Issue 9 Print and Packaging Innovation Asia

ASIAN PACKAGING EXCELLENCE

AWARDS: 2024

Issue 9 - 23

Print - Packaging INNOVATION

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Print Innovation Asia

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Publisher Paul Callaghan paul@printinnovationasia.com

Editorial Elizabeth Liew elizabeth@printinnovationasia.com

Packaging Sales Elizabeth Liew elizabeth@printinnovationasia.com

In Print and Packaging, more than You Think

I am sure you will agree with me that for anyone who listens to the word 'Sustainability', a very special kind of sympathetic emotion gets evoked, and we do get connected with all the positive aspects or meaning of this word, which is not anymore just a buzz word but has become a driving force of multiple economies including print and packaging.

From the perspective of the common man, the most general understanding of this magical word is ‘to preserve the natural resources.’ From the printing and packaging industries perspective, tremendous developments have been made, and over the past few years, the fraternity has succeeded in implementing multiple sustainable concepts by means of innovative materials, machinery solutions, and technical adaptations with a reduced use of natural and other resources.

As far as the origin of Sustainability is concerned, it’s not a new concept for humanity. Long back in 1713, It was Hanns Carl, who was the Head of the Royal Mining Office in Saxony, Germany came up with the idea of using a word with the objective of finding the details of a potential shortage of timber, which was the important resource of the time.

Hanns had proposed to harvest the wood only when replacement would be available by new growth. He used the German word ‘Nachhalten’ (sustained) to describe forestry practices. Later on, with the addition of another German word, ‘Entwicklung’, we got the term ‘Nachhaltige Entwicklung’ (sustainable development).

Fast forward to 2023, and climate change is the single biggest health threat humanity is facing. The impacts are already visible through air pollution,

disease, poor physical and mental health, extreme weather, increased hunger, and poor nutrition in various places, especially where people cannot grow agriculture or find foods.

Climate change refers to the change in the global climate, which is an interconnected system of sun, earth, and oceans, rain, wind, forests, deserts, and savannas, including everything we humans do. Scientists have found various compelling evidence of climate change, including greenhouse gas emissions, mainly atmospheric CO2 and global temperature, changes in sea level, the expanse of ice, the fossil record, and the distribution of species. This data shows a strong correlation between CO2 levels and global warming.

Experts say that if we are serious about stopping the inevitable disastrous effects of climate change on our planet earth, we must minimize the increase in global temperature (warming), which means an immediate and very significant reduction in global greenhouse gas emissions with at least a 43% reduction by 2030.

The million-dollar question is, "What can we do about rising temperatures? Well, there is no single or simple solution to this humongous task. According to OECD (Organization for Economic Co-operation and Development) guidelines, solutions can

By

Sustainability Matters

Kaunain Shahidi - Business & Technology Editor-Contributing, Packaging MEA

be found in finding possibilities in the removal of environmentally damaging subsidies, including fossil fuels, taxes on CO2 and methane gas emissions, collaborative innovation, and support for green technologies. Considering the seriousness of the issue of climate change and its impact, other than the 17SDGs (Sustainable Development Goals) of UNDP (United Nations

Development Programme), various international organizations at different levels have initiated multiple concepts, including Net Zero, Carbon Neutrality, and ESG. All these are directly or indirectly related to the larger scope of sustainability. But more needs to be done and all regions of the world need to contribute

As far as MENA (Middle East & North Africa) is concerned, from a climate hazards perspective, the region is considered one of the most sensitive geographical areas and is facing the headwinds of climate-related challenges, including extremely high temperatures, limited agricultural lands, and water scarcity. On top of that, its population is growing fast, while the GCC states generate among the highest per capita levels of carbon emissions in the world and export large quantities of fossil fuels.

In spite of all the challenges involved in controlling the effects of climate change, the major economies of MENA have pledged to reach net-zero emissions by at least 2060. Various initiatives for controlling emissions, reducing flaring of natural gas, increasing energy efficiency, etc. are being considered with all seriousness, and many other steps are being taken through innovative solutions and new technologies with an emphasis on valorising carbon while focusing on the circular economy.

The UAE is developing a major CCS (carbon capture and storage) project, which is the first in a planned series of similar projects in the country. It is expected that the 2023 UN Climate Change Conference, COP28 (Conference of Parties), which is hosted by the UAE in December this year, will amplify climate action, and serve as a platform for innovative solutions to further drive transformations towards sustainability in the region.

Various local brand owners and packaging manufacturers have already started multiple initiatives to curb the challenges with the focus of meeting the net zero targets, which are well published in their sustainability reports. As reported, Tetra Pak, one of the leading suppliers of packaging materials in the region, reached 80 percent renewable electricity in their operations by doubling solar photovoltaic capacity and reducing 36% of GHG emissions as compared to the 2019 baseline.

As per the latest Sustainability Report of Almarai, the leading food and beverage company in MENA, the company has the target of preventing 9,000 metric tons of waste by 2025, and they have already achieved a total of 6456 metric tons to date. In 2022, the company removed 713 metric tons of plastic and 74 annualized metric tons of paper weight. As part of the packaging design process, Almarai makes a conscious decision in the initial phases to address whether packaging is necessary, and they also consider using recycled materials to encourage circular economy thinking in packaging designs.

In the midst of various sustainability programs, initiatives, and agendas, experts have started asking another million-dollar question: ‘Is the concept of Sustainability enough to manage the challenges the world is facing?’. The discussion is happening that instead of doing less damage to the environment, what else is possible to explore and find out to manage and protect the health of ecological systems through a design thinking approach?

Most of the practices we are doing under the name of Sustainability are mostly focused on attempting to reduce the damage caused by the overexploitation and use of natural resources. The question we all need to ask is, is that enough? or something more to be done?

Experts say that the climate crisis is not a scientific problem that can be solved only by technology. It is a problem created by humans by not aligning with nature in terms of our lifestyle designs. Technologies and systems can play a limited role; we need to have a paradigm shift in our attitude, our lifestyles, and our ways of interaction with nature by bringing elements of respect and compassion for nature and its creation. We need to see beyond seeing and look beyond sustainability and start thinking about redesigning our systems.

Printing is an energy-intensive industry, and relying on wood as one of the raw materials has a unique set of problems, including high water consumption, solid waste production, and air pollution, also emotions of the consumers often express about deforestation. I do not comment on plastic which has its own reputation. Collectively, we all need to look into our system and its design so that we can improve the way we operate in a more sustainable manner, considering the holistic view of all the stakeholders’ involved in the print and packaging value chain.

Here comes the importance and role of drupa, which offers a great opportunity for the printing industry fraternity to come together on a single platform,

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discuss and exchange thoughts and ideas, and evaluate the current practices to redesign the systems for a better future with the focus on minimizing the impact of any action on the environment while considering employment, income, society, and the local economy.

It is expected that drupa 2024 will be showcasing various innovative solutions and the latest trends in sustainable printing methodologies and practices and their drivers, legislation, metrics for sustainable printing and the environment regulations, carbon reduction systems, hazardous waste regulations, integrated pollution prevention and control, and their latest processes and systems to operate in a sustainable manner, as sustainable printing is not just about making environmental claims or achieving accreditations; it is certainly much more than that.

Thinking holistically, since each company, industry, and region face unique challenges, when developing an action plan for sustainability, it’s important to focus on cultures, mindsets, and a futuristic approach with complete seriousness. Well thought and integrated collaboration with the use of the latest transformative technologies is very much required.

Since sustainability has a strong connotation of future matters, it is equally important for all decisionmakers to look into the current design of our education system, as providing students with the knowledge and skills to embrace sustainable habits is the very first step towards building

a greener future. If required, relevant and regional climate education curriculum must be developed. Younger generations must have a comprehensive understanding of what climate change is, its challenges, and the various roles to be played in protecting the environment and mitigating all the associated risks. They also must be equipped to work in the green sector, as this is urgent to transform innovative thoughts and ideas into a new reality.

The UAE has already taken a positive step in this direction, and recently, the Ministry of Education signed the Green Education Partnership with UNESCO and UNICEF to spearhead a worldclass climate education program across schools and universities in the country.

When we reflect our concern towards Sustainability as a professional, it is equally important to look within as an individual as well, we shall not forget that we all have certain responsibilities towards our planet. Maybe we don’t know but based on our lifestyle each and every one of us has our own unique carbon footprint. Through our choices what we make from morning till we hit the bed, we make an impact on our environment. It’s time for self-introspection as well. We need to check the place where we live, our food choices, the number of gadgets, transportation, shopping habits, travels, vacations, and many more things that are very subjective but worth pondering.

Well, if you give a pause and look around the whole ecosystem of nature, the wonder of design comes to mind, as design is a core concept that is responsible for curating the world we

live in, and it is done so beautifully and perfectly by the universe. But if we look at what we, the humans, have done through the designs of our lifestyles and systems, we are certainly not reciprocating as expected to protect and preserve the wonderful creation of nature; we need to redesign our lifestyles and the systems that we have waved and got ourselves trapped in.

It is estimated that a short email from one laptop to another emits 0.3g of CO2e (carbon dioxide equivalent). Hmmmm, can we think up to this level and make some conscious choices?

Certainly, sustainability matters more than what we think, and its high time we think more deeply and take quick action; we are running out of time. Planet Earth, the only one, needs our help and commitment to deploy changes in real.

