October 2012, Flexo Mag by Print Innovation Asia

Asian Flexo, Gravure & Labeling IMAGINE

IGNITE

IDEAS

IMAGINE

Covering the Flexo, Gravure & Labeling Industries across Asia MICA(P)094/08/2008 - KDN PPS 1529/8/2009

IGNITE

OCTOBER 2012

Innovate 2012 is coming to Asia SYDNEY 24 OCTOBER 2012

AUCKLAND 26 OCTOBER 2012

KUALA LUMPUR IDEAS

IMAGINE

30 OCTOBER 2012

IGNITE

SINGAPORE 01 NOVEMBER 2012

GUANGZHOU 05 NOVEMBER 2012

TAIPEI

06 NOVEMBER 2012

Find out more & register today at

www.fxap.com.sg/innovate/

Focus on what matters most.

The service bureau industry is undergoing dramatic changes and is faced with ever increasing operational pressures. At Fuji Xerox, our goal is to partner with you to enable you to grow your business and to deliver greater returns. Utilising industry leading technology Fuji Xerox can help reduce your costs, increase your productivity and profitability. Fuji Xerox will partner with you helping every step of the way to: • Delight your customers – By transitioning to high quality, variable data colour prints • Grow your business – Configure for today’s needs and upgrade for tomorrows growth • Reduce your costs – Through greater automation and improved efficiencies • Produce more jobs – In a shorter time frame at faster speeds

www.fxap.com.sg

Oct 2012

Covering the Flexo, Gravure & Labeling Industries across Asia MICA(P)046-11-2010 - KDN PPS 1529/05/2012(022768)

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Great success for 2012 China Summer Flexo Academy UTECO Kiss & Go® Gallus Proves Hybrid Print Shop Concept Device Packaging: Top 10 Mistakes Apex GTTFlex - Just two profiles for the most demanding requirements First full colour images at 100,000 dpi resolution Booklet labels for single-service fresh food prepacks: A fruitful solution Food Safety and Digital Printing Omet and Ferrostaal’s partnership forges ahead in Asia Practical magic Labels: adding value to packaging TETRA PAK completes €42 million site expansion in Singapore Meeting demands of the Australian Wine Industry. Major Savings through EASY-COL New dimension to structural packaging design The Laser Revolution Strong growth in labels and packaging market. Industry news and happenings from around the world

AFTA Pte Ltd No. 71 Geylang Lorong 23, THK Building, #07-02, Singapore 388386 Tel+65 6733 5342 Fax +656733 3586 Chairman Paul Callaghan paulftw@cpublish.com.sg Managing Director Elizabeth Liew eliew@cpublish.com.sg Editor Christel Lee editorasia@cpublish.com.sg Advertising Sales Matthew Callahan matt@cpublish.com.sg Accounts Radika PS accounts@cpublish.com.sg Chairman Judging Panel 2012 Packaging Excellence Awards Head Judge - Alf Carrigan

AFTA AGA ALA • Issue 3 2012 -

AFTA AGA ALA • Issue 3 2012

AFTA AGA ALA • Issue 3 2012 -

Great success for China Flexo Academy Flint Group Flexographic Products, together with partners, continue to support the development of the Chinese flexographic industry

Like last year, Flint Group’s partners, Auclean, Esko and Tesa, offered presentations and exercises. Additionally, X-Rite and their distributor, Pancolor, as well as the wide format flexographic press manufacturer Huayang, were invited to share their knowledge on colour control and press simulator systems. The international brand management supplier, Schawk, provided

insight into the latest packaging trends. Johnson & Johnson, one of the world’s leading consumer and health care companies, and Philips, a world leader in healthcare, lifestyle and lighting, reported on their experience in creating environmental friendly and sustainable packaging designs. The afternoon session on the fourth day was held at Flint Group Flexographic Products’ Asia technical centre. During practical lessons, teachers learned to produce a digital flexo printing form by going through the complete process from back exposure via laser imaging to main exposure, washing, drying, light finishing and quality check. They were excited to take home their own plate samples, which they had made themselves. During his introductory speech, Gong Renchou, Chairman of the

China Flexographic Technology Association, expressed his appreciation for Flint Group and their partners, who organised such an educational programme to support and promote the Chinese flexo industry. Teachers and media representatives confirmed that the training was fruitful and instructive: “This has been a good opportunity for all of us to learn more about flexography”, states Keyin Malan, media reporter. “The course ranges from the advanced digital plate making technology and plate making practice, to a live demo of the wide web IC flexographic press and brand owner’s opinion to a sustainable development of packages. We really hope that the cooperation between industry-leading suppliers and universities can continue, to train more teachers in this technology and promote the development of the flexographic printing industry in China.” pluess-ag.com

Once again, Flint Group Flexographic Products organised the Chinese Summer Flexo Academy in Shanghai. The subject of this year’s event was flexo wide web printing. The five day programme, including classroom training and on-site practice, focused on helping teachers deepen their knowledge and develop more expertise within the flexographic industry. More than thirty teachers from twelve packaging and printing colleges from all over China attended the training sessions.

Goldstar doctor blade

www.daetwyler-usa.com

Daetwyler SwissTec continuously strives to develop specialized doctor blades for flexographic printing. Through extensive lab and field research, we put the best tools in the pressman’s hands to a ddress specific printing problems. | The G OLDSTAR doctor blade combines extraordinary durability with a smooth and rounded, coated edge. It has a low coefficient of friction and the corrosion resistant coating has a self-lubricating effect. This adds to its long lasting properties, as well as further extends the life of the anilox roller.

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AFTA AGA ALA • Issue 3 2012

AFTA AGA ALA • Issue 3 2012 -

The

UTECO Kiss & Go

Innovative system for automatic setup printing pressures for the Flexo machine CI

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One year after the official presentation of the “kiss & go” system, Uteco is proud to announce the the success of 33 systems sold and the full satisfaction of customers owning the 18 already in production. Initially developed on the ONYX model, the system is now available on the full CI Flexo product line including the Topaz, Diamond, and the newest Crystal models. The extensive testing of the system with different production materials makes the final product fully compatible with any type of substrate, or plate material. The accuracy achieved by the automatic impression settings of the kiss & go system make the proceess fully automated without any additional operator input. The amount of web/material necessary for the automatic impression setting by “ kiss & Go” is approximately 140 meters, and can be as low as 40 meters depending on certain producition

criteria, making it the most efficient such system on the market. The system functionality is broken down into two distinct phases: TOUCH & GO. This patented automatic system establishes the first and lightest contact point between plate/anilox and plate/ CI. The procedure, once selected, initiates automatically once the press is put in run condition and proceeds to advance the printing decks until the appropriate contact torque is measured taking into consideration the possible variables of sleeves, carriers, plates, etc...as well as multiple mechanical and temperature compensations. The “touch & go” system in essence performs the lightest mechanical “touch” impression which will serve as the base reference and starting point for ”kiss & go”

KISS & GO Kiss & Go is a patented system that performs the optical scan of 100% of the printed web and automatically sets the optimal printing impressions. The system performs an actual reading of the printed surface much like the operator’s eye, but then makes use of a mathematical algorythm establish the correct printing impression settings. The optical scanner is a contrast sensor which registers with extreme accuracy and sensitivity the quantity of ink deposited on the substrate independently of the printed subject. The system consists of an extremely compact scanning unit mounted between the last printing deck and the drying tunnel, and a main processing unit. The latter analyzes the data received by the scanning unit and in a few revolutions of the print cylinders calculates and performs the optimal settings by acting on the positioning systems of the plate and anilox cylinders. This function is fully automated in order to avoid external inputs which may compromise the process. The mathematical algorythm which replaces the operator’s subjective assessment eliminates unknown variables such as operator experience, and makes the impression setting process extremely accurate and repetitive.

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XPose! Flex

The CTP system with maximum efficiency and flexibility The XPose! Flex series was developed for narrow web and label printing operations but is also suitable for packaging applications and service providers. These CTP systems are also used extensively in security printing. The XPose! Flex range of models covers all desired formats, from narrow web to corrugated cardboard to a plate size of 1340 x 2900 mm (52.7 x 114 inches), the XXL plate format. The XPose! Flex uses unique hybrid technology to image a wide range of media and is compatible with most available print forms. As well as imaging standardised offset plates on aluminium carriers, the CTP system can also work with ablative plates on polyester, steel or aluminium carriers. With its modular design the XPose! UV can be adapted to your individual requirements. Thanks to resolution up to 12000 dpi an outstanding reproduction of details is achieved. The Continuous Calibration Technology (CCT) guarantees a constant, standardised imaging and maximum production reliability.

Further information and support can be obtained from:

Brochure

Product Movie

www.luescher.com

MultiDX!

The flat-bed CTP system with a maximum number of application areas In the MultiDX! CTP system, L端scher has succeeded in another important innovation providing packaging and industrial printing with the highest level of flexibility. Thanks to its unique hybrid technology, the MultiDX! can image a variety of print forms. In addition to the imaging of standardised offset plates, the CTP system is also capable of imaging all ablative plates as well as all screen print forms. The MultiDX! has a modular design and so can be adapted to specific customer needs. With resolutions as high as 10,000 dpi, the MultiDX! stands for the highest quality and can produce highly precise line details equally well on offset plates and on relief printing plates. The flat-bed design and the customer-specific register systems can be adjusted to enable the use of all standard print forms - rigid or flexible or even a mixture of the two. The Automatic Laser Control System guarantees maximum reliability and uniform, standardised imaging. Further information and support can be obtained from:

Brochure

Product Movie

www.luescher.com

AFTA AGA ALA • Issue 3 2012 -

Gallus Proves Hybrid Print Shop Concept Over three days at Labelexpo Americas in Chicago, Gallus joined forces with Heidelberg to demonstrate efficient integration of multiple printing technologies in a hybrid print shop environment to improve the success of its label printing customers.

According to the live demonstrations, the ideal shop consists of high performance flexographic presses for short, medium and long runs, plus digital equipment for very short runs and variable imaging projects, and converting systems positioned either in-line or offline depending on the type of job being run. Each job is controlled by a management information system (MIS) that defines its path, then reports its performance at the end of the run.

Gallus Print Shop Concept – cost and time savings up to 20 percent Gallus's print shop model is based on the fact that each technology is optimized for different requirements, speeds and capabilities. The job allocation according the machines' strengths maximises efficiency while obtaining the highest possible print quality. All various technologies are integrated into production operations in cooperation with Heidelberger Druckmaschinen AG (Heidelberg)

via the Prinect and CERM workflow solutions. This workflow software calculates on which machine and in which sequence jobs can be produced in the most efficient way. Jobs can now be bundled and produced more efficiently, capacity utilisation improved, and administration and planning levels reduced - all of which maximises job throughput, cuts costs and accelerates the entire process. Label printers benefit from savings up to 20% in both costs and time - while still enjoying the same high quality. Featured equipment Gallus ECS 340: Introduced in 2009, the Gallus ECS 340 is an exceptionally innovative flexographic machine designed for optimum production of commodity labels. In addition to having the industry's shortest web path, many new advancements were unveiled at Labelexpo in Chicago to enhance – besides productivity – the machine's flexibility and performance. Already today – after less than three years after its market introduction – the Gallus ECS 340 is the world’s bestselling short-web label printing press and highly qualified for printing short to long runs with little refinement.

The Gallus Print Shop concept at Labelexpo Americas 2012 with a Gallus ECS 340, a Heidelberg Linoprint L and a Gallus ECS C.

Heidelberg Linoprint L: The inkjet system of Heidelberg, the Linoprint L is a drop-on-demand system for the cost-effective and sophisticated

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The new Heidelberg Linoprint L for cost-effective and highquality digital label printing. printing of very short to medium label and film runs and applications with variable content. Demonstrations included imprinting variable content on labels e.g. types, date stamping, serial numbers, etc., produced on the Gallus ECS 340 as well as short-run labels printed entirely on the Heidelberg Linoprint L. Gallus ECS C: The Gallus ECS C is a high performance digital converting system, which efficiently processes label runs produced by either conventional or digital technologies. Demonstrations at the booth converted labels previously

printed on the Heidelberg Linoprint L digital press. Heidelberg CERM: CERM is Heidelberg's business management and automation software that delivers customized solutions for all workflows along the entire value creation chain of a label print shop. Throughout all the demonstrations, CERM initiated every job and recorded its metrics at the end of the run. Messaging of efficient hybrid production: Very favorable reception

The Gallus exhibit was extremely well attended throughout the show dates, with a steady stream of visitors during and between each of the demonstrations. In fact, far more than 2000 interested attendees took the opportunity to witness a demo or discuss their needs with the Gallus, CERM and Heidelberg staff. The important theme of saving money by the optimised use of a hybrid production environment really hit the mark with the audience, who increasingly need to integrate newer technologies into existing shops to create an increasingly profitable business model.

AFTA AGA ALA • Issue 3 2012 -

Device Packaging: Top 10 Mistakes

Packaging is almost as important as the device itself Packaging for medical devices plays a key role in safely delivering specialised treatment to patients. Most single use, sterilised medical devices can be opened with a high degree of confidence that it has remained sterile throughout storage, handling, and transportation. 1. Losing sterile integrity This is the most common defect in medical packaging and can happen from fractured thermoforms along with pinholes, slits, cuts, and tears in pouch packages. These defects come from handling (or mishandling), vibrations during transportation, storage, and impact caused by dropping. 2. Cutting too many corners Many people in manufacturing are unaware of the need to test their packaging, or the existence of the ISO 11607 standards and the fact that these standards are being used by the FDA and the European Community. So they try to validate the packaging “on the cheap” without using sound, scientific practices. In their haste to get a product to market, companies risk noncompliance with regulations, or worse yet, they risk unknowingly let suspect devices reach patients.

What makes packaging doubly important is that regulatory authorities recognize the critical nature of sterile barrier or primary package by considering them components or accessories to the medical device. This implies that packaging is almost as important as the device itself. And it is. If a package does not, for instance, keep a pacemaker sterile, patients will be put at risk. The design and development of packaging has rightfully come under

closer scrutiny by international and domestic regulatory agencies. This scrutiny has placed a great deal of emphasis on standardising package development.Some standardisation comes in the form of the international standard ISO 11607: Packaging for terminally sterilised medical devices. Below are 10 common mistakes that companies make when developing and validating packaging systems for terminally sterilised (inside a closed package) medical devices.

The time to properly validate a fullpackage system depends on the product’s shelf life and its expiration date. For example, it usually takes three to six months to go from package concept to final qualification for a oneyear shelf life. The validation schedule should also allow for unexpected events, such as finding pin holes in the packaging after a test. 3. Not prequalifying package and product for compatibility A common package development mistake skips the preliminary evaluation and just dives into package validation.

