Digital Printing
The digital revolution: Igniting the future of flexible packaging
Simon Buswell, sales and marketing director at Eco Flexibles
sustainability goals with water-based inks and reduced waste, producing packaging that is designed for circularity.
The digital revolution enhances our work with monopolymer and paper-based fi lms, creating recyclable, high-performance packaging. It allows for shorter runs, reducing warehousing needs and potential waste. The ability to make rapid design changes helps our brand customers to quickly adapt to new regulations or labelling requirements too.
O OVERCOMING BARRIERS
ver the years, the packaging industry has seen more than its fair share of market-changing revolutions, from the early mass production of tin cans to the development of Tetrapaks. It feels like every so often, a change comes that rewrites the packaging rulebook to some degree.
Today, we are witnessing another of these landmark shifts: the digital revolution in fl exible packaging. While not immediately visible to consumers, this behind-the-scenes transformation is redefi ning our approach to fl exible packaging design, production and sustainability.
As it rose to become one of the most popular packaging formats over the last couple of decades, fl exible packaging relied on fl exography and gravure printing. These methods, while eff ective and time-tested, came with limitations that do not always gel with the needs of today’s brand owners: high setup costs, long lead times and infl exibility for small runs. A lot of us will remember when a “quick turnaround” meant weeks, not days, and producing a small batch was fi nancially unfeasible. Recent technological leaps have thrust digital printing fi rmly into the spotlight, off ering a level of adaptability and effi ciency that is previously
unheard of in our industry. Whether you need 500 pouches for a product trial or 500,000 for a major campaign, digital printing is now rising to the challenge. Even more impressively, last-minute design tweaks or personalised packaging variations can be implemented almost instantaneously, without the need for new plates or lengthy setup times. This revolution is not just about quantity and speed. Digital printing quality now rivals traditional print methods in output quality, regularly surpassing them. I have seen clients unable to distinguish between digitally printed packs and fl exo-printed ones; that is the strongest testament to how far we have come.
SUSTAINABILITY IN THE DIGITAL AGE As sustainability shifts from niche topic to a central focus, the digital revolution aligns perfectly with this change. It is particularly crucial as brand owners navigate complex regulatory landscapes like Extended Producer Responsibility (EPR) and the EU’s Packaging and Packaging Waste Regulation (PPWR). At Eco Flexibles, our investment in two Fujifi lm Jet Press FP790 machines, the fi rst outside Japan, exemplifi es our commitment. These presses off er unparalleled fl exibility and quality while supporting
Contrary to expectations, the digital revolution has not diminished the human element in packaging design, it has enhanced it. I recall a recent project where we produced multiple designs in a single run for a snack food brand, each tailored to a specifi c audience segment. The brand manager’s reaction to the cohesive yet distinct designs was priceless. Revolutions are not always easy. It has taken a long time for digital printing technology to reach this point and there are still some myths to bust, typically based on where digital technology was a decade ago. Brand owners might express concerns about colour matching, production speed and costs when considering digital printing, but digital presses like our Fujifi lm Jet Press FP790 can match brand colours accurately, print at competitive speeds and off er cost-eff ective solutions for both short and long runs. The demand for this revolutionary technology has been unprecedented. Less than a year after our initial installation, we ordered a second press. We are seeing interest from diverse markets, like confectionery, snacks, protein and fresh produce, with runs ranging from 1,000m² to 20,000m².
THE FUTURE’S DIGITAL
As we look ahead, it is clear that the digital revolution will continue to reshape the future of sustainable fl exible packaging. At Eco Flexibles, we are not just embracing this future, we are driving the revolution forward. Our investments in cutting-edge technology demonstrate our commitment to supporting our customers today and tomorrow.
30
November 2024
www.convertermag.com
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