About the author

Mr. Kaunain Shahidi is a strategic thinker with over 20 years’ experience in packaging development and procurement. He has a comprehensive understanding, knowledge, and practical exposure to a broad printing and packaging spectrum, with expertise in innovations, trends, and technologies.

He regularly participates in various seminars and conferences to share his ideas on printing, packaging, and supply chain, which he considers fascinating and dynamic subjects with an incredible and complicated future but great potential for brands and business growth in the digitalized economy of the 21st century.

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UV cross-linked adhesives Facts and applications

The first patents describing the crosslinking of hot-melt adhesives with the aid of UV radiation were published in the 1980s – by which time solventbased adhesives, aqueous dispersion adhesives and rubber-based hot-melt adhesives were already well established on the market.

Three-dimensional

The aim here was to achieve different adhesive properties on the basis of a single adhesive by varying the UV dose for cross-linking. This new technology was intended to gradually replace solvent-based adhesives.

But what exactly is UV cross-linking?

In chemistry, cross-linking refers to the process by which macromolecules join together to form three-dimensional networks. This reaction alters the physical properties of the substance concerned, typically causing it to become more rigid, harder, less soluble and more thermally stable.

UV cross-linkable adhesives are adhesives that cure when they are irradiated with UV light. They consist of polyacrylates containing benzophenones which polymerize under UV light. This photochemical process sees double bonds broken down within the photoinitiator, producing radicals which immediately react with acrylate molecules. The resulting molecules have longer chains and form the three-dimensional network outlined above. This crosslinking takes place immediately after the adhesive is applied as a coating at a maximum of 140°C.

UVC

The process for artimelt products uses UVC radiation in the range of 250–260 nm. UVC radiation is distinguished from UVA and UVB waves by its shorter wavelengths and the fact that it does not occur in natural sunlight. That is why adhesives cross-linked using this type of radiation are resistant to aging

and light. The UVC radiation is emitted by medium-pressure mercury lamps with a typical output power of 120–240 W/cm, the kind used in the printing ink industry. Due to the radical reaction, the cross-linking process is extremely fast. The selected cross-linking dose controls the degree of cross-linking. This in turn determines the adhesionto-cohesion ratio and, therefore, the adhesive properties of the adhesive.

However, the short-wave UVC radiation can only penetrate an adhesive layer down to a certain depth. The deeper the penetration, the more radiation is absorbed until there is none left, and thus no more cross-linking. Consequently, the layer thickness of UV hot melts is limited.

Constant dose

It is important that the UV dose remain constant throughout the entire coating process, which requires constant checking. If the dose decreases (e.g. because the UV lamp is old or dusty), the adhesive will exhibit a higher level of adhesion but a lower shear resistance. To keep the adhesion properties exactly the same in such cases, either the lamp output power has to be increased or the belt speed reduced. Modern all-in-

Although UV cross-linkable adhesives have been around for 30 years, they still remain a niche technology within the world of adhesives.

adhesives -

one lamp systems feature measurement and control technology that measures both the UVC output and the dose, and automatically corrects itself to maintain the set value. Measuring instruments such as the UVPowerMAP, Power Puck or UVpad radiometers can be used for these checks.

Measuring the UV dose

The cross-linking reaction requires UVC light in the short wavelength range of 250–260 nm. The crosslinking dose controls the adhesion-tocohesion ratio, thereby determining the adhesive properties. The dose itself is determined by the lamp output power and the system speed.

The UV dose is measured using a UV dosimeter that is capable of detecting the UVC radiation that is crucial for cross-linking. Modern measuring instruments are able to detect UVA, UVB, UVC and UVV radiation along with the associated dose. Modern all-in-one lamp systems now feature measurement and control technology that constantly measures both the UVC output and the dose, and is able to make corrections automatically in line with the set value.

Measurements are taken in different bandwidths (spectral ranges) depending on the type of measuring instrument.

The wider the bandwidth, the higher the energy absorption. There are some measuring instruments that work exclusively in the 250–260 nm range, such as the well-known Power Puck or PowerMAP radiometers. Other instruments measure the values within a bandwidth of 200–280 nm and produce measurement results that are higher by a factor of seven. Here at artimelt, we use instruments of this kind at our laboratory to confirm the values for our technical data sheets, for example.

The calculation example of graphic 3 shows how the different bandwidths influence the values.

Diverse applications

The UV technology supports a wide array of applications, including adhesion levels ranging from ultra removable through to highly adhesive, which can be adjusted by varying the base polymer formulation. UV crosslinked hot-melts can also be used in damp environments. They are the preferred adhesive agent for labels at chemical companies and for resealable packaging in the case of wet wipes, which can contain alcohols, oils and emulsifiers. None of these substances is capable of interfering with the resealable properties.

Other applications include wash-off bottle labels. To recycle glass bottles,

the labels must detach from the bottle without leaving residue. The label must also be easy to remove from PET bottles, before they are shredded or when they are subsequently placed in a solvent bath, for instance.

Typical adhesive tapes are not supposed to yellow and require a high degree of adhesion on various surfaces as well as high levels of shear and temperature resistance.

One special application is the highly adhesive labels containing important information – for instance in chemical plants or on car batteries. Here, the labels are exposed to high temperatures and chemical influences inside the engine compartment, including battery acid, engine oil and gasoline.

Contact with human skin and food

UV cross-linked hot-melt adhesives can be formulated so that they are approved for direct contact with the skin. They do not usually cause skin irritation. Adhesive plasters that incorporate this technology are more breathable, so they can be worn for longer than conventional products without causing the skin to wrinkle.

Radiation-cured hot-melts also meet the stringent standards for adhesives that come into direct or indirect contact with food. That is why labels printed in supermarkets are allowed to be stuck directly onto fruit and vegetables, for example. In addition, the technology also makes it possible to create resealable packaging for cookies, pasta and cheese. In particular, labels coated with artimeltfood hot-melt adhesive can be safely applied to wet or dry non-

greasy foods – a property that external laboratories have confirmed through migration studies.

100% systems

Unlike dispersion and solvent-based adhesives, UV cross-linked adhesives belong to the category of hot-melt products, and are referred to as “100% systems”. This means that nothing but adhesive is applied to a carrier; in other words, there is nothing that needs to dry, evaporate or be recovered. The resulting reduction in materials and weight means significant savings on transport costs. And there is no need for dryer units or hot air (which consume energy) let alone a solvent recovery system.

Production can also be accelerated considerably, particularly in the case of heavier coating, as there is no need to wait for a drying process.

The advantages at a glance UV cross-linkable adhesives offer several advantages over conventional adhesives that cure through exposure to heat or moisture. These include:

1. UV cross-linkable adhesives cure within a few seconds, making them ideal for fast coating speeds.

2. Curing under UV light ensures high strength and high adhesive force.

3. There is no drying process, so the plant does not require a drying installation.

4. UV cross-linked hot-melts consist of thermoplastic polymers that cure when irradiated, making them resistant to a large number of solvents and aggressive chemicals.

5. They have a high level of

temperature resistance: up to 200°C with short-term exposure.

6. The high UV resistance also enables outdoor applications.

7. They are approved for direct contact with food.

8. They support applications that involve contact with human skin.

9. There is no subsequent cross-linking as cross-linking only occurs in the UVC range.

Should I switch to UV cross-linked adhesives?

It is relatively easy to switch from rubber-based hot-melts to UV crosslinked alternatives; there are just a few points to bear in mind. Anyone who processes rubber-based hot-melt adhesives will probably already have most of the equipment they need for radiation cross-linked products: a drum melter, buffer tank and applicator. In this case, the only upgrade required is UV lamps with light emissions within the UVC range. In contrast to the application head (which can be rinsed relatively easily), drum melters and hoses are extremely difficult to clean. Therefore, it is a good idea to have separate equipment for each technology; this also applies to the buffer tank.

At the detail level, the perfect UV investment ultimately depends on the breadth of the system, the speed at which it operates, the coating weight, the amount of space available for installing one or more UV lamps, and the measurement and control technology that will be used. So it certainly makes sense to seek good advice!

Note: if you are intending to use the same system for both technologies, make sure to schedule in the laborious cleaning process involved in each switch. Allowing radiation-curing hot-melt adhesives to mix with rubber-based products creates a risk of unwanted gelling, which – under certain circumstances – can lower the quality. artimelt offers cleaners for this process.

Investment in Jet Press 750s drives business growth

The Jet Press 750S will help the German packaging company to win more short run work and offer fast, high quality samples to its customers

Established five generations ago by the Egger family, EGGER Druck & Medien has more than 150 years of experience producing a variety of high quality printed products, including a range of tailor-made folding carton boxes and other packaging. The company specialises in high value solutions for high-end products across multiple industries, including cosmetics, pharmaceutical, lifestyle, and beverage. The premium print and packaging company has 62 employees.

The Jet Press 750S, installed in April 2023, has revolutionised the company’s business approach, enabling them to target short run work for the first time, while also providing customers and prospects with quick and cost-effective samples.

“The Jet Press 750S has marked a significant strategic shift for us,

positioning EGGER among the quickest and most competitively priced providers of samples for tailor-made packaging solutions,” says Xaver Egger, Managing Director of EGGER. “The decision to invest in the Jet Press 750S was influenced by its exceptional printing quality, which outperformed rival systems. This investment has not only allowed us to better meet the demands of our customers but has also propelled our company’s growth.”

EGGER is using the Jet Press to print to folding carton board, with a minimum run of just one, and typically using standard materials from their online shop. Being able to print extremely low quantities profitably, and at extremely high levels of quality, has enabled the company to target small volume orders for high end customers – while the ability to produce high quality samples has helped them to win new work.