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AFTA AGA ALA â&#x20AC;˘ Issue 3 2012 -

18 Cutting corners to trim time is shortsighted and usually backfires by extending development schedules and increasing overall validation costs because some part of the package fails. That means retests. A few common prequalification tests that should be used to detect potential design and manufacturing problems include seal strength and integrity tests on manufactured packages. A seal test, for instance, measures the force needed to open a seal. Such tests point out potential deficiencies in manufacturing and may indicate the production line needing corrective action. This should be done far in advance of testing package performance, such as for transportation, sterilisation, or handling. Prequalification tests should also be the basis for establishing targets for process quality control. Another test used to prequalify packageproduct compatibility is dynamic testing associated with transportation and handling. A shaker table reproduces the frequencies and amplitudes that the shipping container is likely to experience, for a prescribed duration. Most sterile medical-device packages do not typically lose sterility simply sitting on a shelf. Failures often stem from events in manufacturing, during shipping to the sterilisation facility, or during distribution. Therefore, proposed packages should always undergo a prequalification to isolate potential hazards and determine the package response to each of those hazards.

4. Ignoring the worst-case scenario It is often difficult to determine which shipping configuration to validate. Should you test just one product in one package? Or four products in a box? To determine the worst-case scenario, it is necessary to decide the most common shipping configuration before validating the package. In this way, other package configurations of the same or similar products may be covered by one validation. In fact, a few ISO 11607 guidelines work to device manufacturersâ&#x20AC;&#x2122; benefit. For example, a provision allows validating families of packaged products rather than individual configurations. 5. Not developing protocols Before working on a validation, write a protocol. It provides a blueprint for how testing will be done, including its purpose, scope, responsibilities, parameters, production equipment and settings, and acceptance test criteria. Validation qualifies the materials and processes that make the complete package. If one process is not right, the entire system breaks down and the manufacturer risks harm to patients. 6. Having the wrong sample size The question 'what is the right sample size for testing' is one of the most daunting to answer. Many factors play a role in determining sample size including what type of test it is (e.g. quantittive/ variables or qualitative/attributes); what is the sample population; how many samples are available for testing; what are the economics; and what are the risk factors (e.g. onfidence intervals). Most often, the sample size is too small

AFTA AGA ALA • Issue 3 2012

19 and renders results with no statistical significance. 7. Using the wrong package type/ material Using the wrong package type or material for the product is a packageproduct compatibility issue, which could have been avoided if prequalification of the packaging had been done at an early stage. Some of the typical observations that are prevalent include fracturing of thermoform trays as a result of using the wrong plastic material for the intended product (for instance, if the product mass is too great for the impact resistance of plastic). This can be avoided for large, massive products by using a high-impact resistant plastic, such as polycarbonate, to reduce the possibility of fracturing during normal distribution and handling. The thermoform design is also critical to ensure that the product is held in place firmly so that a loose product is not jettisoned through the tray lid and fracturing of the plastic doesn’t occur from the inside-out. 8. Squeezing oversized pouches into cartons Pinhole defects in pouches can be reduced by inserting the pouch into a carton without folding, wrinkling or creasing the ends. Pinholes occur at the junctures of the creases and folds when they are vibrated, causing the intersection to be ‘worked’ or fatigued at the juncture. This effect is exacerbated by making complex folds of the pouch causing a very concentrated point of stress at the juncture of the materials. This can be circumvented by using secondary packages (cartons/shelf boxes) that are large enough to allow insertion of the pouch without folding. 9. Not recognising Tyvek® separation as a false-positive One phenomenon that was discovered some years ago, but only really came to light when medical device packages began to be integrity tested routinely using bubble and dye-leak methods, was ‘sheet separation’ of the porous web of Tyvek®. In integrity tests, this ‘sheet separation’ appears as false-positive when the material is bent, folded, or wrinkled. DuPont

has

proven

that

this

phenomenon does not change the sterile barrier performance of the material and that any leakage of air or dye solution is only along the transverse direction of the material and not between the Tyvek® and poly material, as would be the case in an adhesive (seal) failure. There is no loss of filtration capability when this occurs. However, when performing these tests, it is incumbent upon the tester to analyse the failure carefully. In some cases, when there is a suspect ‘false-positive,’ it may be necessary to look at it under high magnification to determine the cause of the leakage. 10. Performing accelerated aging at high test temperatures In ill-conceived attempts to reduce costs and time, some manufacturers decide to accelerate the shelf life or expiration date studies to unrealistic and indefensible limits, usually by raising the test temperature to a level that causes packages to melt down, warp, or change in other uncharacteristic behaviors. In addition, temperatures over 65°C are indefensible based on the rationale typically used to justify accelerated aging protocols. Accelerated aging is performed on packaged medical devices to document expiration dates for products. Real time aging can be performed; however, products are often obsolete by the time a three-year expiration date is validated. The FDA does not require expiration dating for products without components with a defined effective life such as batteries, while European Directives imply that all sterile medical devices must have an expiration date. Therefore documented evidence must exist to substantiate those claims. Temperature selection for the accelerated aging study should avoid unrealistic failure conditions, such as deformation due to melting. This advice is sometimes ignored in the haste to bring products to market faster. As critical as packaging is, some companies occasionally don’t take it seriously, considering it too late in the design cycle, cutting corners, or using inappropriate materials. Avoid these above mistakes and plan well in advance to develop and validate your packaging.

AFTA AGA ALA â&#x20AC;˘ Issue 3 2012 -

Apex GTTFlex - Just two profiles for the most demanding requirements True to its ethos of "higher, faster, further", there is now an ever increasing trend towards high quality in some areas of the flexographic printing business. To cover a wide colour spectrum with CMYK alone, to print at ever higher speeds, to protect the environment through lower emissions, to reduce costs and save time and, on top of that, to ensure that every job produces predictable results that are of a consistently good standard and reproducible on a daily basis throughout a print run. Those are pretty demanding requirements! If at all, this can only be achieved if all the available new technologies are harmonised in the best possible way. It was with this in mind that the "Flexo (R)Evolution" Project was developed: an open engineering platform for suppliers and printers in the flexographic printing industry. This

1.Pressure causes counter-pressure

project, initiated and coordinated by the Apex Group of Companies, has shown that, with perfect harmonization of all the new developments in reprographics, plates, inks, tapes, substrates and GTTFlex, it really is possible to deliver reproducible, constant high print quality on a daily basis under uniform production conditions, even in areas that are currently dominated by gravure and offset printing. Achieving success more quickly Implementing new developments in existing production processes, finding the right partners, choosing the right product and, over and above that, extremely lengthy testing of new technologies - these are all very timeconsuming and expensive stages in the

2. Optimal inking

3.Ink goes beyond the cell opening and is forced to lead to over-inking/dosage PROBLEMS WITH INKING WHEN USING CONVENTIONAL ANILOX ROLLS

TECHNICAL DISCUSSION: GEORG SELDERS, APEX SALES DIRECTOR EUROPE IN CONVERSATION WITH CUSTOMERS

process. Which of us hasn't tackled the rocky road from print testing to the successfully reproducible printed product? If you want to save yourself the trouble, Apex can provide you with a concrete solution when it comes to choosing the optimum anilox roll: Leading printers do without benchmarks and with wasted time and money. Practical experience has shown that flexographic printers working in the area of flexible packaging need only choose between two types of anilox roll for high quality applications. "The GTT XS and S give us two types of roll that enable us to satisfy all the requirements of high quality printing in the flexible packaging industry. With its optimum harmonization of the most up-to-date technologies, the XS is used for plates with high ink transfer or flat top dots with very fine screens, while the S allows us to bridge the gap between high quality and conventional jobs involving standard technologies and round dots, even for very fine screens," says Georg Selders, Sales Director Apex Europe.

AFTA AGA ALA â&#x20AC;˘ Issue 3 2012

21 Open profiles instead of closed anilox roll cells What's behind it? A portfolio of different profile types covering the entire range of different industries, i.e. flexible packaging, corrugated board, labels, offset printing, varnishing and coating applications (GTTFLEX, GTTCORR, GTTLABEL, GTTOFFSET, GTTCOAT). In the flexible packaging industry, especially in the high quality range, GTT S and XS make it possible to print fine lines and screens. GTT is suitable even for printing plates with up to 100 L/cm, and even very fine dots can be reproduced without problems since dot gain can be kept under control much more effectively than with conventional anilox rolls. More constant inking allows a stable printing process. Specifically with four colour printing, GTT makes it possible to cover a wide colour spectrum. The problem with the inking of conventional anilox rolls is that the printing plate is always inked at the edge by partial cells as well. This problem is solved by GTT thanks to its innovative surface structure, in which the ink can move. Users of GTT XS have reported producing 400,000 m jobs with optimum harmonisation of all new technologies without involved plate cleaning; according to these users, that was previously inconceivable with conventional anilox rolls. However, thanks to their special surface characteristics and profiling, GTT rolls are also much more resistant to streaking than anilox rolls of comparable fineness. Results from DRUPA Thanks to the HD Flexo-certified S- and XS-generation GTT metering rolls, it's possible to satisfy the demands of both conventional and high quality printing with just two roll profiles. Nick Harvey, technical printing expert at Apex, looks ahead: "It's important to us to deal with both aspects because, even if flexographic printing is clearly moving in the direction of high quality, it must still be possible to print conventional jobs reliably and reproducibly in future!" At Drupa 2012, actual results obtained using the new trend-setting technologies from the "Flexo (R) Evolution" platform were presented by various project groups.

GTT - A NEW SURFACE SHOWS THE WAY TO SUCCESS

AFTA AGA ALA • Issue 3 2012 -

First full colour images at 100,000 dpi resolution Inspired by colourful stained-glass windows, researchers from Singapore have demonstrated an innovative method for producing sharp, full-spectrum colour images at 100,000 dpi which can be applicable in reflective colour displays, anti-counterfeiting, and high-density optical data recording.

Researchers from A*STAR’s Institute of Materials Research and Engineering (IMRE) have developed an innovative method for creating sharp, fullspectrum colour images at 100,000 dots per inch (dpi), using metallaced nanometer-sized structures, without the need for inks or dyes. In comparison, current industrial printers such as inkjet and laserjet printers can only achieve up to 10,000 dpi while research grade methods are able to dispense dyes for only single colour images. This novel breakthrough allows colouring to be treated not as an inking matter but as a lithographic matter, which can potentially revolutionise the way images are printed and be further developed for use in high-resolution reflective colour display! s as well as high density optical data storage. The inspiration for the research was derived from stained glass, which is traditionally made by mixing tiny fragments of metal into the glass. It was found that nanoparticles from these

metal fragments scattered light passing through the glass to give stained glass its colours. Using a similar concept with the help of modern nanotechnology tools, the researchers precisely patterned metal nanostructures, and designed the surface to reflect the light to achieve the colour images. "The resolution of printed colour images very much depends on the size and spacing between individual ‘nanodots’ of colour", explained Dr Karthik Kumar, one of the key researchers involved. "The closer the dots are together and because of their small size, the higher the resolution of the image. With the ability to accurately position these extremely small colour dots, we were able to demonstrate the highest theoretical print colour resolution of 100,000 dpi." “Instead of using different dyes for different colours, we encoded colour information into the size and position of tiny metal disks. These disks then

interacted with light through the phenomenon of plasmon resonances,” said Dr Joel Yang, the project leader of the research. “The team built a database of colour that corresponded to a specific nanostructure pattern, size and spacing. These nanostructures were then positioned accordingly. Similar to a child’s ‘colouring-bynumbers’ image, the sizes and positions of these nanostructures defined the ‘numbers’. But instead of sequentially colouring each area with a different ink, an ultrathin and uniform metal film was deposited across the entire image causing the ‘encoded’ colours to appear all at once, almost like magic!” added Dr Joel Yang. The researchers from IMRE had also collaborated with A*STAR’s Institute of High Performance Computing (IHPC) to design the pattern using computer simulation and modelling. Dr Ravi Hegde of IHPC said, “The computer simulations were vital in understanding how the structures gave rise to such rich colours. This knowledge is currently being used to predict the behaviour of more complicated nanostructure arrays.” The researchers are currently working with Exploit Technologies Pte Ltd (ETPL), A*STAR’s technology transfer arm, to engage potential collaborators and to explore licensing the technology. The research was published online on 12 August 2012 in Nature Nanotechnology, one of the top scientific journals for materials science and nanotechnology.

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Booklet labels for single-service fresh food prepacks: A fruitful solution The label on perishable food prepacks may be extremely transient but, despite its short life, it is still required to perform the key roles of providing both decoration for retail shelf ‘stand out’, as well as a considerable amount of product data.

Achieving these twin goals can be challenging on small containers – but Harmony Fruit and Yoghurt Desserts, developed by leading quality Swiss bakery and foods manufacturers Jowa AG for major Swiss retail chain Migros, certainly prove that it can be done. The challenge Harmony Fruit and Yoghurt Desserts are premium-quality, single-service fresh products, with a shelf life of just four days, packed in clear lidded PET pyramidical containers. They are offered in combinations featuring four fresh fruits – apricot, pineapple, strawberry and raspberry – and provide a delicious and healthy end to a meal. On the retail shelf, for such products, the consumer needs to be able to view the contents; to verify – via the label – the flavour offered; and read all the associated data – nutritional information, ingredients, weight, and sell-by date, etc. Space, however, is limited on the small, unusually-shaped Harmony containers. A creative answer Jowa’s Head of Packaging Development, Christian Pfeiffer, knew he needed a special labelling solution, and challenged specialist label printer Pago AG to deliver the answer. Pago is a regular label print partner of Jowa, and has a particular expertise in the production of self-adhesive leaflet/ booklet labels. Says Fredy Schöb, Pago sales manager: ‘Our long experience with complex label shapes combined with booklet content really helped us to develop a label for the Harmony desserts that delivered all the content elements our client required and, at the same time, looked attractive and clearly identified the flavour in the pot. As a

bonus, because the label also seals the pack lid – it additionally performs a valuable overt tamper-evident function.’ Using a 60 micron gloss white selfadhesive PP film as the base carrier for the FSC paper booklet, Pago prints the labels – incorporating three doublesided pages -- by rotary letterpress in six colours using low-migration inks, providing a double-perforated tear-off section as part of the construction. Label content is printed in three languages – French, German, and Italian. With the needs of plastics recycling in mind, the self-adhesive label laminate also features a removable adhesive. Printed in typical runs of 50,000 labels per flavour, the Harmony labels are hand-applied by Jowa staff as an integral part of their production and packaging process. ‘Real food appeal’ Christian Pfeiffer of Jowa is delighted with the end result. ‘The labels have real food appeal’, he says, ‘and for the consumer it’s easy to choose

the preferred flavour, thanks to the colourful picture of the different fruits. We chose Pago to print them because it has a very good development department, and first-class printing equipment.’ Award-winning labels The sets of labels for Harmony Fruit and Yoghurt Desserts were also recently recognised by FINAT, the European self-adhesive label industry association, in their annual Label Awards competition, where Pago was this year awarded the top prize in the marketing and end-use category for booklet labels. Kurt Walker, President of FINAT, comments: ‘Accommodating the increasing raft of textual content required by law on a food label has meant that label printers today need to be ever more creative. Pago has ably demonstrated that selfadhesive booklet labels can represent an attractive and practical solution.’

