to perform in their particular application and be safe for their intended use,” she says. “We’re taking this a step further and have had all of our factories in the US and EMEIA certified according to the ISO 22000:2018 Food Safety Management System standard. With the FDA’s New Era of Smarter Food Safety initiative, the need for food safe qualified packaging materials will only continue to grow.”
From a product standpoint, Avery Dennison introduced two new hot-melt adhesives in 2021. C4500 has been released for room temperature applications and C4510 for cold temperature applications. Offering greater sustainability, C4510 contains 40% renewable content while C4500 contains 45% renewable content. In addition, C4500 has USDA BioPreferred certification, meaning it uses bio-based and renewable components instead of petroleum-based components.
“Bio-based materials have several benefits over the petroleum-derived materials they replace, and increasing our use of this renewable resource supports our commitment to environmental leadership,” notes Harvey. “
Avery Dennison has also launched TC-2000 topcoat for films. This technology enables a strong bond between the film and inks. Enhanced ink adhesion also means clearer, bolder graphics, and increased shelf appeal. Avery Dennison TC-2000 works beautifully with a wide range of printing techniques, including UV flexo, UV inkjet, water-based flexo and more.
UPM Raflatac has launched its RAFNXT+ CarbonNeutral certified label material, which is part of the UPM Raflatac SmartChoice portfolio. This enables customers to source labeling materials in a sustainable way. RAFNXT+ is a thinner material, verified by the Carbon Trust, and is sourced from sustainably managed forests. It enables a reduced carbon footprint compared to standard labels through the smarter use of natural resources.
“We are continually improving our adhesive formulations, particularly as the types of packaging used by brands evolve, as well,” says Hunt. “There are many new types of packaging substrates that include recycled content. This requires continuous development in labeling materials, as well as collaboration and testing with customers to ensure on-package performance.”
“Expansion of Forest Film as a part of our UPM Raflatac SmartChoice portfolio allows brands to have an efficient way of meeting their sustainability goals with 100% renewable wood-based ISCC certified materials,” adds Whittaker.
From an ink perspective, much of the innovation in recent years has been driven by increasing demand for sustainable packaging and business practices from brand owners. Sun Chemical has seen a push for compostable, bio-renewable and recyclable inks to help brands and CPGs meet their sustainability goals. Sun Chemical has also developed products to keep pace with the growing interest in shrink sleeves, low migration and LED curing.
“As sustainability is an important topic for brands and consumers alike, converters should consider selecting sustainable inks that improve bio-renewability, compostability and recyclability,” explains Dennis Sweet, vice president – NWTL, Commercial, Rycoline and Distributors, Sun Chemical. “For example, Sun Chemical’s SolarFlex CRCL ink range allows the removal of ink from PET film without a primer, increasing the recyclability of products that use shrink labels. SunVisto AquaGreen water-based inks are formulated with the highest level of bio-renewable carbon the industry has to offer while providing converters with a level of performance to which they are accustomed.”
Sun Chemical’s SolarFlex CRCL ink range, developed for UV flexo applications, allows the removal of ink from PET film without the expense of an added primer, increasing the recyclability of products that use shrink labels. These inks also feature strong dot reproduction and high press speeds to ensure quality in addition to meeting customers’ increasing sustainability requirements. In addition, Sun Chemical’s sustainable flexible inks and solutions fall under our SunEco portfolio, which identifies the various products in our portfolio that improve sustainability in packaging.
The flexo ink market has also been significantly impacted by the pandemic. Supply chain stoppages, raw material shortages and price increases all continue to play a role for the industry.
“At Sun Chemical, we’re monitoring purchase orders and supply positions daily to ensure we’re responding to market changes in real time,” says Sweet. “Sun Chemical’s global footprint allows us to respond to these rapidly changing conditions and supply our customers with the products they need to continue operations as smoothly as possible.”
