Comment
Traditional analogue production models still play a critical role, particularly for long-run work, but they are not always designed for the flexibility modern brands now expect. Shorter runs, faster lead times, versioning, localisation and frequent artwork changes have become standard requirements rather than exceptions. This is where digital flexible packaging is gaining real momentum.
For converters already operating in digital labels, the transition into flexible packaging is often far less intimidating than it initially appears. Many already have deep expertise in colour management, workflow automation, variable data, embellishment, short-run production and rapid job changeovers. In many cases, converters are not starting from zero. They are adapting existing operational knowledge to a broader range of packaging applications.
That reality is also influencing how equipment manufacturers approach the market. Increasingly, the focus is shifting away from standalone machines and toward complete production ecosystems. Converters do not simply want to purchase equipment; they want to understand how technologies connect within a practical, scalable workflow. This thinking was central to the recent launch of our new FlexPack Centre of Excellence in Girona, Spain. The facility was created as a dedicated environment where converters can experience digital flexible packaging production in a realistic setting and see how different technologies interact across the entire process.
From our centre of knowledge, what we consistently hear from customers is that they no longer want isolated machine demonstrations. They want to understand the full workflow — from web handling and lamination through to pouch making and finishing — and, most importantly, how these processes integrate into existing operations without unnecessary disruption.
For many businesses, seeing those solutions and technologies working together in a live production environment makes the transition into flexible packaging feel far more achievable.
One of the most important discussions happening within this transition concerns lamination. In flexible packaging, lamination quality is critical. It impacts durability, shelf performance, barrier protection and overall pack functionality. Historically, however, lamination systems were often associated with large-scale production environments and complex operational setups that could
appear difficult for smaller or mid-sized converters to adopt.
That perception is beginning to shift, newer thermal lamination technologies are helping simplify the process, particularly for digital flexible packaging applications where shorter runs and rapid changeovers are essential. At ABG International, the ThermoLam system was developed specifically with these production realities and customers’ needs in mind. Compact footprints, simplified workflows, reduced waste and operational efficiency are becoming increasingly important factors for converters looking to enter the flexpack market in a practical and scalable way. At the same time, collaboration across the industry has become increasingly valuable. Flexible packaging production rarely depends on a single technology. Success often comes from multiple specialist systems working seamlessly together, which is why partnerships between technology providers are becoming more common.
Our collaboration with Galaxy PackTech reflects exactly this approach. By combining technologies through the ABG FlexPack range and the PouchJet solution, the goal is not to offer a single standalone product, but rather to support a broader pouch production ecosystem that includes pouch creation, finishing, and workflow integration. For converters, modularity matters. Very few businesses want to overhaul their production model overnight. Most are looking for ways to expand gradually into flexible packaging while continuing to support their existing label operations. The ability to
integrate pouching technologies alongside established digital print and finishing equipment creates a much more manageable pathway into the market.
Sustainability is also playing an increasingly important role in this evolution. Brands are under pressure to reduce waste, minimise inventory and improve manufacturing efficiency throughout the supply chain. Digital pouch production supports these objectives through shorter runs, reduced obsolescence, and more responsive manufacturing models. Flexible packaging formats can also reduce material usage compared with some rigid packaging alternatives, making them attractive across multiple industries.
Importantly, flexible packaging is not replacing labels. It is complementing them. Many converters are discovering that their existing customers are already seeking pouch solutions alongside traditional label applications. That creates a valuable opportunity to broaden service offerings, strengthen customer relationships, and access higher-value packaging applications through a single supplier partnership.
Ultimately, the movement from labels into digital pouching is not simply about diversification. It reflects a broader shift in how packaging production itself is evolving. Technologies are becoming more connected, workflows more accessible and barriers to entry significantly lower than they once were. For many converters, flexible packaging no longer feels like a separate industry. Increasingly, it feels like the natural next stage of digital print and finishing evolution.
www.convertermag.com
May/June 2026
51
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