SHORTER CYCLE TIME, HIGHER QUALITY AND SUSTAINABILITY. Take a closer look and see how DuPont systems like Cyrel® FAST offer reduced cycle time, reduced steps, reduced waste, reduced greenhouse gases and an overall reduced footprint. Look closer! For higher quality at high-speed.

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AFTA AGA ALA • Issue 3 2012 -

Food Safety and Digital Printing Food safety is hardly ever out of the news. Moreover, it is not only about the hygienic production, processing, and storage of food. There is more to food safety than avoiding bacterial contamination. In 2005, isopropyl thioxanthone (ITX), a photoinitiator used in UV-curable inks, was found in baby milk.

In 2009, other photoinitiators were detected in breakfast cereals packed in polyethylene pouches inside cardboard boxes that were only printed on the outside. More recently, in 2011, mineral oils from liquid printing inks were discovered in recycled paperboard used for food packaging. If it had not done so already, the packaging industry now realized that substances used in printing inks could contaminate food even without direct contact. With digital printing gaining acceptance in the packaging market, this paper aims to provide a better understanding of how different digital printing technologies compare as far as food safety is concerned. Packaging includes folding carton, flexible packaging, and labels. The discussion is limited to indirect contact between printed matter and food – relatively few packaging applications require print on the inside in direct contact with food. For the sake of brevity, contamination from the packaging materials is not considered either. However, the reader should be aware that there are regulatory restrictions on these materials. Rules, Requirements, and Restrictions Different stakeholders apply different requirements regarding food safety. The only legally enforceable rules are those imposed by regulatory authorities. However, organisations and interest groups, certified laboratories, and, not least, brand owners have established requirements as well. Regulatory Authorities Countries worldwide have their own regulations. In Europe, the European

Commission issues directives and regulations, but member states have some leeway on local implementation. While there is a framework regulation on materials and articles intended to come into contact with food, which is applicable to all food packaging, there is not yet any specific European legislation concerning printing inks for these applications. Nevertheless, some European countries may have explicit requirements for packaging inks. Switzerland, for example, has issued restrictions on the components used in inks for food packaging applications. The Swiss Ordinance on Materials and Articles in Contact with Food lays down a list of permitted substances, i.e. the only substances that may be used in the manufacture of food packaging printing inks marketed in Switzerland. This Ordinance is by far the most stringent in Europe and has gained international recognition. In general, European legislation defines authorized substances, for which it imposes contamination limits (see below). Extensive testing by accredited

laboratories is required to demonstrate whether a specific application is ‘safe for purpose’. In the US, FDA regulations apply. Organizations and Interest Groups In the absence of harmonious European – not to mention global – legislation, several organizations and interest groups have each tried to streamline the existing regulations. For example EuPIA, the European Printing Ink Association, has developed guidelines for its members, based on the current European framework regulation, and provides detailed recommendations on how to formulate inks that will comply with this regulation. Certified Laboratories Several independent laboratories test inks and printed matter and issue declarations of conformity and product certifications. Well-known examples are Isega, Intertek, and Eurofins. The findings and advice of these laboratories inevitably influence the consensus.

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AFTA AGA ALA • Issue 3 2012 -

Polymer HDPE (high-density polyethylene) LDPE (low-density polyethylene) LLDPE (linear low-density polyethylene) PP (polypropylene) PVC (polyvinyl chloride) PET (polyethylene terephthalate) EVA (ethylene vinyl acetate) EVOH (ethylene vinyl alcohol) PA (polyamide) PS (polystyrene)

Benzophenone

Phenyl cyclohexane

-log (D)

8.3 7.6 8.3 9.4 8.5 16.0 7.5 9.9 10.5

8.3 7.8 8.1 9.3 8.4 18.0 7.3 10.9 15

-log (D): Diffusion coefficient, a measure of how quickly the molecule can diffuse through the polymer. The higher the number in the table above, the slower the diffusion. A difference of 7.7 (almost 8) between high-density polyethylene and polyethylene terephthalate (a form of polyester) translates to a difference in diffusion speed by a factor of 108 (diffusion through polyester is slower by a factor of 108 than diffusion through HDPE).

Brand Owners Increasingly brand owners are issuing guidelines, including lists of authorized and non-authorised substances. The Nestlé Guidance Note on Packaging Inks, for example, stipulates that only components that are listed in the Swiss Ordinance on Materials and Articles can be used for packaging inks, but it also explicitly excludes some of these (e.g. certain photoinitiators, acrylates, and solvents). Like the Swiss Ordinance, it is increasingly used as a reference. Moreover, while the restrictions imposed by Nestlé are not necessarily required by other brand owners and/or for other applications, there is definitely a market advantage in being able to claim compliance with Nestlé’s guidelines. It is worth noting that food safety, like many health-related issues, is as much about perceived safety concerns as it is about actual concerns. Brand owners increasingly opt for the most stringent rules possible. Printers, designers, and marketers have no option but to comply, as food safety has a significant impact on brand image. Migration and Food Safety As pointed out, the cases mentioned above show that substances from the printed layer on the outside of food packaging could contaminate food, even without direct contact. The mechanism that causes this contamination is known as migration.

Migration and Migration Thresholds Migration refers to the transfer of substances from the packaging to the food. Migration is a diffusioncontrolled process, i.e. it involves a net transport of molecules (known as migrants) from an area of higher concentration to one of lower concentration. The transfer of ink components from the printed layer can occur via penetration of the migrants through the packaging material, via setoff (see below) or through gas-phase migration. Migrants are substances that have sufficient migration potential due to their chemical composition and/or size. Migration depends on several factors: • Size of the migrant molecule – the larger the molecule (the larger its mass),

the lower its mobility, and therefore the less its tendency to migrate. • Temperature – all things being equal, migration is a thousand times faster at 100°C than at room temperature. • Nature of the food inside the packaging – migration of most organic molecules is more pronounced into fatty foods than into dry foods. • Nature of the packaging material – see below. • Type of coating applied onto the printed surface – especially important to avoid set-off migration (see below). With a view to limiting the risk, legislators have defined migration thresholds or limits. Based on toxicological evaluations, the EU authorities have compiled positive lists of ‘evaluated substances’ that are part

AFTA AGA ALA • Issue 3 2012

AFTA AGA ALA • Issue 3 2012 -

30 of the existing packaging regulations. These lists provide acceptable migration thresholds for individual substances, i.e. specific migration limits (SML). The SML is the maximum permitted amount of a given substance that can be released from a material (packaging material and/or printed layer) into food. Migration limits are typically expressed in ppm or ppb . As mentioned earlier, in the EU, printing inks are generally not explicitly regulated, but many evaluated substances are used in printing inks and therefore have to comply with the SML determined by the EU. Nonevaluated substances for which no toxicological data is available should not be detectable. A generally accepted definition of ‘detectable’ is ‘below 10 ppm’. The Swiss Ordinance explicitly imposes thresholds for substances in food packaging inks. It includes a list of permitted substances (part A) that have been toxicologically evaluated and for which an SML has been established. A second list (part B) includes nonevaluated substances for which the default SML has been set at 10 ppb. Set-off Set-off migration is the unintentional

transfer of printing ink components from the outer printed surface to the food contact surface on a reel (reelto-reel printing), in a stack or during storage (e.g. stack of printed paper cups). Note that contamination due to set-off migration can occur even in the presence of a functional or nearperfect barrier (see below). Functional Barrier One way to prevent migration is to apply a perfect barrier that is impermeable to any gaseous, liquid, or solid substance and does not itself release any substances. However, perfect barriers do not exist. A functional barrier is a barrier consisting of one or more layers that reduces the migration of authorised substances into food below their specific migration limit and also reduces the migration of non-authorized substances to a nondetectable level. This functional barrier can be an additional inner pouch (e.g. as used for the packaging of cereals inside cardboard boxes) or the printed substrate. Whether or not a material is a functional barrier depends on (1) its defined conditions of use, (2) the nature and concentration of the

substance for which it should act as a barrier, (3) the nature of the food inside the packaging, and (4) storage time and conditions (e.g. temperature). Solid layers like glass or metal are supposed to act as a functional barrier under all normal circumstances. For plastics, it is impossible to state that any type or thickness will act as a functional barrier under all circumstances. The table below shows diffusion data for benzophenone, a model molecule for a photoinitiator, and phenyl cyclohexane, a model molecule for a solvent, through different polymers at 40°C. Not all Technologies are Equal How do different digital printing technologies compare as far as food safety is concerned? To help answer this question, it is important to understand how they compare with regard to migration. First, a brief description of three commonly used digital technologies explains how they differ in the way in which print is applied to a substrate. Digital Print Technologies - Basic Principles Dry Toner Electrophotography

Digital Print Technologies Compared The table below compares three commonly used digital printing technologies with regard to migration of ink components. Dry toner electrophotography (polyester-based) Fixation Carrier Molecular mass1 of carrier Pigment capsule Molecular mass of resin Potential migrants from ink layer (worst case) Thickness of ink layer State of layer at room temperature Chemical composition of layer Tendency to migrate out of ink layer at room temperature

Liquid toner electrophotography

UV-curable inkjet

fusing and evaporation (transfusion) mineral oil and conductivity agents

acrylic monomers and photoinitiator (~7%)

not relevant

160-170

400-600

polyester polymer with high molecular mass

polyethylene polymer with high molecular mass

high

low molecular mass polyester resin fragments, some toner ingredients (e.g. charge-controlling agents)

residual mineral oil, low molecular mass polyethylene resin fragments, some toner ingredients

dispersing agent – cross-linked polymer to be formed during curing high, provided curing is complete unreacted monomer molecules, photoinitiator fragments, dispersing agent

4 microns

1.5 microns

5 microns

solid

flexible

polyester

polyethylene

polyacrylate

low

low, provided evaporation of the carrier liquid is complete

low, provided curing is complete

fusing air

curing with UV light

AFTA AGA ALA • Issue 3 2012

During electrophotographic printing, electrically charged toner particles are transferred to a substrate by an electrostatic field to form the printed image. The colorant used to produce dry toner is a pigment. Surrounding the pigment particles is a polyester resin, which is a polymer with a high molecular mass. Charge-controlling agents are dispersed in the resin to either speed up or – if necessary – slow down the charging rate and maintain the charging properties of the toner. Once the image is transferred to the substrate, heat is applied to fuse the toner to the substrate: Heat causes the toner particles to coagulate (i.e. the resin melts), forming a homogeneous, solid polyester film. Liquid Toner Electrophotography Liquid toner electrophotography differs from dry toner electrophotography in that the pigment particles are slightly smaller. Surrounding the toner particles is a polyethylene-like resin, which, like polyester, is a polymer with a high molecular mass. The amount of resin surrounding the pigment is much less than in dry toner. The electrostatic transfer of liquid toner involves a ‘carrier liquid’, a mineral oil that is partly dissolved inside the pigmentresin system. In the final step of the printing process, prior to the transfer of the image to the substrate, heat is

applied. The toner melts and most of the carrier liquid evaporates. The toner particles coagulate, forming a homogeneous, flexible polyethylene film on the substrate. After the image transfer, the evaporation process continues. Any residual carrier liquid should have evaporated within a few days. Inkjet In the inkjet printing process, liquid ink is ‘jetted’ through nozzles directly onto the substrate to form the printed image.

The colorant used to produce the highperformance inks is a pigment, as in toner. The solid pigment particles are dispersed in a carrier liquid to form a fluid. Surface treatment of the pigment particles with dispersion agents ensures a stable colloidal solution. In water-based inkjet, the carrier liquid is water. Heat is applied to dry the image and the water simply evaporates. This printing technique is rarely used for packaging applications, since adhesion to polymeric substrates is problematic.

AFTA AGA ALA • Issue 3 2012 -

32 Tendency to Migrate Given the inevitable presence of potential migrants, how likely is it that these actually migrate out of the ink layer?

Instead, packaging applications rely on UV-curable inkjet ink, which can be used on a wider variety of substrates, including polymeric substrates. In UV-curable inkjet, the ink is not dried but cured with ultraviolet light to fix the ink film to the substrate. The carrier liquid in UV ink is a reactive solvent containing monomers (e.g. acrylates) and photoinitiators. A monomer is a chemical with a simple molecular structure that can combine with other similar molecules to form a polymer. Under the influence of UV light, the photoinitiators form free radicals that react (cross-link) with other ink components (the monomers) to form a polymerized (cured) film. The ink is ‘dry’ when the cross-linking reaction is complete, i.e. when all components have been cross-linked. It is clear that some technologies are more prone to contamination caused by migration than others are. Potential Migrants As outlined above, migration depends on several factors, a major one being the size of the potential migrant molecule: The larger the molecule, the lower its mobility, and the less its tendency to migrate from one layer to another. The potential migrants differ depending on the digital print technology. Pigments are large, solid molecules that are not considered migrants. Migrants stem from the other ink components, one source being the pigment capsule, a polymer. Polymerisation generally leads

to a mixture of polymer molecules of different lengths and different mass. Indeed, the mass of a polymer is not fixed, but distributed around a mean value . In dry and liquid toner, the pigment particles are encapsulated in a high molecular mass polyester or polyethylene resin. In practice, there will be trace amounts of low molecular weight fragments present as well. The same holds for UV-curable inkjet ink where unreacted monomers or photoinitiator fragments may remain. The migration speed of acrylic monomers is a billion times faster than that of polyester resin fragments . Therefore, from a food safety point of view, it is crucial that the curing be complete. Among the potential migrants are not only low molecular mass fragments of the polymer pigment capsules, but also additives such as charge-controlling agents (dry toner), conductivity agents, mineral oil fractions (liquid toner), and dispersing agents (UV-curable ink). Evaporation and curing will eliminate these substances in liquid toner and UV-curable inkjet, provided the evaporation and curing processes are complete. However, there are many factors affecting the evaporation and curing process and most are beyond a printer’s control. The result may be different and difficult to predict, depending on the substrate, the printing conditions and printing speed, the age of the UV-curing lamp, the coating, the use of in-line or off-line finishing, and the time elapsed between the printing and the packaging of the food.

Both the state and the chemical composition of the layer are important. At room temperature, dry toner forms a thick, solid layer from which virtually nothing can escape. Due to their lower polymer content, liquid toner systems produce a thinner, slightly flexible ink layer. UV-curable inkjet produces a thicker, but equally flexible layer. The table listing the diffusion data through different polymers at 40°C (see above) also illustrates the tendency to migrate from these printed layers, with dry toner, liquid toner, and UV-curable inkjet forming polyester, polyethylene, and polyacrylate layers, respectively. Dry toner clearly has an intrinsic advantage over the other two digital technologies as far as migration is concerned. Dry Toner is One Step Ahead There are many aspects to food safety. Dry toner per se does not guarantee that the printed food packaging is safe for purpose. The toxicology of the toner components plays a role as well. However, with migration being of pivotal concern, dry toner does have an intrinsic advantage over other digital technologies. Further acceptance of digital printing for packaging applications will depend on specific developments to broaden the application area. Accurate color reproduction, color consistency, and lightfastness are equally important. Xeikon leads the way with its QA-I dry toner, which has been developed and formulated specifically with lightfastness and food safety in mind.