Sun Chemical has also developed an Ink Troubleshooting Guide designed to solve issues specific to different printing markets. In flexographic printing, these challenges include ink adhesion, blocking/offset, ink smearing, weak print color and mottled print. Users can click through each challenge to review more specific problems and general solutions, allowing them to troubleshoot issues on their end.
Flint Group Narrow Web has introduced two UV flexo coating products to improve the recyclability for shrink sleeves and pressure sensitive labels. These coatings are currently available in North America and will soon be available in Europe and other regions. Using different chemistries, the Evolution Deinking Primer for shrink sleeves, and the Evolution Caustic Resistant Overprint Varnish (OPV) for self-adhesive labels, are designed to increase the yield of material in the recycling process. Both coatings have been recognized by the Association of Plastic Recyclers to comply with the critical guidance for PET packaging.
“The Deinking Primer and Caustic Resistant OPV are simple to use and offer optimal performance at all stages of the label or sleeve lifecycle while meeting the stringent requirements of the APR critical guidance,” states John Pogatschnik, North America marketing manager, Flint Group Narrow Web. “Switching to these new products is disruption-free, has no adverse effect on functionality, and works with our standard inks.
“Both products are ‘plug and play’ solutions that enable better recycling without impacting the quality or application performance,” he adds. “A converter doesn’t need to qualify a new ink series and rematch several colors: simply splice into a recognized substrate, turn on the primer or OPV, and more sustainable labels or sleeves are rolling up on the winder.”
Flexo supplies
From anilox roll technology to printing plates, the latest flexo supplies have been optimized to ensure quality and speed. Harper, for example, recently unveiled its X-CAT engraving technology, which the company says is a “game-changer” for flexo printing. Designed to overcome the industry issue with spitting in UV inks, the Xtreme Channeled Application Technology has been shown to be successful in water and solvent-based inks too. “The X-CAT excels in all aspects of the printing process such as process, solids, whites, and coatings,” explains Holly Cook, marketing and design specialist, Harper Corporation of America. “Our patent-pending engraving eliminates spitting in UV inks while allowing the user to specify cells per inch and volume as they would with a standard 60° Hex engraving. X-CAT has shown to work effectively in press auto-wash press systems, reducing off-line anilox cleaning time and providing users with quicker reuse of anilox rolls between press runs.”
Anderson & Vreeland, which describes itself as a “Partner in Flexo,” has simplified the process of getting the right supplies with a full onboarding program that helps converters integrate new solutions into their existing workflow. Anderson & Vreeland also trains converters’ teams on how to use the equipment.
According to Anderson & Vreeland, choosing the right flexo supplies streamlines the entire printing process and contributes largely to a company’s ROI. Careful consideration must be taken when choosing from a host of products, including plates to anilox rolls to cleaning solutions.
Anderson & Vreeland’s portfolio, which features solutions from Apex International, Eaglewood Technologies and more, enables customers to choose the right product for their application. The right flexo printing partner will present multiple options across different brands, enabling customers to choose from the best equipment at the most economical prices. Plus, Anderson & Vreeland offers extensive after-sales service.
For Gallus, its relationship with parent company Heidelberg has helped improve its anilox roll capabilities. “Heidelberg has developed a new laser procedure that enables an even better quality than the usual laser gravures,” says Gallus’ Nagel. “Soon these anilox rollers will be available for Gallus machine systems. Gallus continues to be a technological innovator, in particular, because of the R&D work of Heidelberg.”
Flexo presses have been designed with robotics and newer CNC machining technologies in mind. Production workflows and quality control procedures have been enhanced, as Industry 4.0 technologies continue to play a prominent role.
“Flexo is a truly beautiful process that continues to evolve and has made significant advancements over the past few years,” says Keith Nagle, sales manager, MPS Systems North America. “I can’t remember a time where every contributing part has made such strides to improve the process for the converter. The technical advancements in inks, anilox rolls, doctor blades, plates, tapes, sleeves, curing technology, embellishments (foil, tactile, embossing) and the actual flexo press have all improved the process.”
