Flexible packaging, the label industry’s next savior?

By Ron Augustin

Following a major trend in the manufacture, Labelexpo Europe in its 40th year included a meaning panoply of presses and coincident equipment suitable for flexible packaging, even though substrates and other consumables for this segment were missing entirely at the show. (There were some movie suppliers but they came to Labelexpo mainly to projection their films for use equally face up stocks in force per unit area-sensitive materials and to some extent for use in wraparound labels, IML and shrink packaging.)

Increasingly, characterization converters have been compelled to diversify into packaging, to offer their customers a combination of pressure-sensitive label stock, wraparound labels, IML, lids, tubes, shrink sleeves, standup pouches, rolls of single- or multiple-layer flexible packaging, or folding carton boxes. And technology developments take been an enabling factor in this trend, as narrow- and mid-spider web presses and their converting and finishing extensions are converging on all levels. This has also made label product more attainable for companies who started as flexible packaging converters, and fifty-fifty for those whose core concern is in commercial offset.

Labelexpo's flagship trade fair has been able to keep exhibitor and company numbers adequately stable, even though both were slightly downwards this yr. Well-nigh a quarter of the 600 exhibitors were companies from Asia, including 85 from Cathay, 20 from Republic of india, xvi from Japan, 12 each from Taiwan and Korea, and one from Malaysia, non counting the representatives at the stands of the European and American brands.

Many of these told us that they came to Brussels to target the Eastern European, Russian, African and Middle Eastern markets, rather than the industry's largely saturated client base in Western Europe. Next to the flexo, kickoff and hybrid presses running at the stands of the big international brands merely too at some of the Indian, Chinese, Turkish and other manufacturers' booths, there were about l inkjet presses from 30 manufacturers at the evidence, as well as inkjet modules and print bars from more than fifteen manufacturers.

5 misconceptions on the latest generation of label presses

' The future is digital' – Patently, digital printing is replacing the other printing technologies in many areas. However, there are every bit many applications where digital volition remain ane mature ready of technologies amongst other ones, side-past-side and in combination with flexo, kickoff, gravure, screen, intaglio and various embellishing techniques, which each have their specific characteristics and advantages in terms of quality, feel, productivity and economics. These are unlikely to disappear in the foreseeable future, and the Labelexpo organizers are quite correct in observing the current "flexo fightback." Opposing digital and analog as a sign of progress is a marketing bubble, that we can but hope will soon exist something of the past.
Hybrid presses – In the characterization industry, most of the larger narrow-web presses accept a long history of integrating modules that combine the main flexo or first units with rotary screen, gravure, and other technologies. They have now been complemented by inkjet modules and industrial engines based on inkjet or toner. Presses based entirely on digital units are being complimented, for example, by flexo units for blanket, varnishing or white inks. Same story for converting equipment. So, what'due south new, and what is real? As nearly all presses use 'hybrid' technologies in one mode or another, the 'hybrid' buzz discussion should soon be redundant also. Without questioning at all the fabulous capabilities of these presses.
In-line converting – Narrow- and mid-web presses have been at the forefront of integrating converting functionalities into press presses. Diecutting and foiling are typical examples. Bobst's Lemanic is an instance of a press almost fully integrated into the terminal product processing line, where cigarette boxes can exist printed, coated, embossed, die-cutting, inspected, and directly conveyed into the cigarette packaging line. But again, there is no 1-for-all solution, and many applications, for reasons of speed, quality, operator expertise or simple economic science, require off-line converting and finishing. That's why, besides at Labelexpo, so many converting and finishing devices can be found, overtaking the number of presses there.
On-press switching between labels and packaging – The merits of easy switching between characterization and packaging products on the same press hardly corresponds to market requirements. There is a clear trend of label converters venturing into folding carton or flexible packaging, and packaging converters adding agglutinative labels, tubes, and pouches to their portfolio. For converters, the ability to offering both adhesive and wrap-around labels, or for commercial printers to add together roll-to-curl to sheetfed label and packaging products, is a logical step, facilitated by more and more attainable technology developments. However, in most cases, they will dedicate their presses to specific task categories, and not switch between labels and packaging on the same machine! Typically, a converter working with a particular type of presses will buy another type of press to expand in a new type of business concern but will dedicate each printing to either labels or pouches or shrink sleeves or flexible packaging, each based on their settings, technical requirements, and economic science.
Industry 4.0 readiness – Almost printing manufacturers merits to be 'Industry 4.0 gear up,' but does this make much sense for a press printing? Artificial intelligence and robots may be useful at the interface between printing and finishing, and between finishing and processing, just for the actual printing procedure, they have no meaning. Color management and inspection systems may take some built-in autocorrection capabilities, but they will never tell me at which press speed and at which solvent concentration a particular color volition reach its optimal hue. Robots may be used to load and unload the substrate, but at what cost?The only application of Industry iv.0 readiness that has whatever relevance is the interaction with customers' packaging and processing workflows, such equally linerless labels or IML that can be picked upwards and applied by a robot arm in the packaging process. Once more, much marketing fizz in an industry which in reality is much more down-to-earth.