AFTA AGA ALA • Issue 3 2012 -

Omet and Ferrostaal’s partnership forges ahead in Asia On Omet’s stand at drupa 2012, the six-colour XFlex X6 press took centre stage. To date, with Ferrostaal’s distribution, three units have entered Asia. Christel Lee reports. It has been two years since Ferrostaal began representing Omet in Southeast Asia. The Italian company that is known for its range of hybrid presses has been steadily anchoring its position in Europe. However, although drupa is the industry’s biggest show, it wasn’t the right focal point for Omet. Paolo Grasso, international sales manager for Omet srl, commented: “Our focus is labels, therefore we will have a better advantage if we are at label expos. We have solutions for both labels and flexible packaging as well as folding cartons. Although drupa will be assessed after two weeks, I feel it’s more of a show for emerging countries. We have had very few people from Europe, almost none from United States, on our stand.” David Wong, sales manager from Ferrostaal, added: “Omet has been in the in-

dustry for a long time. However for Asia, the company is just beginning to get active and the results are showing – which is very encouraging for both Omet and us in the region. We hope to see more success in the area of packaging and labelling as they manufacture a wide range of specialised presses compatible to packaging, labelling and flexible packaging. This places Omet in a good position as the market trend is moving towards both flexibility and versatility.” Although the industry has suffered from the economic downturn over the past two years, Omet’s XFlex presses have successfully penetrated Southeast Asia with Ferrostaal’s distribution. Grasso notes, “Things started with the change of agency for Southeast Asia. In the two years we have been working together with Ferrostaal in Southeast Asia we have managed to sell to two units of

Xflex X6 to Thailand in 2011, and one to Vietnam. In 2012, we sold an Xflex X4 to Malaysia.” In response to the challenges faced in selling to Asia, Wong’s reply conspicuously reflects the traditional thinking of Asian customers. “Cost is a very important factor yet it’s a tricky topic in Asia. One can opt for economically-priced equipment but I am sure that doesn’t offer a low-cost and high productivity benefit. We have to balance this as if the price difference is too high, investors would need to justify the cost. They will only “have no choice” if it’s a niche product and there’s only one supplier around,” he points out. “If the variety is wide, you need to be really competitive and I believe that applies to all European suppliers. However this can be overcome especially when it involves a combination of technologies within a line,” he adds. Grasso shares that Omet’s brand is forging ahead well in western parts of the world but for Asia, more time is needed to establish the brand, “Our results reflect a big improvement in comparison to the previous years, and credit is due to Ferrostaal. We have also been successful in India and China. Wong concludes, “The market is still there – especially for those in traditional packaging. Those companies are looking at ways to improve their margins and quality. Run lengths are shorter and such sized printing presses would be a good way to manage today’s volume.

David Wong, sales manager from Ferrostaal (left), with Paolo Grasso, international sales manager for Omet srl

“Additionally, inline solutions and the variety of technologies able to be incorporated, give us an edge. However, customers still need to be convinced of the effectiveness of such add ons.”

AFTA AGA ALA • Issue 3 2012

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AFTA AGA ALA • Issue 3 2012 -

Practical magic China’s 12th round of five year target plans for the print industry has industry players all riled up about the government’s support in boosting the economy. It is ambitious in its thinking, yet practicality seems missing. Christel Lee reports. The sheer size of the Chinese economy means that its print market can stand independent of the rest of the world. That China is achieving recognition as a leading global player is evidenced by the growth in the number of print trade shows now held in China, which are no way inferior to those hosted in the United States and Europe. Additionally, many European players are declaring their position in Asia via diverse means – be it setting up their own operations or going through distributors to introduce, if not reinforce, the presence of the brand. A survey conducted by China-based Keyin Media on digital printing revealed a rapid installation rate of digital printing equipment in the republic. Reportedly, there were 2537 units of colour digital printing equipment installed by July 2011 – an increase of 753 units from August 2010. The survey was done on brands including HP, Kodak, Fuji Xerox, Xeikon, Océ, Canon Konica Minolta and Epson. InfoTrends’ research supports the strong growth with their research showing the China print on demand market will have an 18.8% compound annual growth rate (CAGR) on the overall retail value of print between 2010 through 2015. Given the Chinese government’s apparent measures to make the republic

the world leader in the print industry, conspicuous signs remain that contribute to further hinder the country’s controversial reputation in placing more focus on margins.

ever, the diplomatic way of putting it would be a lack of channels to transmit information and knowledge, and promote cooperative relationships. The known ones are in the minority.

Green issues? It’s not a new buzzword but, for obvious reasons, being “environmentallyfriendly” remains the most popular goal for players. However, a report from China revealed in its study that all is not hunky-dory. It was quoted as saying: “We should see that the concept, technology, management, and especially input of green printing are utterly inadequate for a massive industry with 100,000 enterprises and an annual output of RMB700 billion.”

High costs This is the obvious permanent factor, with which companies continue to grapple. It’s not hard to conclude why it is so; green initiatives-supported equipment and materials are known to cost more. Manufacturers are constantly negotiating the alarm bells that ring “Budget!” with the “Long-term returnon-investment” mantra.

The report added the factors that influence the effectiveness of green printing include: Poor communication One of the major sources of confusion that occurs in the process of implementing green printing is from the failure to understand various policies and standards in execution, use of raw materials and the preparation of certification. Lack of benchmark and interactions Not many players are “gracious” enough to share trade secrets. How-

While being green is something deemed right yet beyond reach as of now, it remains to be seen how long before the republic will eventually realise its target of being known as a greenprinting economy. Europe is reportedly sliding back to recession after the topsy-turvy political situations plus the known monetary deficits suffered in a few nations. This will render China in a perfect position to claim its position in the market; after all, the republic is also known as the world’s factory. It is also inevitable that as competition gets fiercer, values will risk being put on a pedestal when margins take top priority. A battle of willpower will prevail in the next few years.

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AFTA AGA ALA • Issue 3 2012 -

Labels: adding value to packaging

by Jules Lejeune, managing director FINAT

The evolution of supply and demand for self-adhesive labels is not just a matter of collecting and interpreting industry statistics and quantitative indicators. Especially in the last three to five years, macro-economic factors such as the twin crises of bank credit and sovereign debt, and the associated volatilities, have distorted the picture of underlying longer-term trends and developments. What are these underlying trends? How is the label industry positioned in the context of the broader packaging industry? What is driving demand for labels in comparison to alternative decoration technologies? What is the label printer’s share of the total added value created along the supply chain? How are continuous innovations in technology and materials helping label printers to claim a bigger share of the pie? What are the corporate strategic options to be pursued to ensure a sustainable company future? In this article FINAT aims to address these questions and monitor relevant trends and developments. The advent of the paper bag – the universal packaging in a 19th century grocer’s shop – created the need to

a particular brand, as the consumer society gained momentum after the Second World War.

identify the contents with some kind of ‘label’. This was, of course, really helpful for customers; and, since then, labels have been expanding their role in packaging, driven by legislative demands as well as the need to promote

Labels: adding convenience and versatility Today, it is certainly true that a self-adhesive label adds value to a product’s packaging in a variety of ways: as a source of information on pack contents; as a location for barcodes and other track-and-trace and authentication devices; and as a promotion and decoration. In all these spheres, the convenience and versatility of the self-adhesive laminate have been key contributors to product packaging. They serve manufacturers across the whole spectrum of products, providing a valuable and easily-accessed tool for product development and marketing, particularly for direct-label goods – today the world’s dominant brand, and the leading driver for demand in packaging and labels. Even in the 21st century, self-adhesive labels are adding value to products and brands in new and developing ways, around the world, in partnership with an ever-changing base of packaging materials. Label converters benefit -- almost uniquely in a manufacturing environment – from being part of a harmonised but complex value chain that embraces raw materials suppliers, self-adhesive laminators, ink, die, and other press consumables suppliers. All levels of this value chain are assisted and nurtured by the European association for self-adhesive labelling, FINAT, and its counterpart organisations around the world.

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AFTA AGA ALA • Issue 3 2012

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AFTA AGA ALA • Issue 3 2012 -

Trade associations – facilitators of global standards and best practice As ‘umbrella’ organisations, trade associations create industry standards and drive ‘best practice’; facilitate networking, lobbying, and promotional opportunities; and provide technical and legislative updates. At a time when sustainability, food safety, and optimisation of the world’s natural resources are key criteria, uninterrupted status information on global and regional legislative issues such as REACH, is essential for everyone in the label supply chain.

a key factor in the region’s positive growth. North American self-adhesive label demand growth has been was driven primarily by VIP applications. Asia Pacific takes the largest global share of the overall label market today, and here self-adhesive labels demonstrate healthy growth, with new label laminating companies, as well as converters, proliferating. The newest label market, Africa and the Middle East, combines both mature and unstable economies, but is evidencing healthy overall growth for self-adhesive labels.

After all, today’s self-adhesive label industry is increasingly global in its reach, serving the international brand owners and retailers across all their regional markets.

Raw materials inflation and sustainability: push for downgauging With its complex make-up, the selfadhesive labelstock is particularly susceptible to raw material price

Global breakdown of label demand Global label demand (across all technologies) is expected to reach over 50 billion m2 by 2015. World label demand growth for 2012/13 will be approximately 6-7%. The prime volume markets are foods, beverages, personal care products, and pharmaceuticals. The world’s emerging economies – particularly the BRIC countries – are driving that growth. Self-adhesive labels, along with glueapplied labels, still represent together nearly four fifths of the total label market, but face competition today from sleeving and in-mould labels – both of which are exhibiting positive growth, particularly in the food and beverage markets. In Europe, the dynamic development in recent years in the eastern countries has slowed somewhat, but remains

increases – and these have characterised the market for nearly two years, creating margin pressures at every level of the value chain. Prices for platinum – the initiator for silicone release coatings – remain extremely high, and crude oil prices, fluctuating in response to world political issues, continue to be of high concern, particularly in relation to plastic films. While paper labels and release liners continue to dominate self-adhesive label use, film facestocks and release liners are gaining market share. Environmental concerns and the quest for sustainability are encouraging the use of ‘downgauged’ self-adhesive labelstocks – in order to reduce material usage; to save cost; to reduce inventory storage space; to save (thanks to lighter weight) on transport costs. Lower-gauge film facestocks and release liners are key players in this arena, with significant reductions in basis weight achieved. Secondary use of label materials: towards commercially-viable solutions In papers, the manufacturers have more limited opportunities to downgauge, but are concentrating on specialties, like wash-off labelstocks for bottles, security papers embedded with forensic and other taggants, and wine label laminates offering ‘ice bucket’ performance. The proven recyclability of glassine release liner

AFTA AGA ALA • Issue 3 2012

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42 is now beginning to encourage the continuing use of paper labelstocks. At the same time, the skills of the papermaker are being increasingly employed in the ‘cradle to cradle’ repulping of glassine release liner. It is a sad fact of life, however, that the label industry and its customers have yet to fully take advantage of such schemes: their commercial capacity has not yet been filled. It is important to add that the remainder of the waste stream created by converting self-adhesive labels – namely the matrix waste – has yet to find a ‘cradle to cradle’ solution – although, as has been proven over a number of years, it can be successfully used in industrial incinerators for waste-to-energy recycling. The continuing popularity of the ‘no label look’, created using clear film label facestocks, is not the only driver for film usage in self-adhesive labels today. Film release liner, PET or PP, is increasingly a choice today. The combination of film facestock and film liner enables serious downgauging of label laminate, to deliver more labels per reel, fewer roll changes on press and on the labelling line, and therefore significant time and cost savings. Cost savings are additionally enhanced by recycling the film release liner: world shortages of PE granulate and high demand have made recycled liner a financially viable commodity.

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eltromat Automation South Asia Pvt. Ltd. Ahmedabad, India T +91 79 40322848 southasia@eltromat.de

Broadening the agenda Label converters today are, indeed, at the centre of an intermingling of technologies in the packaging chain, offering both web-fed self-adhesive labels and sheet-fed wet glue labels, as well as flexible packaging and tube laminate. They are also experiencing, in the M&A arena, buyouts by flexible packaging companies

eltromat GmbH Hong Kong office T +852 8201 6832 (Hong Kong) T +86 139 2602 7506 (China) china@eltromat.de

sincon_star_90x260mm_120706.indd 1

Film-based labels: where decoration technologies meet in narrow webspace However, it is in the realms of film that self-adhesive labels today see their greatest competition. As stated, film-based shrink sleeve labels, stretch and wraparound sleeves, and in-mould labels are today enjoying faster growth rates. However, these technologies are opportunities as well as threats, and self-adhesive label converters today are embracing the concept of ‘one-stop shopping’ – offering their customers not only the self-adhesive path, but also the non-adhesive technologies which can be profitably and ably printed on their narrow-web presses.

08.07.12 10:56

THINK BEFORE YOU INK

color es of digital ri e S 0 0 0 3 ard “ The Xeikon al step forw re a ts n e s re us presses rep has allowed It t. e rk a m l vels for the labe unreached le ly s u io v re p to achieve and quality.” y it v ti c u d ro of p r, — Jay Ziegle g,

tin ales & Marke Inc n o c e p Ta

Director of S

code Use this QR e. to read mor

You want to feel confident about choosing your digital label press. Selecting the right digital press is a difficult process – which one will be right for your business both now and in the future? You need to be able to rely on the experience, know-how and excellence of Xeikon equipment.

Xeikon simply ticks all the boxes: ✔ High profitability ✔ Superb print quality ✔ Unique flexibility ✔ Unrivalled sustainable technology Xeikon International BV T. +31 (0) 117 37 50 20 info@xeikon.com

www.xeikon.com

Think about it. Think Xeikon.

