Flexible Packaging
Technical innovation in CI Flexo: BOBST’s advanced solutions for fl exible packaging
Central Impression (CI) flexographic presses remain key in global flexible packaging production A
s a leading name in this market, BOBST continues to deliver technological advancements that address evolving production challenges while
implementing the company’s vision for the future of packaging production - centered on digitalisation, automation, connectivity, and sustainability.
MARKET DYNAMICS AND TECHNICAL CHALLENGES The fl exo printing market across all applications is projected to grow at a 3.0% compound annual growth rate (CAGR) through 2029, according to a Smithers analysis. Specifi cally within the fl exible packaging category, consumption is forecast to increase at a 4.2% CAGR between 2023 and 2028, with market value expected to reach $341.6 billion by the period’s end. Notably, biodegradable and compostable packaging segments show even stronger potential, with an anticipated 8.8% CAGR to reach 1.17 million tonnes by 2029. Despite these opportunities, the CI fl exo segment (often called “wide web”) faces signifi cant technical challenges. Production runs are becoming shorter, pricing pressures continue to mount, and a shortage of qualifi ed press operators impacts workforce planning. Simultaneously, sustainability requirements are intensifying through both consumer demand and increasing legislative frameworks - all while maintaining production quality, colour consistency, and faster delivery times.
BOBST’S CI FLEXO PORTFOLIO
To help converters capitalise on growth opportunities while addressing these challenges, BOBST has developed a comprehensive CI fl exo press portfolio including the EXPERT CI, VISION CI, and MASTER CI models. Each machine incorporates targeted innovations in automation, connectivity, and waste reduction specifi cally designed for fl exible packaging applications in the global wide web market. The capabilities of BOBST’s fl exo technology are showcased at the Bielefeld Packaging Center in Germany, where new VISION CI and EXPERT CI printing presses demonstrate the modular architecture and automation features that distinguish these solutions in the marketplace. Both demonstrated presses highlight confi guration
34 May 2025
fl exibility with 10-colour setups, though customers can alternatively select 8-colour arrangements supplemented with dedicated varnish and white ink stations. The intelligent design accommodates additional downstream units (fl exo or gravure) for specialised applications, which can be integrated either initially or as future retrofi ts. This adaptable architecture delivers excellent price-performance value with signifi cant substrate versatility and superior print quality, while maintaining operator safety and ease-of-use as primary considerations.
THE ‘ONE COMPLETE SOLUTION’ ECOSYSTEM BOBST’s CI fl exo presses integrate into a broader ecosystem, orchestrated through the BOBST Connect digital workfl ow platform. This comprehensive approach incorporates the VISION CI or EXPERT CI fl exographic press, NOVALAM S 550 solventless laminator, smartGPS plate mounting system, and Digital Inspection Table (DIT) for quality assurance. This integrated approach creates a seamless end- to-end workfl ow that is particularly well-suited for shorter production runs and just-in-time delivery requirements. The various automation features built into the system assist operators, accelerate production, enhance productivity and signifi cantly reduce setup resource requirements including ink, substrate materials, and energy.
ONEECG TECHNOLOGY
BOBST’s oneECG (Extended Colour Gamut) technology represents a signifi cant advancement in colour management for fl exible packaging production. This system optimises colour matching through a digitalised process that ensures consistency and repeatability. By employing a fi xed ink set of either CMYK alone or enhanced with orange, green, and violet, oneECG eliminates the
need for expensive spot colours and reduces job changeover time. The digitalisation of colour matching minimises operator intervention, reducing colour variations attributable to human error while simultaneously lowering the skill threshold required in press operations. Benefi ts of oneECG include reduced setup waste, faster makeready process, increased productivity through continuous press operation, exceptional colour consistency across production runs, improved repeatability for subsequent jobs, and streamlined inventory management through standardised ink sets.
SMARTGPS: OPTIMISING PRESS SETUP The smartGPS (Graphic Positioning System) technology addresses a critical production bottleneck by revolutionising plate mounting procedures. This system automatically generates registration and impression settings offl ine during the mounting stage and transmits this data to the press either digitally or via RFID chip. By performing these adjustments away from the press, jobs are ready to print immediately upon cylinder loading without additional operator intervention. This technological approach accelerates job startup times, reduces setup waste compared to traditional methods, minimises press downtime between jobs, decreases reliance on operator experience and judgment, and provides consistent, reproducible setup parameters. As the fl exible packaging industry evolves to meet new market demands, BOBST’s innovations in CI fl exo printing technology exemplify the company’s commitment to digitalisation, automation, connectivity, and sustainability. These technical advancements provide converters with practical solutions to succeed in an increasingly competitive landscape where effi ciency, quality, and environmental responsibility have become essential operational requirements. By focusing on these technological developments, BOBST continues to advance the state of CI fl exo printing, enabling packaging converters worldwide to adapt to changing market dynamics and position themselves for long-term success.
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