In an ever-evolving printing industry, EGGER acknowledges the challenges they face. Xaver Egger explains, “The current print landscape is characterised by a growing number of price-sensitive customers, resulting in an uncertain economic outlook. We have observed a shift in demand with reduced run lengths and expanding product portfolios. However, with the Jet Press 750S investment, we have gained a competitive advantage through the ability to offer cost-effective and rapid prototypes.”

Mr Egger continues, “At EGGER we are thrilled with this investment, and we are satisfied with the assistance that Fujifilm has provided us with. We would highly recommend the Jet Press 750S as it has not only broadened our business offering, but also elevated the quality of our printed results, enhancing our products and services.”

Taro Aoki, Head of Digital Press Solutions, Fujifilm Europe comments:

“The Fujifilm Jet Press 750S has been setting the standard in commercial print and folding carton packaging for many years now. We’re delighted to see another widely respected packaging company recognise its potential to transform their business. We look forward to a long and successful partnership with them.”

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BOBST’s wide-web flexo technology materials: compendium of a story

The process and equipment solutions developed are at the forefront of technological development and innovation and are the sum of a legacy which covered all the historic steps of the technology’s development its very early days.

Looking at long-established packaging printing methods, flexography can rightfully claim top spot for the fastest technological evolution in the relatively short period of time since the early 1990s. This is especially true for flexography in the flexible packaging printing industry, where the historical challenges related to the quality and consistency of printing have been compounded of late by the issues related to plastic packaging sustainability and circular economy.

A short foray into history

“I think it is important to highlight where today’s CI flexo technology by

BOBST comes from in order to understand the foundations of the strength and power behind the solutions we develop for our flexible packaging flexo printing customers”, explained Frank Jurczyk, Head of Product Marketing Management, CI Flexo, Bobst Bielefeld.

Historically, the development of CI drum configuration started after WWII. Demand really took off in the 1950s, following the availability of cellophane and new extensible materials such as polyethylene and polyamide films that started to replace traditional paper packaging in several product segments. A trend that went hand in hand with the growth of supermarkets and shopping centers.

CI flexo presses technology was pioneered mainly by European press manufacturers, including Officine Padane,

Schiavi and Fischer & Krecke whose legacy of know-how and experience in printing and converting equipment for flexible materials was added over the years to BOBST’s own which goes back to 1890.

At the time and for some decades after, CI flexo presses offered some advantages to printers in terms of the process capability to print on a wider range of substrates - extensible, porous, and non-porous – the faster availability and lower cost of the plates and faster job changes. However, for a period of time flexography could not match the print quality of gravure, and its repeatability. As technology improved, flexography was able to produce high quality print on short runs.

How has BOBST won the challenges of the making flexography qualitative, consistent, and repeatable?

BOBST’s flexo technology addresses the packaging industry in each of the three industries corrugated board, and flexible packaging.

The VISION CI from the current range of BOBST CI flexo printing presses

technology for flexible story 75 years in the making

industries it serves, folding carton,

Let’s fast forward to BOBST today’s flexography, just mentioning in passing some of the milestones to its credits, from the launch of the world’s first CNC-controlled flexo printing press in 1983, through to the development of the completely servo-driven flexo press and the smartGPS fully automatic registration and impression setting carried out offline at plate mounting in 2008.

From the point of view of the actual presses, the focus of R&D was targeted to doing away the weakness of the process, namely the lack of consistency and repeatability.

“We started by addressing the process weaknesses and were able to devise effective solutions relating to press vibration, ink consistency in dosing and metering, drying at high speed with both solvent- and water-based inks and the register tenure that have been applied to our current range of flexo presses”, said Frank Jurczyk “The ability to overcome the process pain points that hindered the quality development of flexo, has enabled further advances to tackle for instance the issue of color consistency.”

The stability of the printing process is essential for the qualitative results of the Extended Color Gamut technology. BOBST’s oneECG is a wellproven seamless process developed for CI flexo printing with industry leading partners.

The quality and efficiency evolution of flexography is by no means only due the printing press: it is the sum of the major advancements along the value chain from flexo plate and pre-press technology, with the focus on automation and connectivity playing a key role in providing the process with unprec-

edented quality, efficiency, and repeatability.

Why converters choose BOBST for CI flexo and flexible packaging

“Wide-web flexible packaging printing is dominated by CI drum flexo presses. Out of our legacy of 75 years in the flexo industry, almost 60 have been dedicated to the advancement of CI flexo. This is an important factor that vouches for the quality of our technology,” commented Frank Jurczyk “This is compounded by two more factors where collaborative R&D and BOBST being an end-to-end printing and converting equipment supplier are major pluses for flexible packaging flexo printers and converters: sustainability and integrated workflow.”

BOBST’s oneBARRIER family of recycle-ready ultra-high and high-barrier duplex or triplex substrates is well-established with solutions that are commercially available today. They address polymer-based mono-material substrates with PrimeCycle, and full fibre/ paper-based mono-material structures with FibreCycle. These new substrates are tested from the substrate produc-

tion through to the finished reels. This ensures that BOBST CI flexo technology is perfected to handle qualitatively and efficiently new recycle-ready substrates and the new consumable formulations that are required for their production.

Of course, the quality and efficiency of flexographic printing is at its best when all the steps in the process are connected and integrated so that production is a seamless process. To this end BOBST offers One complete solution, which includes includes dedicated workflows that connect all steps, from production file and pre-press through to the reels of printed or laminated substrates.

“BOBST is the only supplier in the industry that can supply all printing and converting technologies for production of flexible packaging. This enables us to deliver converter what they seek, namely dedicated workflows for their flexible packaging production which are the right combination of technological advancement built on a legacy that encompasses 75 years of flexo knowledge and experience,” concluded Frank Jurczyk.

One of the very first CI flexo printing presses for flexible packaging developed by Fischer & Krecke as of 1971

UV Choice Printing brings “remarkable” savings and benefits

UV Choice Printing, available through KODAK FLEXCEL NX Print

Suite for Narrow Web and enabled by the latest advanced plate surface patterning technology from Miraclon, is delivering significant time, ink and substrate waste savings for leading Spanish flexo tag and label manufacturer, Adhesivos Orcajada.

Over the past twelve months, the company monitored the performance of UV Choice Printing on their seven Omet UV presses that produce around 65% of all its flexo printed tag and label jobs. Documented savings include:

• Reduced ink consumption by over 20%

• Faster job changeover & set-up times of 15-20%

• Significant substrate savings thanks to faster start-ups

“The results are remarkable,” said Pedro Orcajada Montalban, Owner of Adhesivos Orcajada. “The impact on job changeover and set-up times are especially positive, at 15-20% faster. All this translates into significantly reduced substrate wastage and over 20% in ink consumption savings, which saves money and makes the process more sustainable. We’ve also reduced prepress times with much faster platemaking.

“On press, KODAK FLEXCEL NX Plates also perform consistently, throughout the run and from jobto-job. The greater latitude on press means reduced operator interventions and fewer press stops for cleaning or color adjustments. Add these benefits together with UV Choice Printing has proved a highly beneficial investment.”

Growing with FLEXCEL NX Technology

Adhesivos Orcajada is a longtime

user of KODAK FLEXCEL NX Technology from Miraclon. “When we decided to upgrade our platemaking technology from analogue to digital more than 10 years ago, we tested and ultimately invested in a FLEXCEL NX System based on our first impressions and the overwhelming positive feedback we received from industry colleagues,” recalls Pedro.

“From day one, we enjoyed a step change in stability on press, resulting

in less dot gain, better highlights and consistent reproduction. Our customers were impressed with the positive change, but even more so our production team, who welcomed the simpler, less stressful, and more consistent press production process. Since then, we’ve established a close consultative relationship with Miraclon, so it was another collaborative approach when Miraclon selected us as a beta site for UV Choice Printing.”

UV Choice Printing, enabled by advanced plate surface patterning technology and accessed through FLEXCEL NX Print Suite for Narrow Web, is specifically designed to deliver better performance and stability for label and other UV flexo printed narrow web applications across a range of substrates. It optimizes UV ink transfer and increases ink density by up to 15%, minimizes on-press troubleshooting of quality issues, and delivers better reproduction of solids, fine lines, crisp barcodes and text at lower ink volumes. Other benefits are faster press set-up, reduced substrate wastage, and faster plate imaging times.

“Immediate impact” of UV Choice Printing

José Sanchez Gallego, Design & Prepress Manager for Adhesivos

Orcajada, says UV Choice Printing made “an immediate impact — literally from the first job. With any new way of working, it’s vital to have the support of the production team, but in this case we decided to deliver the first set of plates to the press without any advance warning. That way, we believed we’d get an objective, unprejudiced reaction from the press crew. Their response was overwhelmingly positive — they

saw the efficiency and consistency benefits at once. It was the same with customers, that complimented us on the clear improvement in quality.

“UV Choice Printing is delivering onpress benefits that makes a really big difference for us in terms of efficiency, ink and substrate savings, and print quality,” continues José. “In particular, ink laydown is much improved. We achieve 100% uniform coverage in both solids and shadows without impacting midtones and highlights, which we no longer have to sacrifice to achieve both solid colors and a wide tonal range.