The continued impact of the Covid-19 pandemic has even influenced product development. As converters struggle to find skilled press operators, doing more with less will emerge as a mantra for many. Automation will allow converters to accomplish that goal while also promoting process improvements to the next-generation workforce.
“In recent years, flexo technology has advanced greatly, mainly through improvements in automation,” states Andrea Pasquinelli, product marketing manager, narrow and mid web, Bobst. “All Bobst inline flexo presses can be equipped with a high level of automation, which means that even less skilled operators can run them properly and profitably. More automation also helps to eliminate waste in the entire process by reducing job setups, changeovers and machine downtime, thereby improving the sustainability of flexo and meeting brand owners’ requirements for greener production methods.”
“It’s pretty straightforward: increased automation means that operators are required in fewer numbers and can operate more efficiently, effectively and with less knowledge than operators traditionally need with more mechanical equipment,” states Steve Schulte, vice president of sales, Mark Andy. “The use of software enhances the automation possibilities for flexography. Simple user interfaces, greater flexibility and increased control are just some of the reasons why flexo machines are having a major impact on productivity.”
According to companies throughout the industry, the quality produced on flexo presses has never been better. “With servo technology and better tension control, flexographic presses compete closely with offset and gravure due to higher print quality and tighter registration,” explains Chris Baldwin, sales and marketing director, Omet Americas. “With the improvement in electronic technology, presses are very easy to operate, set up faster with minimal waste, and have less downtime.”
With quality comes the need for speed. The two work in tandem, as converters strive for greater throughput, but speed is meaningless if it cannot match the quality demanded by discerning brands. “Profitability is higher in today’s production because a stable production is ensured even at high running speeds,” comments Claudio Nagel, product manager, Conventional Systems, Gallus.
Nilpeter, meanwhile, has optimized its equipment to meet the latest industry trends. “Many machine manufacturers have gone the economic route and provided the industry with commodity presses – entry level – to fight back on the digital offerings with lower priced investments,” comments Jakob Landberg, sales and marketing director, Nilpeter. “We have gone the route of vertical standardization and automatization of the originally manual conventional presses, thus improving the features to compete in shorter and shorter runs. We use these elements across our product program and manufacturing sites in Europe, the USA and India. This fight goes hand-in-hand with the focus on sustainability – saving waste and setup time both for our customers and ourselves.”
The flexographic improvements are not limited to the presses, either. The requisite supplies have improved, as well, which has led to a more robust process.
“The flexographic printing process has improved greatly over the years due to newer technologies in inks, anilox rolls, mounting tapes, photopolymer plates, UV and LED curing and so on,” adds Baldwin.
As converters are increasingly looking to expand their book of business, flexible packaging will continue to emerge as a trend for label printers. Flexo press manufacturers have engineered wider presses intended to accommodate more printing applications.
“Flexo is perfect for shorter runs of flexible packaging when produced with highly automated presses that are suitable for multiple substrates, can run ECG printing, and are fully connected,” notes Pasquinelli. “By creating only low waste and offering a faster time to market combined with high quality, inline flexo can be very competitive in this particular market.”
“Flexible packing is one of the fastest growing markets, especially in the mid-web widths of 26"-33",” adds Baldwin. “With servo-driven presses and tension controls, inline flexo presses can print a wide range of packaging applications, from shrink sleeves, roll-feed wrap around labels, pouches and sachets, etc.”
Shrink sleeves represent another opportunity for label converters, and flexo is ideally suited to serve this application, as well. “Flexible packaging and shrink sleeves are two applications that continue to be growth opportunities for flexo converters,” remarks Nagle. “Flexo is well positioned with the technical advancements that lend themselves to fast changeover times, shorter runs, and most importantly, a fully printed and decorated piece in a single pass.”
