Making packaging print growth sustainable with flexo

The growth trend in package printing is forecast to take the sector to over $695 billion by 2029, according to global data and research company Smithers, but while growth continues, economic challenges have made cost savings a big focus for brands. A recent survey by consultants L.E.K found that brand owners are looking to achieve sales growth and cost savings in tandem with progress on sustainability.

How does the industry continue to grow while making progress towards these important environmental goals?

A big part of the answer lies in innovation that can deliver maximum impact throughout the flexo print process. Modern flexo, a standardized, sustainable manufacturing process, allows packaging to be printed in a more sustainable and efficient manner than ever before.

“Modern flexo champion Uflex needed a more sustainable packaging option for short runs while maintaining visual consistency with their previous gravure-printed packs.”

While implementing modern flexo practices requires collaboration between printers and their key suppliers, the flexo plate sits at the center of the flexographic print process. The plate brings together substrates, inks, tape and anilox for a dramatic impact on press capability and results.

The unique FLEXCEL plate, a key enabler for sustainable printing, has been at the heart of a steady stream of flexographic innovation over the last decade, involving press, ink and anilox manufacturers and prepress providers.

The on-press performance benefits a FLEXCEL plate provides also reduce waste, increase resource utilization, and enable support for a wide range of eco-friendly materials, such as recyclable substrates and water-based inks, without impacting cost and actually improving the bottom line for printer/converters.

“In Australia, flexographic printer Perfection halved  the waste materials created when producing printed packaging for Arnotts biscuits.”

It supports a double materiality approach to sustainability: addressing the impact on the environment and the financial impact for a business.

“The reassuring thing about how we’re focusing on sustainability is that it’s inextricably linked with efforts to help drive financial return on investment for our customers,” says Miraclon chief marketing officer Emma Weston. “Sustainability can’t be a separate part of the business agenda”.

Here’s how a modern flexo approach is helping printer/converters and prepress businesses all over the world make strides forward on improving sustainability while decreasing costs.

LESS WASTE

In Australia, flexographic printer Perfection halved the waste materials created when producing printed packaging for Arnotts biscuits. FLEXCEL NX Plates enabled them to achieve smoother ink laydown, more consistent printing and a better match to proof, resulting in 50% reduced waste, 50% faster set-up time and no unscheduled stops for cleaning.

Overall, they achieved sustained production at 400 mpm – a level of performance previously unattainable. From the cost side, they were able to reduce overall expenses while boosting shelf sales – an all-round win-win, for Perfection and their client.

CLEANER INKS

Uflex needed a more sustainable packaging option for short runs while maintaining visual consistency with their previous gravure-printed packs. Using recycled polypropylene film, FLEXCEL NX Plates and PureFlexo™ Printing enabled Uflex to transition to 100% water-based inks, reducing ink film weights to 0.9 gsm, while matching previous gravure press speeds with solvent inks.

Reprint production times were cut from three days to just four hours, resulting in a 15% lower resource footprint overall. By minimizing rework and reducing substrate waste and ink usage, the overall costs of the project were lower.

EFFICIENCY WITH MORE SUSTAINABLE SUBSTRATES

With a multitude of sustainable substrates in their business, Walki Poland struggled to get consistent results.

But thanks to the improved ink transfer and multi-form surface patterning of FLEXCEL NX Plates, they achieved more stable, repeatable results across all substrates – resulting in faster set-ups, lower energy costs and reduced consumables wastage. That means they’re now one step further towards their goal of a circular, resource-efficient, low-carbon future.