AFTA AGA ALA • Issue 3 2012 -

wishing to expand their offering, and also mainstream packaging companies purchasing self-adhesive label converters to develop their capability to provide perosnalised packaging. Digital: shorter runs, higher break-even point The narrow-web presses that characterise self-adhesive label production have in recent years mostly employed the flexographic print process, most recently coupled with

Linerless: a revival of interest for special applications Linerless self-adhesive labels – which briefly enjoyed popularity in the 1980s – are enjoying a resurgence of interest; and technology advances have made them a real success currently for supermarket catchweigh food prepacks in particular. Limitations on label shape have held this format back, but developments are ongoing and this is an area to watch. Technology advances: enhancing t he brand experience On-press trends include an everbroader toolcase of special finishes for labels, such as photochromic and high-

gloss metallic inks; time-temperature indicators; holograms; and tactile varnishes. Designed to enhance the consumer’s experience of a product’s packaging and create shelf ‘standout’, they partner highly-engineered permanent and removable adhesives to deliver the perfect performance for the brand owner’s needs. Connecting the global label industry network In an increasingly-global label market, there is a real need for a ‘living’ network for the whole base of industry players, sharing information and knowledge, transcending the boundaries of countries and languages. Within less than three years, the L9 – the global collective of label industry associations, of which FINAT is a founder member – has made enormous strides in this direction, sharing knowledge and experience on sustainability and recycling; jointly promoting the label industry’s ‘best-in-class’ at the World Label Awards; introducing benchmarking and standardised best practices; And thus bringing benefits for all members and their end-user customers. pluess-ag.com

speedy UV curing. However, the fastdeveloping narrow-web digital colour print options – particularly the HP Indigo and Xeikon – are dramatically changing the face of label print today. As brand owners and retailers opt for shorter production runs of their products, delivered more often, as well as multi-versioning of products using the same basic packaging, so the speed, flexibility, and shorter-run capability of digital print is proving itself.

SOFT DOCTOR BLADE

www.swisstec-ag.com

For decades Daetwyler SwissTec, formerly known as Daetwyler, has been the leader in innovation for doctor blades. During this time many of the Daetwyler products have set new standards in the printing industry. | The innovative SOFT Doctor Blade is made of carbon doctor blade steel with a corrosionresistant coating. With its self-repairing feature this doctor blade has a softer, gentler point of contact, resulting in a significant reduction of score lines in Flexographic printing and reduced streaks and hazing in Gravure applications.

SwissTec AG Inserat_Soft_EU_178x130.indd 1

11.02.10 11:26

IST METZ presents: The new MBS®-6 Most efficient UV system of the world

Thanks to the completely new URS® Duo Reflector Geometry the MBS®-6 sets new standards. The system requires a lamp output of just 120 W/cm in order to achieve the same curing results as standard 200 W/cm UV units. The energy saved has a direct influence on electricity bills.

For further information please visit our website www.MBS-6.com.

IST METZ GmbH Lauterstraße 14-18, D-72622 Nürtingen Tel. +49 7022 60 02-0, Fax +49 7022 6002-775 info@ist-uv.com, www.ist-uv.com

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46 businesses. Equally, there are lessons to be learned from other industries about what NOT to do.

Labels: the interactive medium connecting product and consumer Label content is becoming increasingly an issue as the requirements of brand owner and retailer are transcended by the requirements of legislation on information and food safety, security and logistics input, and customeraccessible additional information via QR codes and similar devices. As a result of this broader agenda for label content, label size has increased; and leaflet label usage has grown considerably – particularly for pharmaceuticals. In the pharmaceutical field in particular, in the face of growing instances of counterfeiting, the addition of Braille content, and overt and covert security and trackand-trace devices is extensive. In this context, there are real opportunities for label printers to engage with commercial packaging companies – in cartons, for example – to add value in terms of enhanced customer experience and engagement with a particular brand. Self-adhesive labels can certainly enable mainstream sectors of the packaging industry to benefit from 21st century brand identification strategies, without the need to change their core technology base. Corporate strategies for the label printer The self-adhesive label converting industry came into existence very much as a family concern, based on small businesses, initially serving regional or

specialist markets. The international nature of today’s leading brands and growing globalisation have necessarily changed the face of the industry via a continuing stream of mergers and acquisitions. However, the industry values its origins, and there is a strong desire to retain the ‘family’ aspects of the business, even in the context of ‘growing’ the company. As a relatively young industry in the context of printing, and a downstream user of a variety of raw materials, there are many things label converters can learn from old-established industries like paper and board, and from new packaging formats like flexible packaging. Their successes can be analysed, and could indeed be replicated in part in label converting

A dynamic and creative sector of the packaging chain Packaging has come a long way since the original paper bag – and labelling has had to move with the times to embrace developments that have encompassed tin cans, plastic bottles, and flexible packaging. Self-adhesive labels have proved themselves perfect, innovative partners in all these developments. They continue to represent a dynamic and creative sector of the packaging chain, offering unparalleled flexibility and versatility. What is more, they are the product of a value chain that is deeply committed to sustainability, lean manufacturing, and – above all – meeting the buyers’ needs in terms of aesthetics, applied performance, and price. About FINAT FINAT, founded in Paris in 1958, with headquarters in The Hague (The Netherlands), is the worldwide association for manufacturers of self-adhesive labels and related products and services. With 600 members in over 50 countries around the world, FINAT has much to offer to label converters and all suppliers to the labeling industry in terms of information exchange and the opportunity to network internationally. www.finat.com

2 versatile workhorses AFTA AGA ALA • Issue 3 2012

The Rotomag MXP 5 colour Flexographic high-speed press for tickets, labels and packaging Up to 10 colours – 520 wide highspeed line drive or servo drive Machine accessories: UV dryer servo tension control camera system 52” Jumbo unwind 52” Jumbo rewind Turn bar 3 x die cutting units High-speed, quick make ready press

Rotomag SP7 Rotomag Spy multi-purpose plough folding, booklet inserting, inkjet numbering, die cut to register, roll to roll, roll to sheet. This machine can also be used as a finishing machine, die cutting to register of digitally printed stock and digital finishing.

We customise and design to suit your needs. For sales information and enquiries, please contact Peter Jessop on +61 (0)418 475 045 21 Bullecourt Avenue, Milperra NSW 2214 Australia Phone (61) 02 9792 4444 Fax (61) 02 9774 2317 Email sales@rotaryeng.com.au www.rotaryeng.com.au

AZ_Fas

AFTA AGA ALA • Issue 3 2012 -

TETRA PAK completes €42 million site expansion in Singapore Tetra Pak announced that the company has inaugurated a Coconut Knowledge Centre and completed a €42 million (S$67 million) investment to upgrade and expand its operations in Singapore, which includes a state-of-the art printer and new building. The investment is designed to meet customer needs across the growing Southeast Asian market and to improve the company’s competitiveness in other parts of the world. “The Coconut Knowledge Centre’s objective is to build market and technology expertise that will extend our leadership in coconut beverage innovation. This will be very important for our customers in the region who are growing their local markets and expanding sales abroad, particularly in the US,” said Rusty Kekuewa, Tetra Pak Vice President, South and Southeast Asia. Coconut water is a popular beverage in Asian countries but has generated increasing interest and sales in developed countries in recent years as a sports and health drink. Global coconut water consumption is expected to increase,

A minor

driven mostly by the United States. Volume sales of coconut water in Tetra Pak packages have grown by an average of 26% annually from 2007 to 2011.

the Philippines – accounting for over 75% of total world production, according to the UN’s Food and Agriculture Organization.

Three of the world’s largest producers of coconuts are located in South and Southeast Asia – Indonesia, India and

The Coconut Knowledge Centre will provide technology and innovation support to customers; build knowl-

investment with RENZMANN into your washing area improves

Safety, Health, Environment and

saves your money !

D.W. Renzmann · Apparatebau GmbH · Industriestraße 1 · D-55569 Monzingen/Germany Phone: +49 (0) 67 51 878-0 · Fax: +49 (0) 67 51 878-111 · info@dw-renzmann.de · www.dw-renzmann.de

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Making Mounting Fast and Easy tesa Softprint® Fast & Easy has a new adhesive, that meets the modern requirements of flexographic printers; a tape so pliant that it will form itself to every sleeve or cylinder, is easy to use and enables fast mounting without problems. After the job is done, demounting can be managed without damaging the plate or leaving behind adhesive residues.

tesa Softprint® Fast & Easy

Benefits Easy mounting Easy repositioning Easy demounting No adhesive residues High quality print results

tesa® – Process Improvement in Every Roll

tesa SE · D-20253 Hamburg · Phone: +4940-4909 2103 · Mail: flexo.tapes@tesa.com · www.tesa.com

AFTA AGA ALA • Issue 3 2012 -

liver on innovation and quality to our customers in the region and around the world,” said Kekuewa.

edge of coconut products such as water, milk and cream; develop new recipes and expand knowledge sharing amongst its international network of coconut experts. Tetra Pak also announced the completion of a €42 million investment in its Singapore operations that took place over the course of three years. The investment included a new printer installation and a laminator upgrade in its packaging material factory that will boost production capacity by 33%

from 15 billion to 20 billion packs per year. It also included new facilities for staff and customers. “Demand for food processing and packaging solutions in this region has been on the rise, and looks set to continue to climb over the next decade,” said Kekuewa. He noted that demand for Tetra Pak packages in the region is forecast to nearly double from 2012 to 2020. “Tetra Pak continues to invest to de-

Exports from the Singapore plant serve 45 markets, with around 90% heading for countries in South and Southeast Asia. Tetra Pak’s business units and functions located there include one of three Global Information Management centres, R&D capabilities, Processing Solutions, an HR Service Centre for the region, Technical Services & Parts Support and part of the Global Supply Chain and Global Audit teams. The site is staffed by 650 employees representing 24 nationalities, reflecting Singapore’s cosmopolitan profile. pluess-ag.com

Tetra Brik® Aseptic

Both the new printer, which boasts the cutting edge Flexo process, and the upgraded laminator began production earlier this year. The additional capacity will enable the plant to produce packages with closures requiring pre-laminated holes. This will be used for Tetra Brik® Aseptic packages with Helicap 23 & 27. Next year the plant will be producing Tetra Prisma® Aseptic 330ml and 1000ml packages.

SOFT DOCTOR BLADE

www.swisstec-ag.com

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Click. Click. Click... Friends, the numbers are in. And they prove our new way of moving ink to plate has made many people happy. Very happy, evidently. As of September this year, Apex has sold 31,884 patented GTT ink-metering cylinders worldwide. ( Wow. That’s a lot of printers counting on GTT. )

Four years later, thousands of flexographers the world over have welcomed GTT inkmetering cylinders to upgrade from their old-school closed-cell anilox rolls. Why do you suppose our customers order – and then re-order – GTT engravings? Is it

because GTT can deliver a more precise dot? And can do the work of two or three conventional anilox rolls on fewer stations? Can enable faster printing and drying? Can even save on ink usage — and is a snap to clean? It’s no surprise why so many call GTT their “secret weapon.”

What can we engrave for you today?

But don’t get the wrong idea: we love anilox. It’s our bread and butter. In fact, we actually pioneered 60° hexagon anilox geometry. And as the world’s largest anilox manufacturer, we’ve sold over 400,000 UltraCell®

anilox rolls since 1989. What sets UltraCell anilox apart is Apex’s continual innovation: our UltraMelt laser engraving, nickel corrosion barriers, new super-dense ceramics and advanced QC/QA. Among other things – like prompt delivery. But enough about us. See for yourself what so many of your competitors already know: GTT and UltraCell can help you print better, faster and more profitably.

31,884

432,891

Hello, GTT

Apex invented GTT to solve a problem many printers didn’t even know they had: unpredictable, wasteful and inefficient anilox ink-transfer to plate. Our “big idea?” An open slalom ink channel where ink can flow. Sayonara, closed cells.

UltraCell GTT Global Unit Sales

Start counting on Apex – and count on quality. Download the facts today. Or just ask for your quote.

visit www.apex-groupofcompanies.com

THE FUTURE OF FLEXO

AsianFlexoGravLblng 2-12.indd 1

CONVENTIONAL ANILOX. UNCONVENTIONAL QUALITY.

Apex AsiA T 65 (0) 6284 7606 E apexasia@singnet.com.sg W apex-groupofcompanies.com

The Measure of Quality.

Apex eUROpe Apex nORth AmeRicA T 31 (0) 497 36 11 11 T (724) 379 8880 E info@apex-europe.com E info@apexnorthamerica.com W apex-groupofcompanies.com W www.apexnorthamerica.com

Apex lAtin AmeRicA T 55 (41) 3677 2678 E info@apexlatinamerica.com W www.apexlatinamerica.com

9/28/12 5:10:54 PM

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Meeting demands of the Australian Wine Industry. In an endeavour to lower costs to keep the Australian Wine Industry competitive due to the increase in value of the Australian dollar, a local company has answered all the calls to create products for lower grade label stocks. Many may not realize that 20 years ago Australians were pioneers in changing the wine labeling industry to using pressure sensitive labels. Pressure sensitive means that the adhesive is preapplied to the label and that it is peeled off a siliconized backing paper before transfer to the bottle. Prior to using P/S labels, the industry relied on “wet gum” gluing. The labels were printed like any other print job and then guillotined into single labels that were fed through an automatic gluing machine. Registration was often difficult and the label lacked embellishments. Using P/S labels, the label can be foiled, embossed and print can be raised. The labels can be Matt, Satin or Gloss or a combination of the three. Naturally the labels cannot scuff in the bottling race nor in the carton – either against themselves or by rubbing of the dividers or corrugated board. The first criteria of an acceptable label is suitable “rub” resistance and this is achieved by using the right combination of resins and waxes. These days the demand is for more and more of a Matt or “Flat” look. The more Matt a product the more difficult it is to get the “machining” properties right. Monocure Pty. Ltd. a privately owned company in Auburn, NSW has managed to solve all these problems. “It started to make UV curable varnishes for the wine industry when the company was in its infancy in 1982 “ Alan Anderson the Managing Director said. At that stage Collotype in South Australia had installed the first UV curable printing press. Labels in those days were still made by the “sheet fed”

process but still had to have water and scuff resistant properties. Both companies installed “rub testing” machines and new standards were established for the industry. The first narrow web pressure sensitive label machine for production of wine labels was purchased by them soon after this. The same standards applied but varnishes had to be made to suit all the different applications, UV inks and varnishes “cure” by passing the wet inked label under a synthetic source of UV light. This is provided by a mercury lamp that has to be cooled and the fumes exhausted to prevent ozone build-up. It means inks are solvent free and there is no need for expensive “drying tunnels” to dry the wet ink or varnish. Since then printing machines have been made to run faster and faster. Machines today are moving at 170M/Minute compared to 20-40 to start with. Inks, varnishes and embellishments all have to be able to work at these speeds.

Monocure began life as an offshoot to a successful Australian owned adhesive company. Alan Anderson the owner started Staybond Pty. Ltd. In 1968 after returning from his grandfather’s company in Scandinavia. He introduced PVA adhesive to Australia and was instrumental in changing Unilever to using PVA instead of hot animal glue to seal their soap cartons. Staybond changed the wine and beer industry to using water resistant adhesives for their labels so labels did not come off in ice buckets or eskys. The adhesive industry in Europe was much more advanced than Australia and having had experience selling to the packaging and woodworking industry in Europe and Ireland during the early 60’s, Alan was in a perfect position to build his adhesive empire in Australia. Staybond was sold to National Starch and Monocure was separated as a stand alone company. It may be of interest that the company began by doing work for the CSIRO.