It is worth noting, too, that all major flexo press manufacturers have embraced digital as a complementary technology. “Today, many flexo presses share their frame and integrate digital processes like digital foiling, digital serialization and customization, and not to forget the full hybrid press that shares the best of both worlds,” states Nagle. “Flexo is the process that offers the most flexibility to the converter of multiple complex and highly decorated applications. If you are a standard label converter, whose customers are comfortable with the difference in graphic appearance (screens, spot color builds), then a full digital process or flexo hybrid process could suit your needs. If you are a converter with a complex product portfolio that covers all labels, sleeves and flexible packaging, the flexo process offers the most flexibility.”
“Bobst’s answer is to support production floor optimization,” says Pasquinelli. “By mastering digital, flexo and all-in-one printing, we offer converters exactly what they need. Rather than pitching one technology against another, it is important to understand that each has its strengths and that you must find the perfect fit according to your business model, the market and your customers’ needs. For this reason, we continue to promote all three technologies equally, as they are complementary to each other, not competing.”
According to Mark Andy’s Schulte, the next evolution of flexo printing will come from the ink delivery system. While the industry has strived to progress in this area, the applications have not been practical in daily use. “This will be a fertile area of development as we continue to strive for waste reduction, environmental sustainability, operator safety and even better print quality,” he concludes.
MacDermid Graphics Solutions has conceptualized The Flexo Xperience Center (The FXC) to “move flexo forward.” The Flexo Xperience Center is a partnership between MacDermid and Soma and is an expansion of their initial plans to install a Soma Optima2 printing press at MacDermid’s facility in Atlanta, GA, USA, announced in December 2020. The FXC will include multiple industry-leading partners providing software, equipment and consumables. The Flexo Xperience Center was a concept developed in late 2020 by the leadership, marketing, R&D, and sales teams at MacDermid and Soma. The goal is to develop products that will best serve flexo in the future.
“MacDermid is a customer-centric, innovative company looking to push creative boundaries and transform the industry,” says Brad Wills, global senior vice president at MacDermid Graphics Solutions. “The Flexo Xperience Center is one of the many ways we plan to do this.”
Press technology
For Bobst, its newest press technology has been categorized by improved automation. The company has ensured seamless integration between digital and flexo, specifically in the Bobst All-in-One press.
“Bobst has always offered high levels of automation on its inline flexo presses to bypass any human-related bottleneck and to deliver non-stop production with only minimal waste of time, substrate and ink,” says Pasquinelli.
The newest concept in the Bobst oneLABEL portfolio is the All-in-One platform, where digital printing has been integrated with the most advanced and automated flexo and converting modules for priming, printing, embellishing and cutting in one pass.
“Each module is digitally automated for on-the-fly changeovers, offering highest press uptime and outstanding repeatability, guaranteeing a fast time-to-market for most label applications,” adds Pasquinelli. “These are all technologies 100% developed and manufactured by Bobst to deliver a seamless integration. It also means that converters have only one point of contact for sales, service and support for both the digital and flexo parts.”
Gallus is currently working on two new flexo products. The first one is the Gallus Labelmaster 570, intended as an entry point into the flexible packaging market. According to Gallus’ Nagel, the Labelmaster 570 offers a machine that is ideally suited for a smooth entry into this profitable segment, with a width of 22.4". This iteration of the Labelmaster is suitable for short and medium runs in the sleeve sector and achieves excellent productivity in the label segment, the company says.
The second addition is the Gallus RCS 570, which offers print shops maximum customization and process flexibility. “The stable and modular design forms the base of this machine,” explains Nagel. “The Gallus RCS 570 is equipped with individual direct drives for operating flexographic, screen and hot foil printing units. The Gallus RCS 570 can be ideally adapted to the necessary requirements needed. Customized integration of processing modules and OEM equipment is carried out on the secondary rail system, thus offering the highest level of customization. A team of specialists stands behind every customer project and provides individual support.”
Mark Andy has multiple options for label converters looking at flexographic equipment. The Performance Series has seen more than 1,500 global installations, and the newest presses promote AI packages to support Industry 4.0 demands for enhanced automation. Plus, 360-degree registration adjustment and controlled ink densities allow for high-quality dots in a simple and repeatable fashion.
