Flexible Packaging
Boxing clever with flexo T
Tom Kerchiss, chairman of RK Print Coat Instruments, says dramatic shiſts in the retail environment in markets around the world have resulted in the need for corrugated packaging to function and communicate in ways never previously imagined.
hese developments have also led to a degree of merging between the historically segregated corrugated sectors and so-called folding cartons into an inclusive category of packaging materials, one that despite pressure from other material sources remains more than just tenable for a variety of reasons.
Corrugated materials meet many of the checklist requirements. Material is derived from managed forests and is renewable and recyclable after use. Corrugated combines strength and rigidity with the flexibility to absorb shocks typically associated with package handling and transportation.
Corrugated/micro flute systems integrate effectively in with the Retail-Ready Packaging concept favoured by high-volume retailing organisations. RRP and high-quality printing go hand in hand as the concept is designed to reinforce product branding throughout the supply chain. Over 80% of the packaging may be visible on the shelf and primary consumer information, which normally goes unnoticed unless the product is picked up and handled, is made more visible. In many instances the consumer of today may not even be aware that they are encountering corrugating as a packaging medium. Much of corrugated is printed flexo or UV flexo or flexo in tandem with a digital configuration (hybrid presses). Presentation is particularly important, methods employed include: pre-printing the outer layer or liner or by
lamination.Control of process variables particularly those associated with colour branding are critical, even for low volume products that may be regarded as commodity items. In order to create high quality process print using water-based flexo inks it is necessary to print very small, very defined dots of ink. This is possible providing the ink thickness deposited on the material is minimal. However, when reducing ink film thickness, ink colour strength is also reduced. For this reason a printer will generally opt for high pigmented inks and then print them at very low film weights. There are a couple of issues that the print operative and others in the supply chain should be aware of. To begin with, if the board is far from smooth, there could be insufficient ink coverage when using low weight inks.
is covered with brand colour, graphics, and other value added enhancements. Pre-printed liners provide so many decorative possibilities for corrugated; a downside is that manufacturing corrugated board with pre- printed liners is expensive. Pre-printed liner is favoured for long runs and for high profile branded goods.
Another option is to laminate a pre-printed liner. Everyone these days is striving for the ultimate in brand presentation. Pre-printed and laminated liners enhance brand
image.as printing can be
undertaken on the best grades of material. However, poor printability, colour out of spec and other variables results in client disappointment; poor presentation will also affect sales. Ink producers and providers also need to keep a sharp eye out for variation is ink appearance and performance.
Compromising on dot gain and paper quality may be acceptable, but not often.
The second issue is related to the formulation of the ink. If the ink formulator raises the pigmentation level of the ink too much, then there will be insufficient resin in the ink to bind the pigment to the paper surface, compromising rub resistance. The amount of ink printed onto the material is also dependent on the viscosity of the ink. Viscosity is determined through a combination of consultation and experimentation. The tricky part is perhaps maintaining the determined viscosity, as any variation will affect colour strength and colour appearance.
Ink manufactures also face challenges when it comes to formulating faster drying inks for the faster processing requirements of today without compromising on re-solubility and wash up. Other issues to contend with include substrate surface properties and rub and slip resistance. In building brand image and attracting the browsing shopper more and more of the box
Colour communication devices such as the FlexiProof 100 and variants FlexiProof UV and FlexiProof LED UV for users and producers of flexographic inks enables package printers and converters, ink manufacturers, chemists, additive/ resin producers and others to trial various formulations and materials under conditions that replicate production line press conditions. Whether sited in a pre-press printing department, an ink manufacturer’s laboratory or an R&D centre, the FlexiProof can determine how materials and ink interact over time; printability issues such as scuff resistance, rub resistance, durability and gloss can be evaluated. Press component producers can ensure their anilox rollers, etc., are optimised for the application. The FlexiProof is of course used for visual and computer colour matching.
Colour communication devices are also manufactured by RK Print Coat Instruments for multi-print processors using gravure, gravure- offset and flexo processes. RK Print Coat Instruments who export more than 80% of their colour communication and pilot/production coaters also make a dedicated gravure proofer, the GP-100 for gravure printing and converting shops.
22
May 2023
www.convertermag.com
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46