Label presses at Labelexpo Europe

Traditional narrow-web manufacturers such every bit Gallus, Nilpeter, Omet, Mark Andy, Bobst, MPS, and Edale all had inkjet presses and hybrid presses with inkjet components at the show. Side by side to the toner-based systems from HP, Xeikon and Konica Minolta, new inkjet presses were introduced past Canon Océ, Dantex, Dilli, Durst, Epson, Inx, Memjet, Miyakoshi, Mouvent, Screen, Xeikon and others, while Atlantic Zeiser, FFEI, Fujifilm, Gallus, Kodak, Xaar, and a dozen others showcased inkjet modules and print bars.

Bobst

Bobst launched its Master DM5 at the show, combining flexo and digital at speeds of up to 100 meters a minute, and showcased a complete range of Mouvent digital presses, the LB701-UV, LB702-UV and LB702-WB, all running at speeds of up to 100 meters a minute. The Bobst stand up also included the Main M6 and Vision M1X UV flexo presses.

Gallus

Gallus introduced a new rotary die-cutting unit of measurement for the Labelmaster, and a modular, hands shiftable, digital print bar for highly opaque white ink. Other presentations at the Gallus stand included the Heidelberg Phoenix UV LED imagesetter, Screeny plates used with the Gallus Rotascreen organization, and iii presses, the Labelfire, Smartfire, and Labelmaster.

Nilpeter

Nilpeter added a new press to its FA series, the FA-26, a 670 mm wide printing for short-run flexible packaging and labels. The visitor besides showcased new inkjet varnish, opaque white inkjet, and semi-rotary die-cutting units for its FA-17, and new UV lamination, UV LED drying and dice-cutting stations for its FA-22 printing. Omet launched its Xflex X7, a 670 mm broad flexo press including a rotogravure unit. The visitor also came to the show with its compact entry-level 8-color UV LED flexo press iFlex, the Xjet hybrid press powered by Durst, and a new linerless laminating module for the processing of CLS film.

Marking Andy

Mark Andy introduced its new Evolution series, available in widths of 330 and 460 mm at speeds of up to 230 meters a infinitesimal, and its toner-based Digital Proline, a modular entry- to the mid-marketplace level digital system adult with Konica Minolta and running at speeds of upwardly to 24 meters a minute. Mark Andy also showcased its Digital Hard disk serial, a 430 mm wide 7-color UV inkjet printing introduced early 2022 and running at speeds of upward to 73 meters a minute.

MPS

MPS showcased its contempo 430 mm broad hybrid EF SymJet press including five flexo stations and equipped with a Domino digital N617i inkjet printer, running at speeds of upwardly to 75 meters a minute in hybrid mode. The MPS stand included three other presses, the EXL mid-web packaging press in widths of up to 670 mm and speeds of upwardly to 300 meters a infinitesimal, and the EFS and EFA multi-substrate presses in widths of upwardly to 530 mm and speeds of up to 200 meters a minute.

Lombardi presented a new press, the Invicta i2, bachelor in widths of 750, 850 and ane,100 mm for flexible packaging. The Invicta i2 in 750 mm width was the widest label printing shown running at this Labelexpo. The company also showcased its Synchroline flexo press and the Digistar hybrid printing with an inkjet module by Domino, including new foiling and embossing, flatbed screen and semi-rotary die-cutting units.

Codimag, Rotatek, and Spande

Codimag and Rotatek both showcased first presses with in-line flexo, gravure, screen, lamination, die-cut, common cold and hot stamping, and embossing options. Spande based in Shanghai, for the showtime time at Labelexpo Europe, showcased a flexo press, the S7 Series available in widths of 370, 450 and 520 mm and speeds of up to 200 meters a infinitesimal.

Durst

Durst launched a new press, the Tau 330 RSCi Low Migration, in addition to its Tau 330 RSC and RSC E also at the show, and bachelor in widths of 330, 420 and 508 mm at speeds of up to 100 meters a infinitesimal.

HP

HP'due south presentations included HP Indigos 6900 and 8000 printing labels, an HP Indigo 20000 producing standup pouches with Karlville pouch making equipment, a beta-testing HP Indigo Gem for digital embellishments, and various in-line converting partnerships for the production of metalized labels, shrink sleeves and brand protection applications. HP also announced a partnership with Agfa for the creation of the HP Indigo Secure Studio application for make protection and security printing.

Xeikon

Xeikon had a big line-up of inkjet presses adjacent to its toner-based engines, including the PX2000 and PX3000 with speeds of up to 50 meters a infinitesimal, and the Jetrion 4900 and 4950 serial with speeds of upwards to 24 or 48 meters a minute. Konica Minolta showcased its proven 230 mm wide AcurioLabel press developed with GM and MGI. Screen introduced new versions of its Truepress Jet L350 series with twin power UV and speeds of up to 60 meters a minute, while Canon relied on its 330 to 410 mm broad Océ LabelStream 4000 series with speeds of upwardly to 75 meters a minute.

Domino

Domino came to Labelexpo with a 445 mm wide high-speed dual-bar K600i inkjet printer mounted on an ABG Omega SRI with slitter, rewinder, inspection, and digital embellishment units, and printing at speeds of upwards to 150 meters a infinitesimal. The Domino stand up likewise included an N610i ABG Hybrid press.