Mark Andy’s Evolution Series has been designed to make full servo flexo attainable at a cost-effective price point. The new Evolution line, which was unveiled at Labelexpo Brussels 2019, is a perfect complement to Mark Andy’s award-winning Performance Series. Built around the fully servo driven P7 platform, the Evolution is a modular press that can adapt its configuration to current working circumstances and be modified later if necessary.
MPS recently unveiled its next generation EF flexo platform, which provides technology enhancements and new features in connectivity for better press performance and output. As a fully automated, multi-substrate flexo press ready for 24/7 operations, the EF has provided printers years of high-level automation, flexibility, connectivity and ease of operation. Based on the successful foundation of six previous EF platform generations, including MPS features such as Crisp.Dot Technology, Non-stop Print Change, and the Ultraflex Rail System, many enhancements were made to the next generation EF machine. These improved features include the MPS designed slide-out ink drawer for faster changeovers as standard on all machines, MPS E-sleeve with quick release, advanced job memory, M2M (Mark-to-Mark) register, extended web width to 580mm, and more.
“We recently launched and will show the EF7 press at Labelexpo Brussels and Labelexpo North America,” says MPS’ Nagle. “The EF7 press is part of the continuing evolution of the MPS EF flexo line that offers industry best automation and connectivity.”
Nilpeter’s FA-26 has been described as a “Swiss army knife for the production of packaging solutions.” This multi-process and multi-purpose flexo machine has been designed to take Lean printing to a new high, Landberg notes.
“Flexible packaging features a multitude of different substrates with very different characteristics and specifications – and the run lengths are shrinking,” he explains. “So more complex and more setups are required for every shift. We lean on the virtues from the innovative world of labeling: Our new solution for flexible packaging materials and constructions utilizes multi-process inline printing, laminating and converting, as well as UV LED, solvent and water-based flexo printing.”
Meanwhile, Omet has introduced a mid-web press (26") that is designed around flexible packaging. With a smaller footprint and short web path, the converter can be more efficient with faster job setups and minimal waste, all with a platform that’s simple to learn and operate.
Rotary screen, gravure and inline lamination are but a few of the additional options that can be added to the X7. “For label printers that are looking at expanding into the flexible packaging market, the X7 can still run their current pressure sensitive work as they grow into new markets,” says Baldwin.
Omet also offers a hybrid press solution called XJet. This allows customers to take advantage of digital inkjet printing for short-run jobs while adding the flexibility for one pass printing with diecutting, cold foil and other embellishments.
“For heavier ink coverage using whites, varnishes, etc. the addition of flexo printing stations helps reduce the cost of more expensive digital inks,” adds Baldwin. “In a hybrid configuration, the customer can take advantage of both technologies without sacrificing quality and efficiencies.”
Inks and materials
Substrate suppliers have worked in concert with flexo press manufacturers to ensure that their materials will deliver the highest quality print. For instance, converter trialing is part of the Avery Dennison innovation process, as it tests new materials on different presses, as well as testing different print methods and line speeds to validate the materials and gain insights into the products.
“Almost all of our materials can be printed flexo,” states Angel Harvey, senior product manager – paper, Avery Dennison Label and Packaging Materials. “One of the areas we see as particularly popular for flexo printing is our wine and spirits portfolio. These unique papers are often printed on flexo presses with high-quality graphics and decorative finishes.
“Avery Dennison has continued to innovate with flexo printing in mind,” she adds. “Our materials continue to see fast converting and increased productivity for converters, as well as maintaining the performance and aesthetic qualities expected.”
The most popular materials for flexo-printed PSL labels are paper and film, where the print surface is optimized for printing. Primary film types include PET, BOPP and PE.
“Paper facestocks were used primarily in the past, and quickly the market is growing in film demand because, in addition to it providing a good print surface, it also provides benefits for the final product such as strength, moisture impermeability, transparency, chemical resistance, and gloss,” explains Gabrielle Whittaker, director, Films & Specials SBU, UPM Raflatac, Americas.