“As a rule, UV printed jobs are of higher quality and mostly on coated substrates. Because UV Choice Printing eliminates many of the difficult-to-control variables, press set-up is much simpler and more streamlined, and we get to color much faster than before. Without UV Choice Printing, for example, anilox selection could be complicated on certain jobs and changes more frequent as operators searched for the ideal anilox/ink combination. That no longer happens, as we now utilize UV Choice Printing for 100% of UV printed jobs.”

Up to 50% saving in press set-up times

As part of its investment in Print Suite for Narrow Web to utilize UV Choice Printing, Adhesivos Orcajada gained access to PureFlexo™ Printing for water-based ink applications, which “is especially beneficial when we’re producing a lot of solids.”

José says that working in tandem, the two solutions have yielded further significant savings when UV jobs have to be rerouted to water-based

production, and vice versa. “This happens occasionally for scheduling reasons, and it used to be a headache because of the prepress adjustments involved — modifying the TIFF and re-RIPing, for example. Now, despite working with different patterns, in most cases modifications are unnecessary, and we can consistently set up the new job being confident the results will be predictable. As a result, we’re saving around 50% in job set-up time — a huge difference.”

José adds that even when they don’t need to switch between presses for a specific job, the production team has reported a 15-20% reduction in press set-up times.

Continued benefits

UV Choice Printing is also enabling Adhesivos Orcajada to grow the business and take on additional work. “The addition of UV Choice Printing further allows us to shift certain jobs from digital printing to flexo as it enables us to produce stable, highquality prints at profitable speeds while enjoying measurable ink and substrate savings. Being able to utilize flexo for a wider range of jobs is especially beneficial when we’re dealing with highly porous, textured substrates.”

Pedro concludes: “UV Choice Printing with its widely versatile advanced plate surface patterning, together with the Miraclon team behind it, has completely changed my perception on the quality and efficiency that can be achieved in narrow web flexo printing. I thought we were doing just fine before, but now I know that with it, we’re doing just so much better.”

CTP – Why now might be the time to invest in new equipment

Prepress and platemaking serve to keep the pressroom continuously supplied with printing plates, so that the presses can be set up smoothly ready for reliable, high-quality printing. Computer-to-plate (CTP) has been firmly established as a proven technology, but times have changed in the printing business.

As run lengths continue to decline, there is an increasing trend towards production methods that enable more automation, produce less waste, shorten job turnaround times and bring greater efficiency as well as cost savings. In the case of offset presses, for example, this has led to the development of solutions for autonomous or fully automated printing.

The presses handle print jobs from start to finish without any operator intervention. The automation of complex production processes is also a welcome opportunity to alleviate the growing shortage of skilled labor. In addition, the trend towards greater sustainability and more environmentally

friendly practices in printing, which has already been evident for a number of years, has intensified.

Times have changed – and so have the requirements for CTP

As a result of these developments, the requirements for offset platemaking

have also changed. The question for print shops is whether their existing CTP technology still meets today's requirements or whether they should consider making a new investment that could offer significant gains in productivity.

Purchasing a latest-generation CTP solution is an effective step for printers seeking to future-proof their prepress operations. And that's not all: modern platesetters provide significantly higher plate throughput than models that are getting on in years. Increased throughput is an advantage because as print runs become shorter, more plates

are needed in less time. To name just one example, the KODAK MAGNUS Q800 Platesetter with the T-speed Plus Option images up to 84 plates per hour and is the world's fastest CTP system in the B1/8-page size category.

Consequently, the acquisition of a stateof-the-art, highly productive platesetter represents a great chance to replace two or even more older CTP systems and gain far greater efficiencies. Prepress operations can be streamlined this way while reducing maintenance and saving space.

Platemaking automation at the cutting edge

As printing gets more and more automated, it's only logical that platemaking, too, should follow suit. Advanced CTP automation eliminates bottlenecks in finding qualified staff thereby cutting labor costs. Kodak has a whole range of options available for fully automatic plate loading and unloading in its portfolio for the MAGNUS, TRENDSETTER and ACHIEVE Platesetters. Printers can choose whatever automation solution is best tailored to their individual needs. For instance, Kodak offers automation solutions such as Single Cassette Unit (SCU), Multi-Cassette Unit (MCU), Single Pallet Loader (SPL), and MultiPallet Loader (MPL) for the MAGNUS Q800 Platesetter. The MPL for the MAGNUS Q800 holds up to 3,200 plates in up to four different sizes, enabling plate imaging without human intervention over very long periods of time.

Automation can be additionally supported with the KODAK Mobile CTP Control App, which allows printers to control and monitor up to 10 KODAK platesetters remotely on their smartphone or tablet. It shows whether the CTP device is running or stopped for any reason, plus detailed information such as current job, jobs in the queue, active plate cassette

count, environmental conditions, event history, and more.

If you want sustainability, modern CTP technology is a must

Of course, platemaking today has taken into account that sustainability issues have taken on a new urgency in the printing industry. When Kodak's state-of-the-art, high-performance platesetters are employed to image KODAK SONORA Process Free plates, this marks a major step forward for print shops on the way to more sustainability and a lower environmental impact. SONORA Plates are simply imaged in a fully automated process and can then be taken straight to the press which helps reduce turnaround times.

The switch from wet processed plates to KODAK SONORA Process Free Plates completely eliminates electricity, water, developer, replenisher and gumming solution required for traditional plate processing. Since there isn't any chemistry used, and no plate processor in need of cleaning and maintenance, there are also no waste chemicals or contaminated residual liquids to be disposed of.

By opting for a latest-generation KODAK CTP solution, printers can leave an even smaller carbon footprint with their platemaking operations –and in doing so bring down the total cost of ownership. Kodak's newest platesetters use far less energy than other, older models. Thanks to a whole

series of technical refinements, some current KODAK CTP systems have over 90% lower electricity consumption compared to similar equipment from competitors.

It should not be forgotten that replacing aging CTP systems with new technology ensures there are no unplanned platemaking interruptions, press stops and service engineer calls due to platesetter malfunctions. What's more, cutting-edge platesetters from KODAK offer significantly improved serviceability in comparison with previous system generations.

A wealth of comprehensive options – all from a single source

There are plenty of reasons for printers to turn to new, more productive CTP technology. It's helpful to know in this context that Kodak is the only company in the world that develops, manufactures, sells and services complete CTP solutions: platesetters and related automation solutions, plates and innovative workflow software platforms

The upshot is that printers of any size and specialization can get a complete, integrated solution from a single source. That's why they can be certain the various solution components are precisely matched, so that maximum reliability and performance are guaranteed in daily use.

Touching the future – the enduring qualities of paper

significant reversal, up from 35% two years earlier. Even functional content such as personal health information, shows a significant increase, up to 39% from 29%. (Source: Two SidesEuropean Consumer Preference for Printed Materials Has Recovered PostPandemic)

Clearly, paper works thanks to its various unique attributes, and because we have a very different relationship with it.

Sadly, we will never know what Groucho would have made of the digital age and social media. But we can speculate that he would be encouraged by the resilience - and indeed recovery - of the printed word.

Recent years clearly posed formidable challenges for the paper industry. During the pandemic, there was a widespread withdrawal of printed communications - people read more on digital devices, across all categories of communications, newspapers, magazines, books, catalogues, bills and statements, tax statements and personal health.

However, post-pandemic, there is clear and consistent evidence that in an age where people are offered a seemingly limitless choice of digital mediums, there is an enduring desire for print –and in some cases, such as magazines and books, that preference is flipping back to a majority.

The results of the huge bi-annual Trend Tracker by Two Sides (polling 10,000 consumers in 16 countries) are striking. It revealed that a majority of European consumers prefer to read printed books (65%.) and printed magazines (51%). The magazine preference is a

This is supported by psychological studies on learning, that show we retain more when we read the printed word versus a digital device. (Source: TheMantic Education - Digital vs. Print Reading: Which One's Better)

While digital reading undoubtedly has its merits, print offers a distinctive cognitive advantage. The tactile and spatial aspects of engaging with printed materials foster a deeper connection with the content, leading to enhanced comprehension and memory retention. It is also suggested that we are less distracted when reading the printed word, versus on a device, so we simply digest more.

But does that impact extend into other arenas, such as marketing and direct mail?

Evidence suggests, yes. According to sources like JICMAIL, direct mail enjoys high levels of attention, capturing audiences in a way that digital communication often struggles to achieve. Trust in the tactile and tangible nature of mail holds a distinctive advantage over its digital counterpart, email.

A study by automation specialist Quadient found that 62% of consumers in the UK are more likely

to open a physical letter than an email. (Source: Two Sides - Mail more trusted than email). Why? The theory is that we experience a series of sensory inputs when hold a letter or a document - the feel of the paper, the texture of the envelope, the weight of the package. This sensory engagement fosters a sense of presence and connection that digital communication often lacks. It's a tangible reminder to us that a real effort was made to convey the message, while we increasingly filter out endless email spam.

Paper is carving out its own space in the evolving media landscape, with brands and publishers innovating fiercely across platforms to connect to customers and readers in a meaningful and tangible way.

The unescapable truth is that paper is real and unique. It carries a sense of authenticity that transcends its material form. The historical significance, the sentiment it conveys, and the role it plays in our daily lives for communication, education, and inspiration are unmatched. Sourced sustainably, recyclable and renewed by nature, paper connects us to our roots, reminding us of the tangible and tactile beauty that exists, beyond screens and devices.

As we are given an endless choice of mediums, it emerges that paper is not simply a material, but much more. It occupies a much deeper connection and, like Groucho perhaps predicted, cannot simply be replaced with a screen, if we want to learn, grow and share.

