Sustainable Converting
Boosting sustainability efforts with single-pass flexo
ByLachlan Buirds, managing director, Edale I
factory fl oor, or worse, between sites. Every additional step means more forklift journeys, more packaging for semi-fi nished goods, and more energy spent running multiple machines. By contrast, single-pass fl exo integrates these stages into one continuous line. Cartons or labels emerge retail-ready at the end of the press, cutting down on handling, fl oor transport and intermediate storage. That not only frees up factory space but directly reduces Scope 3 emissions associated with internal logistics.
n the push towards more sustainability-led converting, technology choices are becoming just as important as material decisions. While a great deal of attention has rightly been paid to substrates, coatings and inks, the mechanics of how we manufacture cartons and labels are often overlooked.
Yet the production process itself represents a signifi cant share of a converter’s environmental impact. This is particularly the case when it comes to energy consumption, material waste and Scope 3 emissions monitoring. And it is here that single-pass fl exographic printing is proving itself to be more than just a production upgrade. By consolidating what were once multiple steps into one streamlined workfl ow, single-pass fl exo brings inherent sustainability benefi ts that help converters cut carbon at source, save waste, energy and costs.
LESS WORK IN PROGRESS, LESS MOVEMENT Traditional multi-stage carton and label workfl ows typically involve several machines: printing, varnishing, die-cutting, stripping, sometimes even offl ine embellishment. Each stage introduces new work-in-progress (WIP), new handling, and in many cases, movement across diff erent parts of the
LOWER ENERGY USE
Running one machine instead of three or four translates directly into energy savings. Motors, chillers, dryers and compressors all contribute to a site’s energy profi le, so consolidation matters. Advances in UV-LED curing, servo-driven registration and precision tension control have further reduced the energy burden of fl exo presses. Modern systems, like the Edale CartonLine, achieve off set-rivalling quality without the same heavy power draw. When multiplied across thousands of jobs annually, the reductions become signifi cant, helping converters not just meet sustainability pledges but also protect themselves against rising energy costs.
WASTE REDUCTION BY DESIGN Setup waste is another area where fl exo is proving itself to be a wise option. Automated inking, impression and registration systems mean presses can achieve sellable output in just a few metres of substrate, rather than hundreds. For converters working with expensive or specialist sustainable boards and fi lms, the ability to reduce waste at setup makes both environmental and commercial sense. Inline fi nishing also minimises waste by
eliminating additional handling stages where damage or loss can occur. With embellishment, varnishing, die-cutting and stripping all integrated, converters retain full quality control and reduce the likelihood of rejects later in the process.
SUPPORTING SCOPE 3 GOALS Regulatory and brand pressures around Scope 3 emissions are intensifying. From 2027, many converters will need to provide full emissions data across their supply chain. Here, the effi ciency of single-pass fl exo provides an advantage that goes beyond the factory gates.
Fewer machine steps mean fewer consumables, less auxiliary packaging and less transport between processes. Consolidated workfl ows also shorten lead times, enabling converters to align production more closely with demand, reducing overproduction and its associated carbon cost.
FUTURE-READY FLEXO
Importantly, none of these sustainability benefi ts come at the expense of quality or fl exibility. HD fl exo now truly delivers print results comparable to off set, with the added advantage of inline embellishment for premium applications. Substrate fl exibility is widening too, with presses able to run everything from lightweight fi lms to recycled boards, which enables converters to match sustainability commitments without compromising brand impact.
Sustainability in converting cannot be achieved by materials alone. Process effi ciency, energy use and supply chain movement are just as critical. Single-pass fl exo addresses all three, cutting carbon by design and helping converters prepare for the regulatory and commercial pressures of the years ahead.
24
October 2025
www.convertermag.com
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