AFTA AGA ALA • Issue 3 2012

They were supplying a binder to bond straw along the side of roads and the CSIRO asked them to try it bonding bagasse (sugar cane fibre) to nude sheep after they were chemically de-shorn. The sheep suffered from frostbite in the winter and sunburn in the summer and had to be protected until the new wool growth appeared. “Nothing we had stuck to the lanolin” Alan Anderson said. A recent graduate from the University of NSW working in the company’s laboratory said he knew how to solve it. He mixed a resin with a foaming agent which once sprayed became like a sponge. When the sheep went into the sun the coating “cured” and the spongy coating lasted two months until the new wool grew. One day whilst lunching with the Women’s Weekly production crew, one of them heard this story and said let’s leave the foaming agent out and replace it with pigment. This was then passed under a synthetic source of UV light and a waterbased environmentally friendly UV curable ink was born. With the assistance of venture capitalists, the company grew and in recent years its focus has been on increasing market share rather than largely R&D (funded by grants). The company’s success lies in its ability to create a product for an end use - often at short notice. It still has an excellent R&D team and is well known for its ability to react quickly and solve customers’ problems. Monocure now supplies to all states of Australia and exports to Asia, New Zealand and South Africa. With a favourable dollar they sold to a Scottish label producing company and its products have been used on labels for leading brands of whisky. Monocure is a typical example of what can be achieved in Australia using personal initiative, perseverance and expertise. Opposition products come in from all around the world often at very cheap pricing but it is the continuing high quality of its products and the ability to react to day to day problems that keep the company alive. Its website can be seen on www.monocure.com.au and any enquiries from Asia are welcomed.

165 Asia

AFTA AGA ALA • Issue 3 2012 -

Major Savings through EASY-COL Since its launch, EASY-COL, the color management system developed by Windmöller & Hölscher (W&H) for automatic colour matching and residual ink reduction on W&H central impression presses has been sold more than 70 times world-wide.

MIRAFLEX AM 8 with EASY-COL at JG SERVICE AG based in Bavarian Hohenwart. ever was operating the press, absolutely consistent colour matching results were achieved with EASY-COL. With a maximum of two-colour match cycles, colour specifications were accomplished, resulting in less waste, reduced time expenditure, and minimum left-over inks”, says Ernst Schönacher, operations and production manager at JG SERVICE, summarising the positive results.

Reproducible color matching on the press, thanks to EASY-COL German based package printing company JG SERVICE AG has been using EASY-COL on a MIRAFLEX AM 8 since the end of 2010 and has achieved perfect colour matching results in everyday production, resulting in major savings in terms of waste, residual inks and press make-ready times. Fast, reliable and reproducible color matching at job change-over has become of vital importance to the commercial efficiency of the printing press. Without the color matching feature installed, up to 50% of the complete job change time goes to this make-ready step alone. With EASY-COL installed, the time needed for colour matching is notably reduced, while, at the same time, ink usages are constantly logged during production to minimise the quantity of left over inks.

Medium-size JG SERVICE AG, located in Bavarian Hohenwart / Germany, decided in 2010 to buy a MIRAFLEX AM 8 with EASY-COL – by the way, their first W&H flexo press – in order to extend its equipment in the field of high quality flexo printing. The company was established in 1992 and currently employs a workforce of around 50. The production portfolio essentially encompasses packaging material for the pharmaceutical, cosmetics and other non-food industries. When specifying the MIRAFLEX, JG SERVICE’s focus was, from the outset, on extensive process automation to ease and accelerate job changeover procedures to the greatest extent possible. EASY-SET and EASY-REG modules for automatic impression setting and registration were, therefore, a must. To complete the automation options, the company decided to add another W&H innovation, i.e. EASY-COL for ink weighing, residual ink reduction, and decentralised colour matching on the press. “From the time the MIRAFLEX in conjunction with EASY-COL went on stream, it became clear that who-

Today, EASY-COL is being used by all printers operating the MIRAFLEX, resulting in reproducible and provable color corrections. The quantity of left over inks has been dramatically cut down. In judging the results all press operators at JG SERVICE unanimously arrive at the same positive conclusion that EASY-COL is a must-have also for any future investment in printing equipment. There is of course more than just the enthusiasm about EASY-COL as a highly useful feature of the MIRAFLEX. Since production start-up, the MIRAFLEX AM 8 has been producing superb print results. The 2011 DFTA award testifies to the fact that JG SERVICE is achieving print quality of distinction and does count among the leaders in package printing. Lengerich/Germany based Windmöller & Hölscher is an internationally leading manufacturer of machinery and equipment for the flexible packaging industry. The product line encompasses blown and cast film lines, flexographic and gravure printing presses, equipment for surface finishing and converting of paper, film and woven plastic material, as well as FFS (FormFill-Seal) packaging systems. With a workforce of currently around 2,100, W&H realised a turnover in 2011 of 550 million Euro.

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165 Asia Pacific Packaging 297x210 + Bleed_Martin 297x210 29/09/2012 18:46 Page 1

NO MATTER HOW GOOD YOUR PIT CREW Stopping Your Press for Roll Changes Costs Time and Money

STAND E17

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OUR EXPERIENCE...YOUR ADVANTAGE

AFTA AGA ALA • Issue 3 2012 -

New dimension to structural packaging design Added 3D features, Intelligent Dielines tools and cloud-based enterprise collaboration help bring products – including Retail Ready Packaging – to market faster With the introduction of a new major release of ArtiosCAD, version 12, Esko offers a paradigm shift in packaging design from 2D to 3D. Providing tools for 3D design, editing, rendering and visualisation, ArtiosCAD 12 assures that the viability of a package is discovered further upstream in the supply chain. It also provides new tools for packaging design and process integration to help users gain productivity and increase efficiency. ArtiosCAD is the flagship structural packaging design editor in Esko's software suite with over 13.000 licenses sold worldwide. “It all starts with structure. The structural design determines the placement of the graphics. The package converting is determined by the structure. Structure and graphics, as well as structure and logistics, are brought together with the use of ArtiosCAD. Only ArtiosCAD offers end-to-end communication for the entire packaging supply chain,” says Richard Deroo, Esko Product Manager, Structural Design. “Our commitment to continuously improve our solutions for our customers help them fulfill increased demand to push more products to market faster, at the lowest cost, in a global market.” ArtiosCAD 12 focuses on 3D tools and communications Supporting Esko’s vision of shifting design from 2D to 3D, ArtiosCAD 12 brings customers many time-saving features. It has integrated the latest native 3D file import libraries from Esko’s technology partner, Spatial. This offers a speed improvement of over 50%, which means designers will spend less time waiting to import 3D models. Users will also benefit from the 3D import preview feature, allowing them to select individual parts from a

ArtiosCAD12 ARD with dynamic artwork and panel info model assembly. This lets the structural designer quickly and automatically build a carton around the imported 3D parts to be packaged. In addition, ArtiosCAD helps to assemble multi-part designs and displays with a number of new timesavings features. For example, with a single mouse click users can fill a carton, case or tray with the product to be packaged. This saves hours developing multi-part designs. Placement of one design With the introduction of a new major release of ArtiosCAD, version 12, Esko (www.esko.com/ArtiosCAD) offers a paradigm shift in packaging design from 2D to 3D. Providing tools for 3D design, editing, rendering and visualisation, ArtiosCAD 12 assures that the viability of a package is discovered further upstream in the supply chain. It also provides new tools for packaging design and process integration to help users gain productivity and increase efficiency. ArtiosCAD is the flagship structural packaging design editor in Esko's software suite with over 13.000

licenses sold worldwide. “It all starts with structure. The structural design determines the placement of the graphics. The package converting is determined by the structure. Structure and graphics, as well as structure and logistics, are brought together with the use of ArtiosCAD. Only ArtiosCAD offers end-to-end communication for the entire packaging supply chain,” says Richard Deroo, Esko Product Manager, Structural Design. “Our commitment to continuously improve our solutions for our customers help them fulfill increased demand to push more products to market faster, at the lowest cost, in a global market.” ArtiosCAD 12 focuses on 3D tools and communications Supporting Esko’s vision of shifting design from 2D to 3D, ArtiosCAD 12 brings customers many time-saving features. It has integrated the latest native 3D file import libraries from Esko’s technology partner, Spatial. This offers a speed improvement of over 50%, which means designers will spend less time waiting to import 3D

www.matthewsworldnet.com

Matthews. We understand brands.

»The most human thing we have is language.« Theodor Fontane, German writer

Anyone who wants to know his way around the world’s brands, who wants to understand them and really look after them, has to speak their language. Which is precisely what we do at Matthews. With superbly trained staff on the spot, no matter whether it’s in Paris or London, New York or Hong Kong.

A global family of world-class specialists focused on bringing brands to market successfully

Matthews International · Rudolf-Diesel-Str. 16 · 52428 Jülich · Germany Tel.: +49 2461 9353 0 · info@matthewsworldnet.com

AFTA AGA ALA • Issue 3 2012 -

58 available in ArtiosCAD, makes it easy for designers to work with curved folds and cuts by allowing them to visualize designs with curved creases as part of its 3D module. Support for thicker materials such as Re-board, along with correctly designing V-notches and edge bands makes it easier to visualise and convert designs of this material..

ArtiosCAD12 shipper with tear strip models. Users will also benefit from the 3D import preview feature, allowing them to select individual parts from a model assembly. This lets the structural designer quickly and automatically build a carton around the imported 3D parts to be packaged. In addition, ArtiosCAD helps to assemble multi-part designs and displays with a number of new timesavings features. For example, with a single mouse click users can fill a carton, case or tray with the product to be packaged. This saves hours developing multi-part designs. Placement of one design Dielines features to communicate brand guidelines within their technical drawings, helping to improve communications between structural and graphic designers. “ArtiosCAD 12 is fantastic. Esko added all the features that I needed, including some 3D rendering tools I suggested to them,” enthuses Peggy Underwood, Graphic Design Manager at Corrugated Container Corp., a company that focuses on POP and displays for product packaging. “I was trained as a graphic designer and knew that Intelligent Dielines would be very helpful as we send structural designs to graphic designers and ad agencies. Before, to assure designs would be correct, I manually placed the art orientation using Adobe® illustrator® and explained which panels would be printed. Now it’s all done with the click of a button. This probably cuts threequarters of the time it took in the past.” “No graphic designer is going to feel so helpless and confused again when looking at flat structure,” adds Underwood. “Some of our projects, including sales kits with many compartments, are very complicated and it is difficult to see which of the

pieces are visible in the final layout. Now, there are ‘up’ and ‘down’ arrows to show orientation in the artwork. The 3D views with arrows help designers understand why a panel is in a certain direction. And, with all the 3D tools in ArtiosCAD and Esko Studio, we are able to show our art without having to produce mock-ups. The new Array and Collision tools make packing out our displays very quick and easy, saving us a ton of time.” Supporting the supply chain downstream, ArtiosCAD 12 supports bi-directional communication between both CAPE and TOPS palletisation software packages. This eliminates the need for structural designers to reenter data into both systems, removing wasted steps and any potential human error. Additionally the full pallet load can be visualised in ArtiosCAD 3D for high-resolution presentations and reports. Building profitable sign & display business with ArtiosCAD 12 and 3D displays In an industry that is becoming more commoditised, sign and display shops are realizing that the uniqueness of 3D display projects offers higher margins. More and more companies are investing in ArtiosCAD for structural design. ArtiosCAD’s extensive library of resizable display designs helps designers so that they do not have to start from scratch designing new displays. The ArtiosCAD Tab & Slot tool ‘assembles’ components of a display with just a few clicks. The Mate tool helps to build and visualize connected folds and multiple parts. Users can identify glue areas and corresponding targets to quickly connect designs or perform simple assembly of displays. Curved Creases, a patent pending technology only

ArtiosCAD Enterprise: sharing structural designs in the cloud ArtiosCAD is available in two versions: the standard version and ArtiosCAD 12 Enterprise, enabling global “cloud” sharing and collaboration with WebCenter 12. With ArtiosCAD 12 Enterprise, all assets are centralised in a corporate private cloud, a secure web-accessible database enabling dynamic online collaboration between design groups, CAD and graphic designers, suppliers, brand owners and production. An easy to use online dashboard provides real-time feedback on project status, task lists and other parameters. An embedded design browser lets users easily search designs on production dies. "I am also looking forward to the increased search ability in ArtiosCAD Enterprise, whether it is Internet or intranet based,” adds Pomles. “We have existing designs in our database and using ArtiosCAD Enterprise we now have a very quick searchable reference. While I certainly like getting design requests off the Internet, it is even a greater timesaver to be able to search existing designs. What used to take 1015 minutes now takes as fast as I can type."

ArtiosCAD 12 tops pallet

SHELF IMPACT PRODUCTION EFFICIENCY

The Kodak Flexcel NX System— for unparalleled print quality and on press performance. It’s not often that you get to have it all. Now, you can deliver the offset or gravure-like print quality that your clients have been longing for, while driving efficiencies and compelling benefits to your bottom line. Differentiate your product offering and increase profitability by choosing Flexcel NX Plates.

Make the change today at www.kodak.com/go/FlexcelNX

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The Laser Revolution " We must let a laser do the difficult job" Lasers are now ubiquitous; they are in our homes, in hospitals and even on Mars.

Lasers should be considered more as an evolution, than a revolution. A laser is a source of monochromatic, intense light. Perhaps one of the first people to consider the significance of the colours of light was Mr. Robert Bunsen, famous for inventing the Bunsen Burner. His main claim to fame is, not so much the Bunsen Burner, as what he did with it. This is really how he earned his reputation. Mr Bunsen realised that the colour of light emitted by a heated material can tell you what the material is. Spectroscopy is how we refer to this now, and is used to identify materials, even on Mars! The colour of laser light is created by the same mechanism as that which gave colour to Mr Bunsen's flame. Many solids and gases will give off light if they have energy put into them in the right way. The energy put into a material, just like Mr Bunsen's Burner, will make the electrons in the material very excited. As the electrons calm down they relax and as they do so, they

Laser Zapping Rocks On Mars

will give up the energy they acquired by giving off photons, which is what makes up light. LASER is an acronym for "Light Amplification by Stimulated Emission of Radiation", but nowadays we talk of lasering, that is to zap with a laser. In the graphic arts industry, lasers are now extensively used, whereas at the start of my working life, thirty five years ago, they were rare beasts. The first major application in the flexo industry was for making seamless wallpaper printing rollers. Soon after came the birth of the laser engraved ceramic anilox roller,

perhaps thirty or more years ago. The major breakthrough for lasers in the flexo industry came when lasers were used to engrave away a black layer, bonded to a photopolymer plate. The improvement in intimacy between the plate and the black mask revolutionised print quality. In today's vernacular, the black mask is a LAM layer, Laser Ablation Mask, and as you can see, it is in vogue to speak of ablation, rather than engraving. So, having hopped through thirty five years of lasers in printing in about three and a half sentences, where to next, other than Mars? Well, for the anilox sector, after more than thirty years of ceramic rollers, we may see some laser engraved metals, carbides or other hard materials. Ceramic coating is a costly affair; it takes a lot of time especially when you include the polishing of the roller after coating. Perhaps, at first, for the narrow web high quality sector, we may see some metal rollers with a "surface treatment" directly laser engraved.

