Flexible Packaging
Dynamic flexible packaging By Tom Kerchiss, chairman of RK Print Coat Instruments
he global market for flexible packaging products, valued in excess of 300 billion US dollars in 2025 is forecast to continue to deliver good returns through 2026, particularly for those market leaders with operational facilities in emerging markets. Strategically sited, many of these satellite plants, operate autonomously, engage in research and development and turn out lightweight, durable and sustainable branded products relevant to consumers in countries with different languages, culture and requirements.
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The Asia-Pacific region which includes India, China, Japan, Korea and Thailand continue to dominate the flexible market for a number of obvious reasons: increased urbanisation, greater expectations on the part of consumers, a growing middle-class, notably in India and China but elsewhere as well; manufacturing expansion; political commitment; liberalisation and an increasingly educated workforce encourage investment and positivity. North America shows the fastest regional growth; high investment; sustainability and the demand for light weight, durable and responsible flexible products such as resealable pouches, bags and e-commerce packaging. In many respects the market for flexible packaging in Europe and in the antipodean countries of Australia and New Zealand mirrors much of what is taking place elsewhere. Brand owners, consumers, legislators and manufacturers aspire towards the on-going development and application of productions and materials that are functional, comply with end-of-life and circularity requirements; comply with the health & safety requirements for food/beverage, pharmaceutical and legislated items and has the necessary barrier properties in place to prevent spoilage and deterioration in the retail environment and with the consumer for as long as possible.
Packaging’s foremost purpose is to protect products from damage during transportation, also when put on display on the shelf or in the freezer and chill cabinet in the retail environment and even of course for some time after, when the consumer has purchased and carried away the item. Product packaging protection is especially important when that item is food.
Effective barriers integrated within the structure of the flexible pack or various protective surface coatings reduce food waste, extend the life of perishable items, prevent contamination and if appropriately formulated may be recycled without costly and uneconomic separation of various components.
Barrier critical properties that may be required
for fl exible constructs, particularly for food include moisture and humidity control, safe sealing; peel ability and grease proofi ng, etc. Oxygen and light are often the main cause of food spoilage and degradation. The ingress of oxygen can result in the oxidation of fats, resulting in some foods becoming rancid and unappealing. Vitamins and nutrients are adversely affected by oxygen, while aerobic microorganisms can multiply. UV light is another spoiler. Exposure to UV can affect many foods: altering the taste and affecting the colour of meat and perishable foods. Although barriers to protect a product from external spoilers are for the most part the norm, this is not always the case. Pouches and bags for ground coffee and tea need a barrier to be in place to lock in flavour and aroma.
Moving along, what about the substate itself? Paper, is regarded as a sustainable flexible substrate, suitable for some applications. But even this is not always clear cut. Paper may be coated with EVOH, which provides protective benefits but is of a hydrophilic nature so an additional polyolefin coating may be applied to prevent water absorption but complicating recyclability, biodegradability and compromising sustainability.
Some of the most interesting product developments is in the area of bio or plant- based polymers, many of which are regarded as being non-damaging to the environment while delivering a level of performance equal to or even superior too existing chemistries and materials. Polysaccharides, proteins, lipids or a combination thereof are renewable and many are compostable. A VCML pilot coater from RK Print Coat Instruments is engaged in trialling Seaweed, Agar and Carrageenan. Difficult to apply and cure because of the high-water content, nevertheless this knife- over-roll coater cures by steam. Many factors influence material and consumable selection, which is why there is a need for vigorous product development programs. A degree of experimentation is needed to ensure that product performance is not going to be compromised and that the item can be processed, coated and dried at an acceptable speed with minimal risk of returns and reworking. VCML pilot coaters offering selectable print and coating applicator technology together with short run capability are in place with companies engaged in flexible packaging and other production centres. Three VCML coaters have been installed at three different plants belonging to Archroma Packaging Solutions. One VCML has been delivered to an Archroma ‘Center of Innovation ‘at Mumbai, India. Another coater is at a ‘Center of Innovation’ in Barcelona, Spain and the third machine is at a ‘Centre of Innovation at Charlotte, North Carolina, USA. Detailed information on these installations is available separately. Suffice to say the applications are for sustainable flexible packaging and that the coaters are capable of reverse and direct gravure, slot die, flexo and knife over roll, etc. The VCMLs also enable operatives to laminate when using pressure sensitive adhesives.
24
March 2026
www.convertermag.com
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