“I find television very educating. Every time somebody turns on the set, I go into the other room and read a book.” Groucho Marx

By Marcus Kuhr, Key Account Director, UPM Communication Papers

XSYS celebrates 70 years of the Shanghai Publishing and Printing College

As a long-term strategic partner, XSYS will join in the 70th anniversary celebrations of the Shanghai Publishing and Printing College on 15 October 2023. The renowned college, which is located within the University of Shanghai for Science and Technology, is home to XSYS’ Asia-Pacific Technology Center.

XSYS, a global leader in flexographic platemaking and printing solutions, is pleased to announce its active participation in the 70th anniversary celebrations of the Shanghai Publishing and Printing College (SPPC). Known for its remarkable achievements in education, the SPPC was founded in 1953 as the first higher educational institution dedicated to the publishing and printing industry in China.

“XSYS is very proud to support the Shanghai Publishing and Printing College and we wish to congratulate the college on 70 years of outstanding contribution to education and innovation. The SPPC has played a pivotal role in shaping the printing and packaging sectors in China and XSYS is honored to have been a part of its remarkable journey,” declared QiHongMagenta Zheng, General Manager, XSYS China.

One of the program highlights of the celebration day on 15 October is a seminar entitled ‘Integration of Industry and Education on Green and Digital Printing under Carbon Peaking and Carbon Neutrality Strategy.’ As part of this topical presentation on sustainability, Florian Hölzle, XSYS Product Manager for the nyloflex® and nylosolv® portfolios, will share valuable insights into the key trends that are driving market developments and technological innovation in flexographic platemaking and printing. Commenting on the significance of this seminar, Mr. Hölzle said, “At XSYS, we are dedicated to advancing sustainable solutions for the printing

and packaging industry. It is an honor to be a part of the SPPC’s 70th anniversary celebrations and contribute to the discussion on environmentally conscious practices that will shape the industry’s future.”

Additionally, the event will include two press conferences unveiling critical industry reports. The first conference will introduce the ‘2023 China Flexographic Printing Development Report’ offering an in-depth analysis of the current state and future prospects of flexographic printing in China. The second conference will present the ‘2023 Report on the Development of Green Packaging Industry in the Yangtze River Delta,’ shedding light on the region’s efforts to promote sustainable packaging solutions.

For over a decade, XSYS and the SPPC have collaborated to promote the cultivation of professional talent

in packaging and flexographic printing technology. This close partnership culminated in March 2019 with the grand opening of the Asia-Pacific Technology Center (ATC) as a location for R&D, manufacturing, training, and education. XSYS made a substantial investment of €2 million into the ATC, establishing a dedicated space where the company’s technicians can collaborate with SPPC members and customers to develop new solutions.

Roy Schoettle, VP XSYS APAC & XSYS Thailand, concluded, “With the 70th anniversary of the SPPC as a backdrop, XSYS remains committed to its mission of pioneering sustainable and brilliant solutions for the printing and packaging sectors. We look forward to further strengthening our partnership with the SPPC and contributing to the industry’s growth and development for years to come.”

Heidelberg Dealer Networl Toan An Co., Ltd.

Change to keep up with a very dynamic market development

As a leading solution provider for the printing industry, HEIDELBERG is supporting print businesses worldwide, and has now entered into a partnership with Toan An, Co., Ltd in the Vietnamese market.

Toan An, Co. is a well-established company in the Vietnamese market with focus on Prepress equipment and consumables. While Sheetfed and Postpress equipment were so far not in their portfolio, Thomas Frank, HEIDELBERG's regional head for Asia Pacific, is convinced that this is not a real hurdle:

"Toan An have a young ambitious team of service technicians and sales specialists under strong and experienced leadership. This is what counts. Some HEIDELBERG colleagues already

had the chance to discuss with this team and we are convinced they are the right business partners for Vietnam. Our HEIDELBERG Service Teams from neighboring countries and our factory in Shanghai will help Toan An to successively build up the required expertise in Speedmaster, Gallus and Postpress technologies. And especially in the beginning of the new partnership our technicians will be around whenever needed".

HEIDELBERG and Rieckermann recently announced the end of their

cooperation in Vietnam, Cambodia and Myanmar due to different

strategies but jointly confirmed that all of their commitments and obligations towards their existing customers will be fulfilled.

The Printing market in Vietnam

In recent years, Vietnam has experienced continuous economic growth in both domestic demand and exports, and the printing industry is also on a growth trend, but at the same time, as in other countries around

Networl in Vietnam.

the world, the Vietnamese printing market has been facing the challenges for further improvement in business efficiency due to shorter run length and delivery times, rising resource and raw material costs and an increasingly competitive environment.

It is more important than ever to keep the entire print production chain in optimum conditions for reducing costs and to maintain high productivity. In this regard, Toan An Co., Ltd. and HEIDELBERG recognize the growing market potential in Vietnam

by founding this strong business relationship. Adds Mr. Khoa, CEO of Toan An: "With Heidelberg we now have a partner that allows us to systematically develop the market in Vietnam and Cambodia. Whether a customer is in the Commercial Print, Packaging or Label segment - we will have the right solution. And with such strong offering in the back my team and I will give the utmost to support our today's and future customers".

Thomas Frank, HEIDELBERG's regional head for Asia Pacific

A pioneer in green environmental protection

As the world's supplier of printing equipment and solutions, Manroland is committed to providing customers with advanced printing equipment and complete solutions. In recent years, Manroland has gradually developed supporting printing materials with a concept of green environmental protection throughout.

It has achieved enviable results and gained a lot of attention and recognition both inside and outside the industry. Recently, the media had in-depth exchanges with Thomas Luk, Head of Printing supplies, Manroland Greater China and Maxco Tang, Factory Manager of Guangzhou Printcom Printing Equipment Co. Ltd., to learn about their exploration and achievements in green development.

Implement the concept of green environmental protection and achieve sustainable development of enterprises

When it comes to green and environmentally friendly printing, what comes to mind are low VOCs content, reducing emissions and waste, and saving energy and consumption. Of course, these are the basic key points of green printing. Mr Tang thinks it’s more than that: “Currently, the country attaches great importance in the development of green printing.

We should also focus on the entire green printing process, which includes every participant and user in the industry chain. From product design to people, machines and the environment in the production process, all should be included in the scope of green printing. Only in this way can the sustainable development of people, enterprises, resources, environment and society be achieved, which is comprehensive green printing".

In the past, many printing companies believed that printing materials were only used to print corresponding products. They only looked at the immediate performance and procurement costs, but ignored an extremely critical point, that is, the environmental protection of printing materials. Whether it is to meet the rigid requirements of national laws and regulations or to achieve longterm development of the enterprise, this is the primary consideration.

As a leader in printing equipment manufacturers, Manroland has always attached great importance to green and environmentally friendly printing.

The group has been committed to the research and development and promotion of green and environmentally friendly printing materials as early as more than ten years ago, and created two brands, printcom and magicpix. Assist printing companies in their green transformation and upgrading.

"When people heard about environmentally friendly printing materials, they would have the misconception that they were expensive and not as easy to use as ordinary materials, which also discouraged many printing companies."

Mr. Luk said. In recent years, with the promotion and development of the country and the improvement of new materials and equipment, printing companies have gradually increased their acceptance of green and environmentally friendly materials, gradually changing from passive acceptance to active participation, and from focusing on unit price costs to focusing on comprehensive costs and enterprise sustainable development.

Left: Thomas Luk, Head of Printing supplies, Manroland Greater China. Right: Maxco Tang, Factory Manager of Guangzhou Printcom Printing Equipment Co. Ltd.,

Raffles City Convention Centre

40% off early bird tickets on sale now!

S$245 / ticket (for a group of 10)

Day 1

Raffles City Convention Centre

•Winning in a Disruptive Landscape

•The Business Case of Sustainability

•Falling in or out of love with Printers

•Artificial Intelligence - Threat or Opportunity

•Design Thinking - Reinventing of Printers

•Differentiation through Branding

• Print Trends

•Panel Discussion

•Company Culture - Retaining and Attract Talents

Day 2

Site visits hosted by:

•Konica Minolta

•Kodak

•Cyber

•Fujifilm

•SPH

Magicpix printing materials help manroland green and environmentally friendly printing

In the process of promoting the green development of the printing industry, Manroland has not stopped its pace. In 2007, in order to meet market demands, Manroland launched the magicpix series of products, including rubber blanket, printing chemicals, varnish, ink, and accessories, vigorously promoting environmentally friendly printing materials in China. When it comes to its advantages, Mr Tang proudly said:

The magicpix series is backed by Manroland printing technology, and its main focus is to make people feel at ease and easy to use. In addition to good printing results, it meets international requirements in terms of technology and quality standards. It not only meets environmental requirements, but also provides protection for personnel and equipment, avoiding harm to personnel and ensuring that every component and junction of the equipment will not suffer from corrosion or damage. As an equipment manufacturer, we guarantee that protecting people and equipment are both our tasks.

The numerous advantages of magicpix series products, It has brought many surprises to printing enterprises: "It has rejected the use of dangerous goods, reduced the management costs and

risks of the enterprise, and equipped with some automation equipment, which can greatly save labour costs. More importantly, the magicpix series products meet relevant national laws and regulations, solving many difficult problems for printing enterprises, helping them gain the trust of many customers, and greatly increasing the order volume of the enterprise,”

Mr. Luk also added, "While the magicpix series of products bring value to printing enterprises, they also further assist in improving their competitiveness in the market. Many printing enterprises will proactively come to their doorstep and ask Manroland to provide high-quality and qualified products, relieving them of their troubles.”