Ceramic Anilox Engraving

The Yellow Light Of Burning Ceramic

The second innovation in the anilox market will be much higher screen counts. This will be achieved by the use of green lasers. It will be quite practical to engrave at two to three thousand lines per inch with a green

AFTA AGA ALA â&#x20AC;˘ Issue 3 2012

61 laser. This may well complement the high definition flexo engraving that can now be achieved. The smallness of a focused laser beam is limited by the colour of the laser light, amongst other things. Mr Bunsen would have known that when burning copper sulphate, the green light emitted from the flame of his Bunsen Burner could be focused to a smaller, sharper spot than red light could be. Mr Bunsen would have been pleased to know that physics has not changed over the last one hundred and fifty years, but maybe our understanding of it has, thanks to him, as well as many other scientists. The major "game changer", for laser technology, in the printing sector, is that a plethora of materials can now be directly laser engraved. Metals, ceramics and polymerics to name but three families of materials. In situations where particular physical properties are required, for example wear resistance, resistance to chemical reactions, tolerance to heat, low coefficient of thermal expansion, etc.; this is where lasers come into their own.

The Blue Light Of Steel Engraving It wouldn't be hard to imagine a stainless steel, directly engraved Gravure roller or a directly engraved tungsten carbide printing roller. Lasers care little what material they heat up. With modern lasers the energy is so intense and rapid that the material cannot conduct heat away, so you have near instant vaporisation. Direct laser engraving is well suited to high mechanical tolerance, oddball material requirement and applications such as printed electronics, which, unlike printed candy wrappers, is a high value market.

Tungsten Carbide Engraving Like so many scientists, Robert Bunsen spent a lifetime searching for solutions to problems. He would have well understood that lasers are now solutions, looking for problems. One day we will bring to earth rocks from Mars and maybe a Bunsen Burner will heat up the rocks, but until then, we must let a laser do the difficult job.

AFTA AGA ALA • Issue 3 2012 -

Strong growth in labels and packaging market. HP announced three beta customers for the 762mm (30-inch) HP Indigo 20000 Digital Press, including the first in the United States, and showcased its recently expanded portfolio of end-to-end solutions for label and packaging production. Today, 12 of the top 15 label converters worldwide use HP Indigo’s marketleading,(1) high-quality technology, contributing to an increase in print volume of close to 50% on the HP Indigo WS6000 and WS6600 presses since Labelexpo 2011. “Our customers report that the HP Indigo WS6600 has made a significant difference in their operations, dramatically extending the breakeven point with run-lengths exceeding 10,000 metres,” said Alon Bar-Shany, Vice President and General Manager, Indigo Division, Graphics Solutions Business, HP. “Now, with the larger formats and higher productivity of our new systems, PSPs can further expand their businesses to penetrate new markets.” With the ILP Unit, converters can run the same standard, non-treated media used in conventional production on the HP Indigo press with no off-line substrate preparation. This capability streamlines mixed production environments and makes last-minute jobs faster and easier to deliver to customers. Michelman, a global developer of water-based barriers and coatings for flexible film packaging, paperboard, and corrugated cartons, has released a new primer for the press’s ILP unit. The Michem ILP040 primer extends the ILP’s media compatibility from paper-based substrates to synthetic media, allowing the WS6600 to support a broader range of applications and offers customers improved total cost of ownership. The ILP and the Michem ILP040 primer are backwards compatible with the HP Indigo WS6000 Digital Press. De Pere, Wisconsin-based Belmark

recently purchased the HP Indigo WS6600 Digital Press and ILP unit to enhance its ability to efficiently produce a wide variety of vivid pressure-sensitive labels and folding cartons, as well as further streamline its lean production practices. "The Inline Priming unit has been a great enhancement to reduce inventory and get materials to the customer faster," said Karl Schmidt, President, Belmark. “It allows us to run more unique materials with very short lead times.” HP is also featuring its dedicated solutions for pharmaceutical and security label and packaging production, including use of micro-text as small as 0.4pt, security elements such as HP Electroink UV Red, and robust variable data capabilities. The HP Indigo WS6600 also features an Enhanced Productivity Mode (EPM) that increases press throughput by 33 per cent(2), from 30 linear metres (98 linear feet) per minute in four-colour mode to 40 linear metres (131 linear feet), enabling faster delivery and print runs of almost any length. New HP Indigo 20000 for Flexible Packaging As the first U.S. beta site for the HP Indigo 20000 Digital Press, Hamilton, Ohio-based Innovative Labeling Solutions (ILS) will build on its success as a profitable, award-winning label

and package print specialist. The larger format of the HP Indigo 20000 makes it possible for ILS to pursue new applications and market opportunities. “Our HP Indigo WS6000 series give us the speed and quality that have helped our company grow,” said Jay Dollries, owner, Innovative Labeling Solutions. “And with the new HP Indigo 20000, we’ll be able to offer a more robust solution to our clients for flexible packaging.” Additional beta customers include U.S.based Belmark and UK-based Shere Print, the digital arm of flexography packaging printer Ultimate Packaging. The recently announced HP Indigo 20000 extends proven HP Indigo technology to a wider format, increasing the addressable market for digital package printing and expanding its cost and flexibility benefits to more applications. The roll-to-roll digital press is designed primarily for flexible packaging and is scheduled for commercial availability in late 2013. HP also recently announced the HP Indigo 30000 Digital Press for folding carton production. Offering a 750 x 530-mm (29.5 x 20.9-inch) format size compatible with carton stocks up to 600 microns thick, the press can run 4,600 sheets per hour in EPM and 3,450 sheets per hour in four-colour mode. The HP Indigo 30000 Digital Press is scheduled for commercial availability in

App

AFTA AGA ALA â&#x20AC;˘ Issue 3 2012

LASER ENGRAVING SYSTEM MANUFACTURERS

ALE design and manufacture laser engraving systems for engraving fine topographic structures on the surface of cylindrical forms. For further information please visit our web site: www.appliedlaser.co.uk

Variable control of anilox cell angle to roller length axis for increased doctor blade support

Complex cell creation with X-Cell engraving function

Channel cell creation with X-Cell engraving function

Complex Cell design with dam - (Arrowdam Cell)

Long hexagon cell functions, Custom Pulse & Custom Cell control

WIDE & NARROW WEB SYSTEMS FOR A RANGE OF INDUSTRIES & APPLICATIONS.

Gravure cell example

BEF 50 micron lens array example engraving

250 micron height text metal engraving example

Printed Electronics. Gravure roller engraving capabilities. Ceramic Anilox roller engraving systems, standard and complex cell engraving capabilities. Security applications. Embossing - Imprinting master tool engraving. BEF, (Brightness Enhancement Film), master roller engraving. Fine topographical organic textures & geometric engraving functions. Flexographic sleeve engraving systems. 3D Depth scanning system.

Tel: +44 (0) 208 941 1101 Fax: +44 (0) 208 783 1348 Website: www.appliedlaser.co.uk

Applied Laser Engineering Ltd, Molesey Business Centre, Central Avenue, West Molesey, Surrey, KT8 2QZ, England This document is subject to change without notice and does not form part of any performance specification or contract of supply. 15/03/2011

AFTA AGA ALA • Issue 3 2012 -

64 Comexi Group installs its new printer COMEXI OFFSET CI8 in the Catalan company Inplacsa

Comexi Group, leading company in the manufacture of machinery for the flexible packaging, installs its first COMEXI OFFSET CI8 printer at Inplacsa, a Catalan company specialist in plastic films flexographic printing. After a four years investigation, Comexi Group has managed to adapt the offset technology benefits to the flexible packaging industry. This achievement means an important step forward in printing but also in laminating, cutting and drying, in addition to the improvements it brings to the environment. The companies’ agreement launches the COMEXI OFFSET CI8 printer after the interest shown at Drupa’s Fair 2012 on the new product. The signing of the agreement entails the installation of the first machine with these features. For the environment The new Comexi Group’s printer reinforces the company’s compromise with the environment since it uses EB ink. This new cured ink eliminates the solvents and it’s more sustainable and eficient than the current technologies. This innovation means an important step forward for the flexible packaging industry and Inplacsa will be the first company to use it from September in its Cassà de la Selva headquarters. Flexible packaging protects and keeps products and it’s an important industry in our society. Comexi Group is a leader in this industry and also in the machinery manufacturing of this kind of packaging, so the COMEXI OFFSET CI8 printer means an important achievement for the industry. It is the first offset printer of variable repetition with a central drum for flexible packaging. The high quality results are achieved by means of a sustainable production.

M-Tech Plastics (South Africa) praises performance of new Titan ER610 compact slitter rewinder

M-Tech Plastics based in Gauteng ( Johannesburg), South Africa is on track towards achieving its long-term service and supply goals, with news of investments in top-class converting equipment to meet a stringent service strategy and to enhance its fast-growing flexible packaging operations. “We’ve embarked on equipment purchases in line with our expansion plans,” explained Barry Le Roux, Managing Director of M-Tech Plastics. “This includes a recently installed Titan ER610 compact slitter rewinder, supplied in collaboration with Beswick Machinery, the local agent for Atlas Converting Equipment Ltd. in the UK. We also plan to place orders for a Nordmeccanica Super-Combi coater/ laminator and a Rotomec ELS tencolour gravure press, both scheduled for delivery in 2013.” “We’re experiencing substantial organic growth and service levels remain of utmost importance to our management

and operations teams. We’re constantly striving to improve our performance to support our customers’ valued brands and believe the latest investments will open the arena for us to produce and deliver exceptional products,” he further commented. Until now, slitting and rewinding at M-Tech Plastics has been completed on two machines. “Our existing equipment carried us through our early growth stages, but it’s now time to push ourselves into the next level. We’ve always appreciated Titan’s worldclass technology and the new Titan ER610 has hit the perfect balance between price and performance. Also Beswick Machinery has an excellent team providing top-class technical and maintenance support, so I’m very happy,” Mr. Le Roux confirmed. The Titan ER610 is an affordable, high-performance slitter rewinder designed to run at a production speed of 450m/min and can handle a minimum 35mm slit width, with a rewind diameter of 610mm. The 1650mm web width machine installed at M-Tech Plastics also features an integral edge-trim extraction system and an integral shaftless unwind for a maximum 1000mm diameter roll. The pneumatically-controlled braking system provides accurate web tension control and a digital edge guide system controls lateral movement of the unwind reel. Also included is a highspeed HMI control system with a 10” touchscreen terminal, non-language symbols, compact flash memory and fault diagnostics.

utecovr@uteco.com • www.uteco.com

H I G H

PRO F ITA B I LIT Y

F LE XO

Flexo printing with Direct Drive Evo®

EN10/12ON-RANGE

• Print conﬁgurations: 6 - 8 - 10 color • Max. print speed: 400 m/min (opt. 450 m/min) • Printing widths: 1000 to 1600 mm • Print repeat range: 300 to 1200 mm

• Fully equipped state of the art machine • Reduced make ready and maintenance times • Quick and simple sleeve changeover

GE IN CH A N Q U I CK R I NTI N G P FLEXO

• P2P®: dynamic adjustment system controls printing pressures • PCT®: Press Control during Transition • Kiss&Go ®: fully automatic impression setting • PTC ®: Predictable Torque Control • SprintWash ®: new automatic washup system • SmartMatch®: reliable and quick color matching • FlexoSmartPackQC ®: Uteco engineering platform for improved performance and proﬁ tability in quick change ﬂexographic printing • ShopWare ® Production Management, Control & Monitoring: easy machine-operator interface to manage high-productivity • LogiPack ®: automatic handling of reels and cores

GENETIC INNOVATION

And a new innovation is coming...

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AFTA AGA ALA • Issue 3 2012 -

66 ‘The control system simplifies operation. Anyone who can use a cell phone can operate the machine,’ commented Riaan Hopley of Beswick Machinery. “Installation and operator training was carried out by our qualified technicians and the ER610 is already having a very positive impact on quality and service to M-Tech's customers,” he added.

Over 40 years of experience in the ﬂexographic industry, design and production of the highest quality systems. innovation is the key to our success.

Advanced MOUNTING & PROOFING EQUIPMENT (for the ﬂexible packaging, corrugated and label industry)

FULLY AUTOMATIC MOUNTING MACHINE for ﬂexo printing plates (for the ﬂexible packaging and corrugated industry)

PHOTOPOLYMER PLATEMAKING EQUIPMENT

Barry Le Roux’s ultimate goal is to reduce lead times drastically and produce consistent, high-quality goods for all customers. “We’re upgrading our systems to enhance our manufacturing capacity and the Titan is already handling the majority of our slitting requirements. From next year, we’ll experience a serious rise in production and then we’ll see this impressive machinery perform to its true potential. We have every confidence that the Titan’s performance will speak for itself and we’ll be purchasing more Titan slitting equipment in the future,’ he concluded. M-Tech Plastics was established in 1990 and has evolved in to one of South Africa’s leading converters of flexible plastic packaging materials. The company produces high quality gravure printed BOPP, PET, PVC, PE and paper, as well as duplex and triplex laminations. These include 5 layer co-extruded Nylon, EVOH, Nucrel & Surlyn barrier films which are all produced in line with ISO22000/ HACCP quality and food safety management systems. The ER610 is available in two standard widths – 1350 & 1650mm – with slitting systems available as shear knives, rotary razor (burst) or razor slitting in air or groove. Optional features include laser (line) core positioning, laser safety scanners and also a shaftless unwind roll pickup from the floor. It is a more environmentally friendly solution with reduced power consumption, no hydraulics for oil-free, hygienic operation, un-lubricated compressed air for zero oil/air emissions and less steel through its compact design. Its ‘one-piece’ construction also enables rapid installation, commissioning and simplified logistics.