Epson

Epson showcased three new models in its SurePress industrial label press serial, the water-based L4533AW and the UV LED L6034 and L6534, as well as a range of ColorWorks printers for packaging lines. Converting and finishing equipment AB Graphic (ABG) with its largest stand up ever showcased 20 machines, including a Digicon, configured for high-cease drink applications and embellishments, with flatbed screen units, foiling heads and a newly designed turret rewinder. One of its latest developments shown was the entry-level Digicon Low-cal incorporating semi-rotary flexo.

Cartes

Cartes had several converting and finishing machines on prove, such as the CE160, GT360 and Gemini platforms for converting, finishing and embellishing, combining light amplification by stimulated emission of radiation die-cutting, silkscreen, hot stamping, metallic doming, high-raised and apartment printing, embossing, debossing, semi-rotary flexo, full and spot varnishing, inspection, slitting, and rewinding. Lesko highlighted some of its finishing systems for shrink sleeves, IML and labels, among which the CF380 equipped with corona handling, flexo, lamination, cold-foiling, die-cut and slitting facilities.

Rietstack

Rietstack presented its IRS serial for dice-cutting, embossing, de-curling, unwinding, rewinding and stacking, bachelor in different combinations. Grafotronic had eleven finishing machines at the show, including 7 new developments. SMAG was at the show with a large line-up of converting equipment in its iConvert series, including multi-process platforms in widths of 850, 1,000 and 1,200 mm for converting, finishing and inspection.

Other converting mechanism brands at the testify included ALS, Bielomatik, Brotech, Contiweb, DCM, ETI, GM, Karlville, Kocher+Brook, Prati, APL from Korea, and several Chinese manufacturers such as Rainbow and half a dozen companies from Shanghai and Shenzhen.

Amid the many interesting developments in consumables at the show, Flint developed a database of 180,000 formulations for spot colors, based on five different anilox and four different substrate settings, which is available for converters mixing their flexo inks in-house.

Monotech

The Indian exhibitors Monotech based in Chennai, who as well represents Xeikon offset CtPs in Bharat, focused its presentations on its Colornovo UV inkjet label press, available in widths of 220 and 330 mm and speeds of upward to 50 meters a minute. This UV digital label press already has an installed base of operations of 12 presses globally, including 7 in China and ii in Bharat.

Multitec

Multitec from Faridabad showcased its E and Due south lines of servo-driven flexo presses in widths of 370 and 450 mm for flexible packaging and folding carton. The press at the stand had been sold to a Russian customer in accelerate of the show. UVGT (UV Graphic Technologies) from Noida presented its Ultraflex UFO flexo press, the Ultraflex USR slitter-rewinder, cutting, inspection, doctoring, curing, punching and plate mounting systems.

Shri

Shri and its sales agent Flexart from Ahmedabad provided information on their Brison series of die-cut, foiling, inspection and anilox cleaning equipment. RK Label from Ahmedabad informed about their FM serial of flexo characterization presses and finishing equipment.

Triad Engineering Works

Triad Engineering Works from New Delhi, a newcomer at Labelexpo, presented a range of handheld label printers, thermal transfer ribbons, and ink rollers for label printers, calculators and cash registers.

IEEC

IEEC from Mumbai showcased their corona treatment systems for narrow web presses.

Acme Rolltech

Acme Rolltech based in Ahmedabad presented its range of anilox rollers for narrow- and wide-spider web flexo, offset, corrugated and coating industries, with hexagon, elongated hexagon, diamond, tri-helical and open channel cell patterns.

Diehard

Diehard, a Labelexpo regular from Guntur, AP, came with its large range of flexible dies for the characterization industry.

Mona Equipments

Mona Equipments headquartered in Noida showcased shafts for various machines and doctor blades.

Convertech

Convertech from New Delhi which is a regular exhibitor at Labelexpo in produces doctor blades for gravure, broad spider web flexo, and narrow web flexo presses had its strong diversity of fit for purpose range of steel physician blades on evidence.

Resource Engimech

Resource Engimech from Baroda presented chucks, shafts, reel lifters, rollers, tubes, springs and air valves for various machines, equally well as a reel shaft extractor.

In addition to Cosmo, Jindal, SMI, Holostik, Garware Polyester, Max Specialty Films and Stic-On Papers came to Labelexpo with their respective substrates for the label manufacture, while Globus International from Raigad, Maharashtra, presented itself every bit a manufacturer of silicone coated release liners with customers in 45 countries. Holostik presented its security holograms as it has washed at past Labelexpos.

The next Labelexpo Europe has been planned for 22-25 September 2021. In the meantime, Labelexpo India is to have place from 29 Oct to i November 2020.

Labelexpo is also starting a new Brand Print Global series, starting in Bangkok 7-ix May 2020, based on the synergy between printers and brand-owners. Information technology will focus on PoP/PoS displays, shelf-stacking units, wide-format signage, direct mail, armada graphics, 3D printing, and interactive technologies.

Ron Augustin is the European Editor of Indian Printer and Publisher and Packaging South asia.

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