One growing requirement of our customers is for third-party validation of the sustainability value these materials deliver to brands. “We have gone through extensive testing of our film materials and have received APR recognition for many of our products as meeting or exceeding APR’s critical guidance,” comments Anna Hunt, senior manager, Brand & Marketing, UPM Raflatac, Americas. “Our most recent APR recognition has been for our printed PP labels in the PET recycling process with UV flexo inks and varnish.”
According to Hunt, food safety continues to be top of mind, with many of UPM Raflatac’s customers, and performance, safety and third-party certification all playing a role. “When it comes to food applications, materials need to perform in their particular application and be safe for their intended use,” she says. “We’re taking this a step further and have had all of our factories in the US and EMEIA certified according to the ISO 22000:2018 Food Safety Management System standard. With the FDA’s New Era of Smarter Food Safety initiative, the need for food safe qualified packaging materials will only continue to grow.”
From a product standpoint, Avery Dennison introduced two new hot-melt adhesives in 2021. C4500 has been released for room temperature applications and C4510 for cold temperature applications. Offering greater sustainability, C4510 contains 40% renewable content while C4500 contains 45% renewable content. In addition, C4500 has USDA BioPreferred certification, meaning it uses bio-based and renewable components instead of petroleum-based components.
“Bio-based materials have several benefits over the petroleum-derived materials they replace, and increasing our use of this renewable resource supports our commitment to environmental leadership,” notes Harvey. “
Avery Dennison has also launched TC-2000 topcoat for films. This technology enables a strong bond between the film and inks. Enhanced ink adhesion also means clearer, bolder graphics, and increased shelf appeal. Avery Dennison TC-2000 works beautifully with a wide range of printing techniques, including UV flexo, UV inkjet, water-based flexo and more.
UPM Raflatac has launched its RAFNXT+ CarbonNeutral certified label material, which is part of the UPM Raflatac SmartChoice portfolio. This enables customers to source labeling materials in a sustainable way. RAFNXT+ is a thinner material, verified by the Carbon Trust, and is sourced from sustainably managed forests. It enables a reduced carbon footprint compared to standard labels through the smarter use of natural resources.
“We are continually improving our adhesive formulations, particularly as the types of packaging used by brands evolve, as well,” says Hunt. “There are many new types of packaging substrates that include recycled content. This requires continuous development in labeling materials, as well as collaboration and testing with customers to ensure on-package performance.”
“Expansion of Forest Film as a part of our UPM Raflatac SmartChoice portfolio allows brands to have an efficient way of meeting their sustainability goals with 100% renewable wood-based ISCC certified materials,” adds Whittaker.
From an ink perspective, much of the innovation in recent years has been driven by increasing demand for sustainable packaging and business practices from brand owners. Sun Chemical has seen a push for compostable, bio-renewable and recyclable inks to help brands and CPGs meet their sustainability goals. Sun Chemical has also developed products to keep pace with the growing interest in shrink sleeves, low migration and LED curing.
“As sustainability is an important topic for brands and consumers alike, converters should consider selecting sustainable inks that improve bio-renewability, compostability and recyclability,” explains Dennis Sweet, vice president – NWTL, Commercial, Rycoline and Distributors, Sun Chemical. “For example, Sun Chemical’s SolarFlex CRCL ink range allows the removal of ink from PET film without a primer, increasing the recyclability of products that use shrink labels. SunVisto AquaGreen water-based inks are formulated with the highest level of bio-renewable carbon the industry has to offer while providing converters with a level of performance to which they are accustomed.”
Sun Chemical’s SolarFlex CRCL ink range, developed for UV flexo applications, allows the removal of ink from PET film without the expense of an added primer, increasing the recyclability of products that use shrink labels. These inks also feature strong dot reproduction and high press speeds to ensure quality in addition to meeting customers’ increasing sustainability requirements. In addition, Sun Chemical’s sustainable flexible inks and solutions fall under our SunEco portfolio, which identifies the various products in our portfolio that improve sustainability in packaging.