Xeikon Introduces Vectorizor Software Add-on to Enhance Laser Die Cutting Integration

COMPUTER CONTROLLED VISCOSITY CONTROL SYSTEM

IN THE ROUND SLEEVEMAKING SYSTEMS

PRE-PRESS EQUIPMENT FROM MODEST SYSTEMS TO THE MOST ADVANCED HIGH-TECH SOLUTIONS Head Ofﬁce AV Flexologic B.V. • H. K. Onnesweg 2 • P.O. Box 252, NL-2400 AG • Alphen aan den Rijn The Netherlands • Tel +31 (0)172 434221 • Fax +31 (0)172 437919 • Mail av@flexologic.nl Toll Free number from the UK 0800-3892121 (only accessible in the UK)

www.ﬂexologic.nl

Xeikon NV, an innovator in digital colour printing technology, today introduced Xeikon Vectorizor, an innovative new software add-on to the Xeikon X-800 digital front-end that defines a new standard in communication with laser die cutting devices. The new functionality brings the integration of Xeikon digital press technology and laser die cutting devices to the next level, creating new opportunities to further automate label production and increase productivity. Xeikon will demonstrate the patent pending Vectorizor software in the technology corner at Labelexpo Americas, taking place at the Donald E. Stephens Convention Center in Chicago. Xeikon’s patent pending Vectorizor enables the digital front-end to generate, next to the printable bitmaps, die

AFTA AGA ALA • Issue 3 2012

67 Agency agreement adds IMPACK Packaging Equipment Design products to BOBST packer range.

cut files that can be used to connect to laser die cutting devices. “Automation and integration are key in making the most out of digital printing,” said Jeroen Van Bauwel, Xeikon’s director of product marketing. “Now that laser die cutting is coming of age, there is a need to drive the die cutter automatically. Xeikon Vectorizor is the perfect tool for doing that. Our customers are driving us to innovate. Xeikon is continuously leveraging its intimate knowledge of its customers’ opportunities and challenges to develop novel products tailored to specific needs in the market. Xeikon Vectorizor is a great example of that.” From JDF or PDF files generated by a Management Information System (MIS) or Enterprise Resource Planning (ERP) system, the Xeikon X-800 creates vector-based files to drive laser die cutting devices. These files contain the shape of “frames” and are transferred to the laser die cutting device. At the same time, barcodes are printed next to the labels telling the laser die cutting system which of the vector based shapes to use. Because every label can have a different shape, in the complete workflow, only the digital front-end knows what labels are positioned where on the web.

BOBST has signed an agency agreement with IMPACK Packaging Equipment Design which will enable it to sell IMPACK’s VIRTUO and ERGOSA packers in most countries of the world. The IMPACK equipment complements the range of packers currently offered by BOBST. Jacques Reymond, Product Marketing Director for BOBST Folder-Gluers, said, “The VIRTUO and ERGOSA packers produced by IMPACK fit neatly into the product matrix of BOBST folder-gluer peripherals, both in terms of capabilities and quality. They will allow us to offer turnkey solutions to customers who need carton packing capabilities on their folder-gluers, whatever materials, styles, and run lengths they handle." The VIRTUO is particularly suited to the automatic packing of micro flute and litho-laminated cartons where run lengths are medium to long. Several configurations of VIRTUO packer are available, depending on customer requirements; the unit can pack a range of carton styles including straight line, and 4/6 corner boxes. IMPACK's ERGOSA universal packer bridges the gap between semiautomatic and automatic packers in the folding carton market, delivering the flexibility of the former and the performance of the latter. The ERGOSA models are designed for low to medium volumes of straight-line and 4-corner boxes.

Jacques Reymond, said, “The ERGOSA fits neatly between our HANDYPACK GT models and our CARTONPACK GT units. Along with the VIRTUO and the existing BOBST range it means we can help all types of carton makers enhance the profitability of their folder-gluers." The agreement between BOBST and IMPACK Packaging Equipment Design covers all countries of the world except the USA, Canada, and UK, where the company has existing representation. About IMPACK PACKAGING EQUIPMENT DESIGN Based in Saint-Jacques (Quebec), Canada, IMPACK specializes in the design of standard and bespoke peripheral equipment for folder-gluer lines. Founded in 2001, IMPACK is well established in North America and Europe. The company now offers more than 20 configurable products within 5 product families and is continually innovating.

EFI Expands Jetrion 4900 Line with Modular, Upgradeable Design and Wider Print Area

EFI™ Electronics For Imaging, Inc, a leader in customer-focused digital printing innovation, has unveiled the new Jetrion® 4900M UV digital inkjet printing system, combining the performance of EFI's existing family of Jetrion UV digital presses with the flexibility of industrial inline web finishing. EFI is also announcing the 4900M-330, which features a 13-inch print width for increased productivity, profitability, and an expanded range of applications. “We believe that the 4900M’s modular platform will position label converters to address head-on today’s challenges while providing an upgradable platform for business growth as the label market continues to evolve from analog to digital,” said Sean Skelly, vice president and general manager of EFI Jetrion. “The wider form factor at 13 inches is a direct response to customer feedback and market demand. Lean Manufacturing Enabled for Today with Upgradable Path for the Future

AFTA AGA ALA • Issue 3 2012 -

68 at the recent LabelExpo Americas show, held in Chicago. The Danish press manufacturer introduced two completely new UV-flexo label and packaging presses, the FA-4* and FB-3. It also demonstrated the latest four-colour CASLON InkJet printing press, now available with a White or spot-colour print head. Also new was the FP-4 flatbed hot foil and embossing unit for increased finishing options.

Until now, production of labels, whether flexo or digital, has required multiple production steps. The new Jetrion 4900M Series changes the game, with modular integration of finishing capabilities that result in the delivery of a finished product in a single operation, removing time and cost from the manufacturing process. This is especially critical for label converters who wish to remain competitive as both lot sizes and cycle times continue to diminish. The 4900M Series’ modular design means that additional capabilities can be added as they become available or are needed, thus future-proofing this investment. Voice of the Customer “We have been partnering with EFI for some time,” said Brian Rhoades, general manager of WS Packaging Group - Consolidated Products, Inc. “We started with a Jetrion 4830, were an early installation site for the 4900 and utilize EFI’s Fiery® XF RIP to ensure color integrity between the presses. With the Jetrion 4900, we can print a million labels with 25 different SKUs back to back with a single setup. It gives us the ability to respond to customer needs in a short timeframe without the added cost of dies or plates. My press doesn’t stop running. That saves a huge amount of time and money, and gives our customers the peace of mind they require.” “Customers are making choices on digital label equipment based on more than just product specifications,” added Skelly. “They want an inkjet partner who can help them understand and keep up the fast- changing world of

inkjet technology, and apply a complete production solution. That’s why our vertically integrated approach of delivering presses, ink, software, color management and system design, combined with our application expertise and extensive global service, differentiates us in the marketplace and brings added value to our customers.” The Jetrion 4900M-330 will be commercially available in the first quarter of 2013. An affordable upgrade path will be provided to the wider format Jetrion 4900M-330 (13”/330mm) for customers who purchase the currently available Jetrion 4900M with a print with of 8.3” (210mm). This ability to choose between two print widths in the same print engine with a modular field upgrade is unique and ensures that customer investments are protected.

New Nilpeter presses a major attraction at LabelExpo

In terms of visitor attraction and sheer size of presence, Nilpeter was one of the leading exhibitors

The equipment was shown to a receptive audience under Nilpeter's latest corporate banner: 'NEXT - Your Challenge - Our Commitment'. The message represents the company's commitment to supply customers with innovative technologies that create solutions designed to meet future challenges. With optimised production efficiencies, Nilpeter users can therefore develop business opportunities in new business areas. During its latest LabelExpo outing, the well-known Nilpeter Bell rang 13 times. In addition to these confirmed press orders, the company's sales staff recorded many more intentions to buy from customers around the world. "We successfully introduced our two new, innovative presses", said Sales & Marketing Director Jakob Landberg. "Visitors were impressed with the quick job changes from the printing units and die-cutting tools on both the FA-4* and FB-3. They also appreciated the latest ergonomic designs of the new presses, with their short web paths and overall user- friendliness". "The new CASLON concept enabling UV-InkJet White was equally well received, as was the new FP-4 flatbed

PARTS WASHERS

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ALPHASONICS (UCS) LTD. – 18 Caddick Road, Knowsley Business Park South, Liverpool, L34 9HP, UK Tel: +44 (0) 151 547 3777 Fax: +44 (0) 151 547 1333 Email: info@alphasonics.co.uk

Find out more at: www.alphasonics.co.uk

Our cutting edge Dual Frequency Alphasound ™ technology provides safe and effective cleaning on even the highest screen counts giving 100% cleaning, 100% of the time. No ifs. No buts. Simply consistent and thorough cleaning that enhances production quality.

Imagine cleaning equipment that can come along for the ride as your business grows...

‘Future Proof’ Pressroom Cleaning Technology is here...

AFTA AGA ALA • Issue 3 2012 -

70 hot foil and embossing unit. The many visitors gave a very positive feedback to our new NEXT concept, which focuses on adding value for our customers by optimising printing processes and adding new market opportunities." The FA-4* for high quality labels and flexible packaging The new press has a maximum web width of 420 mm (16.5 inches), an extra short web path and a top speed of 175 m/min. (574 ft/min.). The sleevebased UV-flexo press is controlled by the Press Management Center (PMC), augmented by an Air Control Satellite

New laser coder is ideal for applications in consumer packaged goods and industrial products markets

Videojet Technologies Inc., a worldleading manufacturer of coding, printing and laser mar king products, fluids and accessories for the product identification industry, today introduced the new Videojet 3020 laser coder, which is ideal for simple marking and coding applications in the consumer packaged goods and industrial products markets. The 10-Watt CO2 laser coder applies high quality codes at low to medium speeds and with minimal operating costs. The affordable and compact single-box design allows for maximum ease-ofuse, simple application set-up, quick installation and uncomplicated line changes. “The Videojet 3020 laser coder meets the needs of customers with simple code requirements such as serial numbers, time and date and other codes in the food, pharmaceutical, personal care and cosmetic, and industrial products industries,” says Markus Vetter, product manager for CO2 laser systems at Videojet. “The new laser coder has been designed for the most cost-sensitive package coding applications that require high quality marks.”

The new Videojet 3020 codes both stationary and moving products while delivering alpha numeric text, simplified Chinese fonts, Eastern and Western European language fonts, variable data (serial numbers, date, time, shift code, GS1), ID matrix and bar codes, logos, symbols and graphical elements. The laser coder marks on various labels, cardboard and carton packages, paper, plastics, glass and wood. Depending on the lens used, mark field sizes up to 126 x 87 mm (5” x 3.4”) are available. Setting up an application, a line and print parameters, as well as creating jobs are easy and take only a few minutes. The 3020 laser marking system can be installed and integrated either as a stand-alone solution using the mobile stand or directly into the line with mounting brackets. The compact design allows for installations even when space is at a premium. At 7 kg (15.4 lbs), the system is one of the lightest in its class. Additional key features follow: Job creation, parameter settings, line setups and system configuration can be managed with the touch-control unit. All tasks are accessed directly through intuitive icons and a job preview is always visible to the operator. Various password-protected security levels are available. Troubleshooting is a simple matter of pressing a button while an integrated help menu is available for key functions. A keypad built directly into the marking system allows for quick access to start and stop buttons. The standard configuration consists of the laser, scanner, lens, controller, I/O panel, built-in keypad, mechanical focus finder, product detector and the touch-control unit. A mobile floor stand, beam shields, exhaust units, encoder, mounting brackets and additional fonts are optional.

The Videojet 3020 laser coder and its user interface are configurable in 19 different languages.

X-Rite launches SpectraLight QC and new training institute X-Rite, Incorporated has introduced the SpectraLight QC light booth and a training institute to give companies involved in global supply chains a superior way to visually evaluate the colors of samples for production readiness, helping to bring products to market quicker and reducing instances of waste.

Responding to the needs of global customers, the SpectraLight QC reduces the rate of sample rejections at multiple locations by providing better consistency of light sources and standard conditions under which the color of products are assessed visually. The result: improved speed to market and reduced overall costs. SpectraLight QC gives Quality Control managers new monitoring and reporting tools to more precisely control and communicate how visual assessments of samples are performed. X-Rite, the world's largest designer and manufacturer of color management and communication solutions, launched the X-Rite Visual Color Assessment Institute concurrent with the SpectraLight QC light booth to introduce vendors and brand owners to best practices and standard operating procedures for the visual evaluation of color. The institute provides easy-tounderstand materials that explain the basics of colour theory and special topics that apply to the visual evaluation of color. Participants in the institute study at their own pace, then take self-administered tests online to earn a certification in best practices for visual evaluation of colours. As an introductory offer, companies that purchase a SpectraLight QC will have access to the institute at no charge. SpectraLight QC offers more standardised illumination sources than any visual assessment QC solution on the market, faithfully replicating the lighting that one would find in natural daylight, at the shopping mall, at home or in other settings. When used in tandem with defined procedures, the SpectraLight QC ensures that quality

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72 Having used an original Domino DDC3 dot matrix laser coder to code directly onto the bottle on its PET production line since 2002, Carola was confident of the capabilities of the Domino technology, and therefore took advantage of the launch of Domino’s new D320i to equip its glass bottling operation. On the glass line, the label is affixed to the bottles once they emerge from the bottling system. The D320i then laser scribes the best before date and time of bottling onto the label.

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control personnel can make valid color evaluations regarding whether samples meet the needs and specifications of customers.

Benefits from increased performance, flexibility & highest quality coding

Situated in Alsace in Eastern France bordering Germany and Switzerland, is the picturesque region of Ribeauvillé, home to the famous Carola brand of natural mineral waters which is now part of the Nestlé Group. Founded in 1888 by Dr Staub who named the spring in honour of his sweetheart Caroline, the Carola range which includes slightly sparkling and sparkling natural and flavoured spring water, has established an enviable reputation amongst restaurateurs and gourmets for the quality of its product and is today distributed to over 25 regions in the East of France. Following the recent installation of a Domino D320i laser coding solution into its glass bottling line, which has delivered increased production flexibility and the highest quality laser coding, Carola is this year taking the opportunity to highlight its 130+ year heritage by introducing a new visual identity across its entire product range, including its 1litre and 500ml glass bottles. The water from the spring, located 150 m underground, is piped into buffer storage tanks before being bottled, thus controlling consumption and protecting the source. The company then produces over 60 million bottles per year, 24,000 bottles per hour at peak output, in 1 litre and 500 ml

formats. As a company of the Nestlé Group, Carola is renowned as much for its distinctive identity and quality of its water, as it is for its environmental policy and high safety standards. It was this same concern for the environment that prompted the company to opt for laser technology to code its bottles of water, the different types - sparkling, slightly sparkling and so on - being easily recognised by their red, blue or green colour. Carola was the first to introduce this colour coding, which is so well known to consumers today. The company carried out a comparative study of various laser models available on the market before finally opting for the next generation Domino D320i compact scribing lasers.

"The new laser had to be reliable and easy to control," says Lefort. "The quality of marking is essential to the consumer. Since installing the D320i laser at the end of 2011, we've been extremely impressed with its performance and quality. Our customers are also very satisfied with the excellent readability of the codes."" Having used the new Domino D320i for a few months, Carola Maintenance Manager Gilles Oehler adds, "I was already very familiar with the DDC3, but even so, the D320i is very simple to use. It requires minimal intervention and maintenance and the interface is very intuitive. For operators, changes and message backups with the associated parameters are quick and easy. A few months ago we still had to replace the coder and make various mechanical adjustments every time we wanted to change formats. With the D320i, this is no longer the case - it adapts very quickly to technical constraints." Number of Employees: 52 Production: 60 million bottles per year Quality: Over 200 checks per day

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