Complete supporting 4S services

Not only can Manroland provide customers with high-quality green and environmentally friendly products, but it also provides a comprehensive service system. In order to serve customers more timely and conveniently, manroland has established warehousing, logistics, and service teams in various key regions of China to ensure continuous product supply and timely delivery. Manroland provides one-stop solutions for various customer needs, including printing materials, processes, equipment, and maintenance.

In addition to daily communication with customers, Manroland also regularly holds training classes to cultivate talents and share printing technology, maintenance, and other content.

“We have a strong technical team, accumulated rich printing experience, and can quickly solve different production application problems for customers. For example, if customers want to comprehensively reduce the generation and emissions of VOCs, our team can provide comprehensive support, from equipment, materials to complete solutions for the process, "Mr. Luk firmly stated.

“WE ARE PRINT” Looking ahead to the future

Green and environmentally friendly printing materials have become a trend, and Manroland will continue to develop green and environmentally friendly printing materials. Mr Tang said:” In order to meet customers' diverse choices, Manroland will continue to improve various series of products, such as low VOC cleaning agents, special effect inks and oils, and water-based materials with low odour and automatic degradation. At the same time, Manroland provides supporting equipment such as automatic rubber cloth cleaning devices and fountain solution filters, which not only cooperate with environmental protection but also assist in saving manpower.

It will actively develop solutions to improve the VOCs content in the workshop and enhance the green and environmental protection of the entire factory area.” “At the commercial level, we will provide matching materials and solutions tailored to the different needs of printing enterprises, making it easier for customers to achieve high-quality, efficient, environmentally friendly, and low-cost production.” Mr. Luk added.

In addition, Manroland strengthens close contact with customers by regularly holding communication seminars and conducting follow-up visits to customers, allowing more people to understand and choose Manroland.

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Revoria PressTM PC1120

Creates Standard for Productivity and Quality

Maruyama Printing Co., Ltd., which has its head office and factory in Hyogo Prefecture, was founded in 1914 and has a history of 109 years. Rooted in the region, it established an integrated manufacturing system from design and planning to prepress, press, and postpress.

In recent years, production efficiency, driven by the growing need for quick deliveries, has become an urgent issue. To address this requirement, Maruyama Printing installed a six-color Lithrone G40 advance LED-UV 40-inch Offset Printing Press and an Apressia CTX115 Programmable Hydraulic Clamp Cutting System. To find out about the purpose and effects of the

introduction, we spoke with Keisuke Maruyama, President, and Yoshiro Kitano, Director, Yoshinori Hamada, General Manager, Kazumi Kitakaze, Section Chief, and Kyoji Ando, Subsection Chief of the Manufacturing Department.

"When considering and introducing the system, I felt Komori's high level of

organizational strength in its preventive maintenance and service."

-- Keisuke Maruyama, Representative Director and President

New equipment brings expectations of a change of mind President Maruyama points out that one of the company's specialties is the integrated production of printing,

for High Quality

binding, and finishing of calendars as well as the design, printing, and processing of various types of labels. The company has received multiple awards at the National Calendar Exhibition (Japan Federation of Printing Industries) and its products are highly rated.

Maruyama Printing had several facilities that were aging, and although productivity and quality had been maintained at the original specifications through overhauls, worries about breakdowns and parts arrangements were never-ending. On the other hand, the company also wanted a press that would handle short delivery times. President Maruyama had an extraordinary desire to "bring change to the manufacturing department" since this was the first renewal of equipment in a long time.

"To meet short delivery needs, it was necessary to perform makereadies and changeovers more quickly. It's not the case that what we had been doing was bad, but I wanted people to feel that it's not just an extension of what we have done so far. Given the chance, people can change easily. I wanted to increase

productivity on the equipment side and at the same time change people's minds by introducing Komori presses," he explains.

For installing the Komori machine, the company visited four printers that have introduced Komori presses. "We have continued to get advice from the presidents and factory managers of the companies even after we visited," says Director Yoshiro Kitano. A new relationship was born at the same time that the decision was supported.

Anxieties solved by training: fullscale operation three weeks after installation

"For the past two months, I have been thinking about the good points of this machine and its efficient workability, and I think we've become able to use it rather well. We want to increase our production output by speeding up in various ways in the future," says Printing Subsection Chief Ando.

UV press was put into full operation beginning in February 2023. The operability of the new machine is different from that of the existing machines, and setup was completed in a very short period of time and it is now running as a production machine.

Regarding the reason for this, Kitano says, "Before installation, I went to the KGC (Komori Graphic Technology Center) West Japan branch office with four operators and we worked out our anxieties by repeating the operation classes." Section Chief Kitakaze, who participated in the training, says, "I learned how to operate the actual machine in the training and was instructed by Komori personnel during the installation, and I could understand the differences in operability and the dampening mechanism, so there were no particular problems and I was able to start up right away," he recalls.

Positive change leads to increased productivity

The new functions of the press solved the existing issues and improved production efficiency. Regarding the increased need for quick delivery, General Manager Yoshinori Hamada says, "Until now, there was the problem of waiting for ink to dry. Our only UV machine was a half-size machine,

which required stock to be cut in the previous process. With the installation of the 40-inch LED press, we're able to meet short delivery times without the time and cost of cutting." There is no waiting time for drying, and production planning has become easier.

In addition, the company has a lot of on-press proofing work. Kitakaze says, "Because we use a handy-type densitometer to measure solid patches, it sometimes took more than an hour to do color matching for high-quality products. With the introduction of the PDC-SX Spectral Print Density Control, we are now able to print highquality images with no difference in density in about 30 minutes."

Regarding getting color, Hamada says, "Since the density can be checked with a graph, anyone can call it OK if it is within standard values. It is very easy because there is no need to worry about color," he says.

Regarding the PQA-S Print Quality Assessment System, Kitano says, "The assessment system has become indispensable. There are jobs that rely on inspection machines, and I can guarantee quality with confidence." Kitakaze says, "Previously, we used a paper inspection device in another

room for inspection, so it was costly in time and labor. With PQA-S, printed material has completed inline inspection, so we can quickly pass it to finishing. Speed is an advantage with strict quality requirements."

The biggest contribution to productivity improvement is the change in printing speed. Conventional work done at about 10,000 sph can be run at the maximum speed of 16,500 sph, and what supports this is the advance press's sheet feeding and delivery performance.

"Sheet feed settings can be done automatically. Since the air adjustment for paper types is memorized, we can now print at maximum speed." As a result, the number of jobs per day has increased significantly. Two months after the start of full-scale operation, positive changes in quality and productivity are already apparent," he says.

Oil-based materials require drying time, so when 40-inch presses were used for 24 hours, there was an accumulation of more than 10 pallets. Work printed with the new Lithrone G40 advance LED-UV can be quickly transferred to the Apressia CTX115 for postpress processing.

Creating a new standard with the G40 advance and KP-Connect Hamada says, "I think of the materials that have been evaluated, K-Supply is very stable. In general, gold and silver inks are difficult, but I would like to use them based on advice."

Maruyama says, "We will use this introduction as an opportunity to review our standards and work on color management." In addition, the company plans to promote "visualization" through KP-Connect. "Press operation is automatically recorded and objective reports can be obtained. Everyone being able to look at and consider the same data is critical for producing the next change," he stresses, emphasizing the importance of sharing information.

Finally, Maruyama says, "The core of our strategy is emotion and kando. We want to focus on assessment items other than price."

High-quality printing & robust under all prepress conditions

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nyloflex® FTF

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nyloflex® ACE

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+ Very good for long clean print jobs (anti-ink filling)

Hybrid machines are on the rise, and for good reason

By Dieter Finna

Since reliability and speed of printing are no longer limiting factors, these are now in fact driving the development of hybrid digital flexo presses. For Swiss press manufacturer Gallus Ferd. Rüesch AG it’s confirmation of the inline concept that they have always pursued. The company says that now, when developing new hybrid solutions, it builds on three phases that have shaped its digital development.

Looking back at the design of Gallus presses, the production of labels and packaging in a single pass is in the DNA of the St. Gallen-based press manufacturer. This did not change even when electrophotographic digital printing processes and production methods with stand-alone machines made their way onto the label printing market.

The basis of current hybrid solutions

Gallus brought a hybrid digital flexographic printing system onto the market when it first entered the field of digital printing, with the Labelfire in 2016. In the years that followed, it underwent significant further development and is now used by highperformance users in 24/7 continuous operations. The demands of brand owners in the tobacco sector have significantly shaped the development of machine systems.

In today’s market, the Gallus Labelfire is used equally for labels, folding cartons

and special packaging. Having reached this stage, the company can look back on three development phases that it has gone through in the design of hybrid machine systems.

Phased development of digital printing

The first phase, which Gallus describes as the innovation phase of digital solutions, involves the challenge of integrating inkjet printing into a hybrid digital/ flexographic printing system. The starting point for development was the initial lack of performance consistency of inkjet, compared to conventional processes. This made it necessary to integrate improved print head technology into the machine concept. With their integration, Gallus then succeeded in significantly expanding the process window in which inkjet print heads function reliably.

