Flexo Technology


using flexo was almost unheard of in the region ,” recalls Patel, “but by combining the Bobst press with Kodak Flexcel NX technology we could offer brands much higher quality in the reverse-printed space — with the added advantage that the pack is recyclable.” The company’s winning entry — flexible


packaging for salt — demonstrates this proposition in action. Salt is traditionally packaged in a PET+PE laminate, printed gravure for reasons of printability and quality. Explains Patel: “The brand owner wanted a sustainable replacement, so we proposed a PE+PE laminated structure — something gravure can’t handle due to quality issues on PE. In the end, the client moved from a non-recyclable package to a 100%-recyclable alternative, giving them the same mechanical properties without affecting shelf-life, and reproduced so accurately that it was difficult to distinguish it from the gravure equivalent. They were also able to recover some cost in the form of packaging waste at their end.” He acknowledges that, considering how


new Pentaflex was to flexo, this was a major achievement, and one that involved a degree of trial and error. “We put a lot of time and effort into trying out new applications, and we’re not shy about experimenting. But we’re fortunate to have a high level of technical expertise running throughout the company — from the directors to the rest of the team. It’s our USP.”


WORK TO BE DONE Three years on from the original decision to enter the flexo market, this expertise is behind an increasingly successful drive to bring more gravure work over to flexo. Recent contract wins include a locally-based manufacturer of ready-to-eat and instant- mix products that is taking the flexo route in a major rebranding of its products. There


remains, however, work to be done before the momentum becomes unstoppable. “We have no trouble showing prospects that flexo produces quality print,” says Patel, “but that’s not the only factor in the decision to switch. We have to remember that brands and their printer-converters have a heavy investment in cylinders for existing jobs. Hopefully, we can get in front of them when they change designs, but that doesn’t happen very often.” When Pentaflex does get to the table, he


says, they can make a strong case. “The Indian market is very cost-conscious, and throughout the supply chain everyone is trying to gain margin. So the cost of gravure cylinders is a factor, particularly for brands


with lots of SKUs or frequent design changes. Flexo plates are cheaper, of course. Faster time-to-market is another powerful argument: for a FMCG brand with multiple products in different sizes, waiting a week for a gravure cylinder is an issue. Flexo offers quicker turnaround for platemaking as well as on the press, so we can handle shorter runs without a drop in quality.”


SMALL CHANGE, BIG IMPACT He adds that the advent of toluene-free inks is beginning to have an impact with larger brands. “A lot of brands in the US have already moved away from toluene, and the same is happening in Europe. The message is getting through in India too, encouraged by the sustainability regulations.” Finally, there’s flexo’s substrate flexibility.


“The amazing thing about flexo is the fantastic quality, whatever the substrate. You can surface-print on PE, reverse-print on PET, surface-print on breathable paper or aluminum foil, or just paper. We’re doing it all.” Pentaflex is confident a flexo future is on


its way, he concludes, and how quickly it arrives will depend on cooperation between all the stakeholders. “There is an enormous variety of potential jobs out there, some more challenging than others. It takes a lot of expertise to bring together the right anilox, the right dot structure and the right ink. Going forward, all of us need to work closely to make the transition happen.” KODAK FLEXCEL Solutions have helped


transform flexographic printing. From Miraclon, KODAK FLEXCEL Solutions – including FLEXCEL NX System – offer high quality and cost efficiency, with a focus on image science, innovation, and collaboration.


upentaflexfilms.com convertermag.com June 2020 21


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