Flexo Technology
Substrate evolution drives CI flexo innovation By Natalie Schneck, marketing & communications manager – product line CI Flexo
he fl exible packaging industry faces mounting pressure to handle an increasingly diverse range of substrates while maintaining high productivity and quality standards. This challenge has become a primary driver of innovation in CI fl exo press development, as converters must now seamlessly process materials ranging from traditional to next- generation substrates, such as compostable fi lms and fi ber-based alternatives. As a result, CI fl exo presses must rise to meet highly specifi c handling requirements across this material spectrum. For example, thin PE fi lms demand precise tension control systems to prevent stretching or wrinkling during production. Compostable fi lms, with their lower heat resistance, require careful temperature management throughout drying and curing processes. Meanwhile, fi ber-based substrates increasingly incorporate high percentages of recycled content, presenting core challenges for ink transfer effi ciency and drying performance. These substrate-specifi c demands have pushed manufacturers like BOBST to rethink traditional CI fl exo architectures. Success in today’s market requires intelligent automation systems that can adapt press parameters in real-time, ensuring consistent quality regardless of material type. This fl exibility has become a non-negotiable factor as converters seek to serve multiple market segments without maintaining separate production lines for diff erent substrate categories. Responding to these pressures, BOBST engineers CI fl exo solutions with adaptability at their core. The company’s press portfolio incorporates substrate-specifi c handling technologies that enable printers to run versatile materials with both confi dence, consistency and stability. By integrating intelligent automation throughout the production process, BOBST presses help converters to reduce waste and energy consumption, while maintaining the productivity levels demanded by today’s competitive marketplace. Each BOBST CI fl exo press can be confi gured to specifi c job demands, off ering exceptional productivity while supporting higher process sustainability. This customisation ensures that converters can optimise their investment for their particular mix of substrates and applications, rather than accepting a one-size-fi ts-all approach
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that may compromise performance across certain material types.
The substrate challenge extends beyond press capabilities alone. BOBST recognises this by collaborating with leading industry suppliers to develop substrate solutions that maximise the potential of fl exo investments. These partnerships have yielded innovations like the oneBARRIER PrimeCycle and oneBARRIER FibreCycle mono- material solutions, which address current sustainability demands while anticipating future regulatory requirements surrounding circularity. These mono-material constructions represent
a signifi cant advancement for the recycling chain, as they eliminate the complexity of separating diff erent material layers at end-of-life. By enabling easier recycling, these solutions help brand owners meet sustainability commitments while maintaining the barrier properties and shelf appeal that consumers expect.
Looking ahead to the future of the category, it’s likely that substrate diversity will continue to increase as the packaging industry responds to sustainability imperatives and evolving consumer preferences. To keep pace, CI fl exo technology must continue advancing to meet these demands, with press manufacturers focusing on fl exibility, automation and energy effi ciency. For converters evaluating CI fl exo investments, substrate versatility has emerged as a critical selection criterion. The ability to effi ciently switch between material types, maintain quality across substrates, and adapt to emerging materials provides competitive advantage in an industry
where agility increasingly determines success. Press solutions that combine mechanical precision with intelligent process control off er the best pathway to meeting today’s challenges while remaining prepared for tomorrow’s demands.
However, equipment capabilities represent only part of the productivity equation. Brand owners increasingly pressure converters to deliver accurate colour quality and consistency, while keeping costs under control. Addressing these twin demands requires examining the entire production workfl ow, particularly the time- intensive colour matching process. On March 18, BOBST’s Packaging Centre in Bielefeld will demonstrate its Demo 3.0, including a ‘fi rst pull right’ job changeover method, developed with process optimisation partner Co-ëffi ciënt. The focus will be on how setup time and waste can be drastically reduced while improving colour quality. The session focuses on best-in-class production methods and business profi tability, demonstrating measurable fi nancial impact through higher OEE, less waste and greater consistency.
www.convertermag.com
February 2026
27
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