Due to a lack of existing solutions on the market, Heidelberg/Gallus decided in 2019 to carry out numerous in-

house developments, which heralded the stabilization and thus the second phase of its hybrid digital flexographic printing system. The focus was on the camera-based "Vision System" for artifact compensation and the associated development of necessary algorithms to counteract detected errors such as missing nozzles and density unevenness in solid areas.

A major leap in print quality was also achieved by lowering the print heads nearer to the substrate, which significantly increased the jet accuracy of the ink droplets. The lowering of the heads, in turn, prompted the installation of an automatic splice detection system using sensors, in order to trigger an increase in the distance between the print heads and the substrate at short notice, when splices were detected in the web, and to protect the print heads from damage.

This phase is generally referred to at Gallus as the period in which the company implemented fundamental development steps that led to stable, continuous operation of the hybrid printing systems, and ensured the company a leading position in the elimination of process errors.

Backed by the established Labelfire technology, at the start of the third phase in 2022 Gallus focused on innovative "ease

Defects caused by missing nozzles as well as density unevenness are monitored by a camera and compensated for using algorithms.

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159 Kampong Ampat, #05-02 KA Place, Singapore 368328 Phone +65 6929 5320, heidelberg.com/sg

of use" concepts. Developments that simplify digital printing and take the strain off operators - an increasingly important aspect, particularly in the age of a shortage of skilled workers. This included the further development of the "Vision System" into a highly automated variant with which a test chart can be printed between each job and not just manually once a day, as is usually the case.

This automated solution provides the operator with quick assistance when “weak nozzles” occur, which only become apparent during day-to-day operations. Their direct elimination affects the print quality through the greatest possible process stability and consistency.

Greater user-friendliness and standardisation are also achieved by cleaning the printheads in a fully automated cleaning process, for which the operator can additionally activate an ultrasonic cleaning step. In practice, this design solution has proven itself to such an extent that physical contact with the printheads is no longer necessary during the cleaning process, and the cleaning principle is proving to be groundbreaking for standardised cleaning of printheads. The fixed installation of the print bars and print heads also contributes to userfriendliness. Permanently mounted printheads minimise the need for servicing and, thanks to this lower maintenance requirement, lead to significantly higher

machine availability and thus an increase in productivity.

In general, all these design solutions are based on a high degree of automation with defined standards that enable the efficient integration of digital printing into hybrid machine systems.

The conventional influence on hybrid printing technology

But it is not only digital printing that has gained in performance for hybrid press solutions. In parallel, the conventional basic/carrier press side has also evolved and its level of automation has increased in favour of user-friendliness. A press pre-set, for example, enables a job to be set up quickly by retrieving all press setting data from the job file. Among other things, format length and format length correction, substrate data with substrate type, web thickness and width, and web transport settings with web tension and web stretch are all pre-set.

The automation also includes longitudinal and cross register presetting, which does this for each printing unit on every job, as well as permanent register control and regulation during the run. This is a real convenience feature that frees the press operator from this otherwise constant monitoring task over the entire run.

With "web-to-web" control, sensors measure the distance between the specially designed register marks and react very precisely and quickly to deviations in the print image/register that may occur, for example, due to substrate tolerances. Since the press automatically adjusts the register as soon as the register marks are in the catching area, this mode of operation contributes significantly to avoiding and thus saving waste

Hybrid is on the rise

If you look at the increase in performance in digital printing on the one hand and the higher degree of automation of conventional press parts on the other, this can be put together to form a coherent picture in the construction of hybrid systems.

The market is currently witnessing an increase in the development of new hybrid digital flexo presses as well as digital presses with inline finishing and/or flexo units, even if various finishing processes such as screen printing, hot foil stamping, digital foiling and digital varnishing still somewhat slow down the inline process.

For cleaning, the cleaning boxes with flood cleaning and ultrasonic cleaning units move under the fixed print heads.

Depending on the order structure, the future often lies in inline operation, especially for medium to long runs and a medium degree of finishing. In this situation, it is not surprising that the Gallus One, recently presented as a stand-alone machine, also follows the hybrid DNA of the St. Gallen mechanical engineering company and contains the expansion capability to become an inline machine or hybrid digital flexographic printing machine.

With web-to-web register control, sensors measure the distance between register mark and reference mark.

Brilliant products and services for brilliant print results and business success.

XSYS

remains one of the largest suppliers for the global flexographic printing industry, offering flexographic and prepress solutions and expert professional services while helping the industry move forward with increasing innovation, improved productivity and a reduced environmental footprint.

A Clear Pathway to Packaging Innovation and Sustainability

Increasing plastic circularity without compromising on performance and consumer experience

By: Shyam Kotak, VP of Global Accounts at Aptar Closures

In today’s market, consumers are continuously seeking safe, innovative and convenient packaging that aligns with their different lifestyles and environmental values. To remain competitive and increase market share, brands around the world are searching for attractive and highly functional packaging solutions that enable them to stand out and attract consumers, while helping them reach their sustainability targets.

At Aptar Closures, we are dedicated to partnering with brands to provide innovative, high-performing and sustainable dispensing closures for a range of applications and markets around the world. We use our exceptional in-house expertise, consumer insights and industry partnerships to design, manufacture and commercialize solutions that improve consumers’ experience while unlocking growth opportunities for brands. In addition to creating memorable consumer experiences, Aptar Closures’ is committed to designing innovative solutions to help brands achieve their sustainability targets without compromising on quality or performance.

Our sustainable innovation approach begins by paying close attention

to emerging global market trends, new market demands and consumer insights. We leverage core expertise and creative thinking to respond to our customers’ needs, from concept ideation to consumer experience.

The Rocket sport cap is an example of our commitment and drive towards developing innovative and sustainable solutions that improve consumer experience. ACTIPH Water, the first alkaline ionized bottled water in Europe, chose our Rocket sport cap due to its unique, highly visible, nondetachable tamper-evident cap. This tethered system was designed for easier recycling and complies with the SingleUse Plastics (SUP) directive on beverage caps in Europe. Rocket helps ACTIPH Water meet consumer expectations in safety and drinking experience, while also addressing the increased market demand for companies to offer fully recyclable solutions.

Our customer-centric approach also led to a close collaboration with Starbucks and Nestlé to create the dispensing closure for ones of their newest line

of coffee creamers. We leveraged our experience with disc top closures, creamer packaging, consumer insights and industry relationships to help them deliver on their aggressive speed-tomarket needs. The custom two-piece closure increases convenience with its unique press-to-open feature that enables consumers to operate with one hand. This is an attractive and highly functional solution, leading to a clean product cut-off and strong shelf appeal. The closure was optimized to be as lightweight as possible while maintaining high performance and recyclability.

Innovation and sustainability — are also critical in the design and manufacturing of dispensing closures that are made to withstand the harsh conditions of the e-commerce supply chain. Brands and retailers often use excessive tertiary packaging to protect packages from breaking or leaking during transit. Aside from creating an unpleasant unboxing experience for consumers, tertiary packaging creates waste since it is not always recyclable and often discarded by consumers. By rethinking primary packaging for the e-commerce supply chain, brands can reduce overall packaging waste, energy used and damaged products. It can also help brands significantly lower charges associated with shipping damage, therefore contributing to downstream savings and bottom-line efficiencies. Aptar has been an official participant in the Amazon Packaging Support and Supplier Network since 2018. We have a fully equipped lab in our Mukwonago,WI, USA facility to test products according to the ISTA6 protocol and experienced design engineers that are at the forefront of developing solutions for e-commerce shipping.

flexibility, no matter what their business requirements are. CuremaX, in combination with our newly launched LuXtreme LED curing system and our Flenex water washable flexo plates, provides customers with the perfect combination of reliability, performance, efficiency and sustainability, via one partner. We look forward to demonstrating the solution at Labelexpo and connecting with visitors at the show."

Fujifilm Launches First

Indirect Food Contact Ink: CuremaX UV LED IDFC

Fujifilm announced at Labelexpo Europe, Brussels, that it is launching CuremaX IDFC – the company’s first ever indirect food contact ink. The ink series is a range of gloss LED UV inks with the added option to cure under conventional lamps. This dual cure range has been specifically developed for printing on food and pharmaceutical packaging with indirect food contact and has minimal risk of migration. The inks are suitable for use on narrow web labels, including a range of applications from selfadhesive labels and unsupported films to saturated pouches and shrink sleeves.

CuremaX is suitable for use on all typical synthetic and non-synthetic substrates used by label printers including PE, PP, OPP, PET, PVC and aluminium as well as coated

high press-ready colours, offering high colourdensity, and can replicate the full pantone colour library. Additionally, the range is over-printable with thermal transfer ribbons and cold foil adhesives.

CuremaX IDFC has been formulated to conform to The Swiss Ordinance (SR 817.023. 21), which defines provisions specifically related to printing inks for non-food contact surfaces of food contact materials. Furthermore, the inks are manufactured to the European Framework regulation and the good manufacturing practice EC regulation.

Steve Wakefield, Aftermarket Manager, Fujifilm Speciality Ink Systems Ltd, comments:

"The launch of CuremaX IDFC marks an exciting time for Fujifilm. We’re confident that these inks will enable customers to explore new markets and achieve new standards with confidence. Additionally, the dual cure option offers printers

A world record – HEIDELBERG supplies leading packaging manufacturer WestRock with two longest sheetfed offset presses ever produced

HEIDELBERG has delivered the two longest sheetfed offset presses ever produced to leading global packaging manufacturer WestRock. The longest, delivered to WestRock’s Tczew, Poland facility, is a 42 metre, specially adapted custom configuration of a Speedmaster XL 106 with a total of 20 printing and coating units.

