While the projections vary, the global flexible packaging market is growing at an approximate 5% CAGR and expected to exceed $250 billion by 2024. This is an average range taking into account market forecasts. According to the April 2016 IDC ‘Digital Printing for Packaging Survey, 92% of brands surveyed said their volume of packaging is increasing, although in shorter runs. Today, flexographic speeds can reach in excess of 1,000 fpm, although factors, including market segmentation, brand campaigns, inventory cost reduction, and compliance with new and changing laws and regulations, are all driving the need for shorter run solutions.
According to the IDC survey, the cost of digital production in flexible packaging has been one of the primary constraints in its more rapid expansion. This increasing need for lower cost higher productivity digital solutions has been driving the development of many new packaging production solutions including those from HP Indigo, Fujifilm, Mark Andy, Xeikon and others. While most packaging segments are affected, Food/Beverage, Pharma and healthcare are the leading areas driving the demand. These are areas that are regulated and have a need for compliance with indirect product contact regulations. Ideally, they would like to comply with these regulations without the need for intermediate barriers that increase the cost of the packaging.
The UTECO Sapphire EVO was developed to address that need. It brings digital flexible packaging production to a new cost and productivity level, challenging both existing digital solutions and even Flexography. This new hybrid press is comprised of an aqueous-based Kodak Stream inkjet imaging system, installed on a Flexo transport. It uses an inline gravure pretreating station to provide for smooth color laydown and ink binding on a wide range of flexible materials. The Sapphire EVO supports and has been tested with a wide range of media, including clear, white and metalized BOPP, PET, PE, and paper. The Sapphire EVO is configured with 4 ink stations (CMYK) that deliver a wide color gamut that can achieve ~97% of the Pantone library. The Sapphire EVO can accommodate an optional 5th color station in future configurations, and since the press is manufactured by UTECO, other inline options can also be added based on specific requirements. The unique drying system uses air blades and IR along with a chilled drum that is in contact with the media to facilitate the drying of wet-on-wet printing while maintaining media stability.
The inline Flexo Onyx XS post-coater can be used for overprint varnish or white or other colors to facilitate reverse printing in register. The water-based pretreatment, inks and varnish all comply with regulatory mandates for indirect food contact in the EU and U.S., as well as many other brand-specific requirements.
This new press supports media of up to a 650 mm (25.6 inches) wide and a printing width of up to 622 mm (24.5 inches). Its productivity derives from maximum linear speeds of up to 300 mpm (1,148 fpm) at 600 x 600 dpi. At 600 x 900 dpi, it runs at speeds of up to 200 mpm (656 fpm). Of course, the speed is dependent on the rate substrates can be dried. I have seen it running with very impressive results at 150 mpm (492 fpm) on BOPP, and they are expecting to be able to reach 175 mpm (574 fpm) on that and other flexible packaging materials.
The press is designed to be cost effective at very short, short and medium run lengths. UTECO estimates that the operating cross-over effectiveness for this press against Flexo will be runs of up to 20,000 square meters (more than 200,000 square feet) depending on cost of Flexo inks and coverage. While there are no other indirect food contact aqueousbased digital solutions available at this point, it is 2x to 4x times faster than the UV and liquid toner based digital flexible printing solutions currently in the market and operates at less than half the cost in many cases.
Originally previewed at drupa 2016 in the Kodak booth, this aqueous ink hybrid press is now released and will be installed in June at its first customer, Nuova Erreplast, a 25-year-old flexible packaging manufacturer in southern Italy. This will be their first digital packaging press to complement existing Flexo press lines, and it will support their current business in Italy and North America. According to Nuova Erreplast CEO Crescenzo Raccioppoli, the demand for shorter and variable runs from their existing food and pharma customers helped drive the decision to bring digital production capabilities into
the company. Racciopolli also feels that the addition of this new “ground breaking” technology will allow him to expand his business in both existing and new directions.
The press will be sold and supported by UTECO
More to Come
I would like to address your interests and concerns in future articles as it relates to the Bespoke manufacturing of Print, Packaging and Labels, and how if at all it drives Industry 4.0. If you have any interesting examples of bespoke manufacturing, I am anxious to hear about them. Please feel free to contact me at david@zwang.com with any questions, suggestions or examples of interesting applications.