The flexo ink market has also been significantly impacted by the pandemic. Supply chain stoppages, raw material shortages and price increases all continue to play a role for the industry.
“At Sun Chemical, we’re monitoring purchase orders and supply positions daily to ensure we’re responding to market changes in real time,” says Sweet. “Sun Chemical’s global footprint allows us to respond to these rapidly changing conditions and supply our customers with the products they need to continue operations as smoothly as possible.”
Sun Chemical has also developed an Ink Troubleshooting Guide designed to solve issues specific to different printing markets. In flexographic printing, these challenges include ink adhesion, blocking/offset, ink smearing, weak print color and mottled print. Users can click through each challenge to review more specific problems and general solutions, allowing them to troubleshoot issues on their end.
Flint Group Narrow Web has introduced two UV flexo coating products to improve the recyclability for shrink sleeves and pressure sensitive labels. These coatings are currently available in North America and will soon be available in Europe and other regions. Using different chemistries, the Evolution Deinking Primer for shrink sleeves, and the Evolution Caustic Resistant Overprint Varnish (OPV) for self-adhesive labels, are designed to increase the yield of material in the recycling process. Both coatings have been recognized by the Association of Plastic Recyclers to comply with the critical guidance for PET packaging.
“The Deinking Primer and Caustic Resistant OPV are simple to use and offer optimal performance at all stages of the label or sleeve lifecycle while meeting the stringent requirements of the APR critical guidance,” states John Pogatschnik, North America marketing manager, Flint Group Narrow Web. “Switching to these new products is disruption-free, has no adverse effect on functionality, and works with our standard inks.
“Both products are ‘plug and play’ solutions that enable better recycling without impacting the quality or application performance,” he adds. “A converter doesn’t need to qualify a new ink series and rematch several colors: simply splice into a recognized substrate, turn on the primer or OPV, and more sustainable labels or sleeves are rolling up on the winder.”
Flexo supplies
From anilox roll technology to printing plates, the latest flexo supplies have been optimized to ensure quality and speed. Harper, for example, recently unveiled its X-CAT engraving technology, which the company says is a “game-changer” for flexo printing. Designed to overcome the industry issue with spitting in UV inks, the Xtreme Channeled Application Technology has been shown to be successful in water and solvent-based inks too. “The X-CAT excels in all aspects of the printing process such as process, solids, whites, and coatings,” explains Holly Cook, marketing and design specialist, Harper Corporation of America. “Our patent-pending engraving eliminates spitting in UV inks while allowing the user to specify cells per inch and volume as they would with a standard 60° Hex engraving. X-CAT has shown to work effectively in press auto-wash press systems, reducing off-line anilox cleaning time and providing users with quicker reuse of anilox rolls between press runs.”
Anderson & Vreeland, which describes itself as a “Partner in Flexo,” has simplified the process of getting the right supplies with a full onboarding program that helps converters integrate new solutions into their existing workflow. Anderson & Vreeland also trains converters’ teams on how to use the equipment.
According to Anderson & Vreeland, choosing the right flexo supplies streamlines the entire printing process and contributes largely to a company’s ROI. Careful consideration must be taken when choosing from a host of products, including plates to anilox rolls to cleaning solutions.
Anderson & Vreeland’s portfolio, which features solutions from Apex International, Eaglewood Technologies and more, enables customers to choose the right product for their application. The right flexo printing partner will present multiple options across different brands, enabling customers to choose from the best equipment at the most economical prices. Plus, Anderson & Vreeland offers extensive after-sales service.
For Gallus, its relationship with parent company Heidelberg has helped improve its anilox roll capabilities. “Heidelberg has developed a new laser procedure that enables an even better quality than the usual laser gravures,” says Gallus’ Nagel. “Soon these anilox rollers will be available for Gallus machine systems. Gallus continues to be a technological innovator, in particular, because of the R&D work of Heidelberg.”