This record-breaking press represents a key HEIDELBERG business strategy: “We help our customers simplify their printing processes and boost their productivity by offering them a high level of automation and flexibility, something that is especially important at a time when the skills shortage is becoming more acute worldwide,” says HEIDELBERG CEO Dr. Ludwin Monz. This business strategy is increasingly paying dividends. With annual growth of

SPEED UP YOUR PROCESSES with optical systems for UV curing and drying

approximately 2.3 percent forecast, the folding carton market is a strategic growth segment for HEIDELBERG.

Around half the sheetfed offset presses HEIDELBERG sells and installs go to packaging customers.

“HEIDELBERG is now the market leader in packaging printing, with Speedmaster XL technology playing a key role,” reveals Monz.

The trend toward ever more sustainable packaging, such as folding cartons, is driving demand. Cartons are increasingly replacing plastic packaging in everything from food and cosmetics to pharmaceuticals.

In addition, HEIDELBERG is supplying a further Speedmaster XL 106 with a total of 19 printing and coating units to a WestRock site in Obersulm, Germany – the second longest in the world.

The record-breaking presses supplied to WestRock can print particularly high-quality and eye-catching packaging. With its large number of printing and coating units, the highly flexible long Speedmaster XL 106 configuration is suitable for handling a wide range of packaging applications with striking coating and metallic effects as well as sustainable products – completely inline, double-sided, and in a single pass.

Over WestRock

Based in the U.S. state of Georgia, WestRock is a global leader in sustainable paper and packaging solutions with more than 50,000 teammates in the Americas, Europe and Asia-Pacific. Its integrated packaging capabilities offer endto-end solutions to help customers across food and beverage, healthcare, e-commerce and beyond meet their greatest challenges.

Mark Shaw, Business Leader, EMEA and APAC at WestRock said: “Innovation and sustainability are the bedrock of WestRock’s operation, and by investing in print technology from HEIDELBERG we are future-proofing our capabilities for our customers. There is no better demonstration of this than the two longest presses in the world being developed specifically for WestRock

facilities. As brands continue to drive demand for sustainable, fibre-based packaging, through our continued investment and industry-leading expertise, we are well positioned to meet these needs.”

Long custom configurations are a specialty at HEIDELBERG

A trend is emerging, particularly in folding carton and label printing, toward customized, long press configurations. After all, manufacturers of branded goods are keen to create new purchase incentives time after time by offering stand-out, sustainable packaging designed with particularly striking effects. HEIDELBERG specialises in custom configurations of this kind. The Speedmaster XL systems in particular can be adapted in numerous ways to meet customerspecific requirements.

“Projects such as the one for WestRock involve particularly high mechanical engineering demands and close consultation with the customer. We combine two things – first-class printing press construction and userfriendly operation,” says Christian Steinmassl, who is in charge of the Packaging segment at HEIDELBERG.

The operating concept must be designed in such a way that, even with a press of this length and complexity, staff always have all processes under control via the Prinect Press Center. “As underlined by the fact that packaging printers are more than ready to invest in custom configurations from HEIDELBERG, users trust our company’s expertise and partnershipbased approach to finding solutions,” Steinmassl adds.

Fujifilm launches LuXtreme, a new LED UV curing system

At Labelexpo Europe, Fujifilm launched LuXtreme, a new LED UV curing system that allows any traditional flexographic press to be converted to LED UV curing, resulting in enhanced label production on a narrow web press.

LuXtreme offers high speeds of up to 200m/min, along with better substrate stability, resulting in enhanced productivity for printers. Additionally, the system offers 30-50% higher radiant intensity than competitive LED curing systems, up to 25W/cm².

The system uses 30-60% fewer LED lamps to achieve the same radiant intensity as other comparable systems. This results in better registration and less material distortion. improving the overall quality of printed materials. The energy savings this offers compared to conventional UV systems, as well as competitive LED curing systems, are significant, with both material usage and waste also significantly reduced, enhancing overall productivity and making the system a highly sustainable mercuryfree solution.

Due to the reductions in power required for the LED UV lamps, cost savings can be made across the production process. Additionally, the lower maintenance, downtime and make-ready times required to support the system also lead to a lower number of replacement parts required over its lifecycle, and lower associated labour costs.

Cut complexity and costs with FLEXCEL NX Solutions.

Simply consistent

Decrease waste and setup with predictable plates

Simply efficient

Increase on-press performance with a robust plate

Simply sustainable

Support sustainable inks and substrates all with the same plate

Simply better Address your most demanding brand and quality requirements

From prepress to on-press, deliver the efficiencies and productivity needed from your plates to maximize your bottom line.

The working environment for operators is also improved, with many undesirable factors eliminated or reduced, including heat from conventional UV and air cooled LED lamps, ambient noise and odours.

The system offers up to 50,000 hours LED life and up to a 720mm lamp length, scalable in 24mm steps. An LED adaptor allows easy integration on to existing mountings.

XSYS launches versatile nyloprint® WS PRO D letterpress plate for brilliant print results in tube, cup and can applications

- Offers exceptional print quality with superior highlight dots

- Shorter processing times due to higher sensitivity to LED exposure

- Longer durability on press as new formulation is less prone to cracking

- Suitable for all types of letterpress plate processing equipment

XSYS has announced the launch of nyloprint® WS PRO Digital, a newly developed water-washable, steelbased letterpress plate ideal for the printing of plastic tubes and cups, and

metal cans and aerosols. Optimized for LED inline exposure and brush washout, the new plate provides superior printing quality independent of the processing equipment. It also excels due to the high stability of the steel used with the nyloprint® materials, which is less prone to kinks and irreversible bending, and its exceptional durability even in the longest print runs at high speed.

“Our customers are under constant pressure to deliver consistent print results quicker, cheaper, and more efficiently, so they need us to continue innovating in this field to give them a competitive edge,” said Dr. Christian Pietsch, Product Manager & Global KAM nyloprint® at XSYS. “The new nyloprint® WS PRO Digital represents a significant addition to our existing portfolio of letterpress printing plates, offering premium results in combination with LED exposure, due to its excellent durability and high stability.”

Available in four thicknesses, the nyloprint® WS PRO D letterpress plate offers better Overall Equipment Effectiveness (OEE) and is suitable

for dry offset, rotary letterpress, imprinting units and special-purpose printing presses. It exhibits higher sensitivity to UVA LED exposure compared to the market standard, meaning it can be processed faster on inline UV units.

The new plate’s greater durability and long cleaning intervals further increase efficiencies on press. In combination with LED exposure, nyloprint® WS PRO D delivers overall excellent print quality with especially superior highlights and finest image details. Customers will also experience the benefits of lower dot gain in print due to dot sharpening.

Because the new formulation is less prone to plate deformation, other advantages include reduced plate waste and longer durability on press, which improve the sustainability of the production process. As well as being suitable for all types of processing equipment, including the XSYS nyloprint® range, the new plate also works well with ThermoFlexX TFxX imagers that have been fitted with a Hybrid drum (with vacuum channels and magnets).

“nyloprint® WS PRO D presents a significant leap in productivity and efficiency, offering invaluable benefits to converters. This advancement empowers them to expedite product delivery without compromising on top-tier quality. Driven by its proven durability on the press, it not only reduces operational costs but also minimizes waste generation.

This sustainability-conscious approach aligns seamlessly with the objectives of brand owners,” emphasized Dr. Christian Pietsch. “With this introduction, XSYS continues its mission to provide brilliance for customers with the latest innovation in plates and platemaking equipment that allows them to succeed.”

For SALE

Polar Mohr 115X paper guillotine

Year of Manufacture 2005

Price GBP 21,000

The machine is in very good condition, ready for production, after a review.

• Mileage of only 50,000 cuts

• The set includes documentation & a set of tools a tapping block a spare knife and one in the machine

If you have any questions or would like more information, please don't hesitate to contact us.

COUNTRY : Europe

For SALE

CONTACT : Michael Fisher • EMAIL: cpisuffolk@cpi-print.eu

WANTED

KOMORI S440 4 COLOUR PRINTING OPERATOR

• 2-3 years practical experience (in printing industry )

• Singapore Citizen / PR

• Able to work independently

• Able to work overtime if needed

• Working Hours Mon to Fri: 9am to 6pm, Sat : 9am to 1pm

COUNTRY

Heidelberg Speedmaster CD 102-5+L

CP2000, Auto Plate, Diagonal Register, Preset, Auto

Impression Cylinder Wash, Auto Blanket Wash, Auto Ink roller wash, I/R Dryer + Hot air, Extended delivery, Powder Spray, Technotrans refrigeration, Ink Temperature Control, Dedicated

Coater

Type: Offset Printing

Year: 2004

Impressions: -

Colours: 5

Perfect: -

Sheet size H: 1020

Sheet size Y: 720

POSITION VACANT

SENIOR PRINTING TECHNICIAN

• Responsible for setting up and operating high-end automated printing machine for quality output and timely delivery

• Ensure machine output is according to specifications required by the job run

• Examines printed results for ink density, accuracy of design and registration conforming to required artwork

• Perform first level analysis and optimize the set-up between the printed sheets

• Constantly monitors the output and take the necessary corrective actions to minimise rejects

• Perform quality control and troubleshoot during job run

• Prepares and updates all production documents required

JET PRESS 1160 CF