The latest developments in packaging means print-service-providers can pack a punch
Packaging a punch
As brands face an increasing amount of pressure to become more environmentally friendly, more companies are turning to packaging as a way to satisfy this demand and ensure they are meeting the green expectations of customers.
This trend has led to incredible levels of growth in recent years, with printed paper-based packaging providing a much more planet friendly option to brands compared to plastic products. With this demand showing no signs of slowing down, packaging print is only set for further growth.
Here, we look at some of the latest technological advancements in packaging print that can help those companies active in the sector gain an advantage and move ahead of the competition.
Driving production
HP recently announced a number of new developments on its HP PageWide corrugated solutions portfolio, with the aim of helping to drive the production of digitally printed packaging applications.
The showpiece advancement is its new HP PageWide T1195i press for preprint corrugated printing. Featuring new HP Thermal Inkjet printheads, the new press is designed to deliver more robust and economical production for roll-fed presses, as well as drive mainstream production and enable converters to move more jobs from flexo preprint and litholam to digital.
The new HP PageWide T1195i press features HP Thermal Inkjet printheads
According to HP, thermal control on the printheads enhances preprint system performance and helps reduce operational costs, while delivering consistent high quality at high speeds.
“Supply chains are facing pressures never experienced before, with market trends accelerated by the pandemic requiring converters to deliver faster and flexible packaging solutions,” HP PageWide industrial vice president and general manager, Carles Farre says.
He adds: “Digital packaging can fundamentally transform the corrugated supply chain for brands in high-volume and mainstream production, especially for e-commerce, food and household products.
Digital packaging can fundamentally transform the corrugated supply chain for brands in high-volume and mainstream production”
“Time-to-market can be reduced from weeks using analog methods to only days with HP digital, in addition to sustainability advantages of reduced waste, and higher shelf impact with greater design versioning.”
Other new developments at HP include that its digital corrugated packaging inks for the HP PageWide C500 have completed tests and received certification for compostability in home and industrial systems. This, HP says, allows both converters and brands to improve their sustainability profile for corrugated packaging and contribute to a circular economy, in addition to printing on-demand quantities, reducing inventory waste, and lowering overall environmental impact.
The HP PageWide C500 receantly received certification for compostability in home and industrial systems
In addition, HP has announced the release of a new set of cloud-based PrintOS applications for HP PageWide C500 owners to improve their overall site efficiency and to optimise the management of their production floor.
These include the PrintOS mobile app that allows users to track real-time status and updates of job status and production; the PrintOS Print Beat optimisation app that delivers press and consumables historical and near real-time data; the PrintOS Supplies and Inventory Management app; and PrintOS Jobs which provides jobs data including consumables, substrates, print time.
Flexible solutions
Elsewhere and for print-service-providers seeking to get ahead in the printed packaging sector, Friedheim International recommends the Scodix Ultra 6000. Designed specifically for the packaging market, the digital enhancement press is a B1 size platform that supports work in the rigid box and folding carton segments.
The Scodix Ultra 6000 digital enhancement press supports work in the rigid box and folding carton segments
The press has a substantial print area of 700 x 1,000mm and can handle substrates ranging from 135gsm to 675gsm, which Friedheim says opens up a wide range of markets for users.
“It represents a flexible solution that gains access to the profitable end of the packaging market straight from the box,” Seth Morgan, marketing assistant at Friedheim says, adding: “However, this can be used for more than just carton printing work.”
As standard, the Scodix Ultra 6000 comes with five of Scodix’s trademarked embellishments with four more available on request. Standard applications include Scodix Sense, Scodix Foil, Scodix Metallic, Scodix Glitter and Scodix Spot. Scodix VDO, Scodix Cast&Cure, Scodix Braille and Scodix Crystal are optional extras.
“The polymer is one-for-all, so the user only needs one type and bottle changeover is done automatically,” Morgan says, adding: “Best-in-class embellishment results in speed of 1,000sph and with low-cost consumables, it makes the Scodix engine a high profit investment.
“Scodix set out to solve as many problems as possible to help lower the bar of entry for printers seeking to move into the packaging market. An example of this is the introduction of robust pallet feeders and deliveries, which are ideal for carton substrates, but more importantly are required by packaging buyers to meet their existing operations.
“To make this a straightforward decision, Scodix has developed business cases in order to demonstrate the profitability and give you the confidence needed to succeed in packaging.”
Finding a niche
Craig Bretherton, area sales for Scotland, and product and marketing manager at Koenig & Bauer UK, agrees that packaging still represents a realistic expansion opportunity for more traditional print companies, but at the same time warns that it is an “extremely competitive market”.
“The type of packaging produced would determine the kit required but many printers have already added packaging to their current offerings successfully,” Bretherton says, adding that newcomers should consider targeting some of the more niche markets within the wider packaging sector.
“The packaging market has lots of subdivisions and niche operators, there are high-volume businesses and short-run luxury packaging printers and everything in between,” he says, adding: “The materials used such as carton board or plastics will also determine what kind of work that could be produced.
“Lots of packaging still uses UV inks and coatings in production but there are many machines out there which produce solely on conventional inks and coatings with many opting for hybrid solutions with multiple print units and coaters.
“For newcomers, simple products such as short-run, non-food, five or six colours with coating jobs would be the best areas to target as many printers already have this capability on their existing machines.”
Turning attention to the more established companies looking to produce more than they do already, Bretherton points in the director of the new Rapida 106 and flagship 106X models, both of which offer speeds of up to 20,000 sheets per hour.
Koenig & Bauer also introduced a new flat-bed die cutting device in the form of the CutPro Q 106 during the virtual Drupa 2020 event, as well as its rotary die cutting device in the CutPRO X 106, which can produce at speeds up to 15,000 sheets per hour.
Koenig & Bauer’s flagship Rapida 106X has a top speed of 20,000 sheets per hour
The newest addition is the VariJET 106, which is a hybrid digital press designed specifically for use in the packaging market, and jointly produced by Koenig & Bauer and Durst.
Cost-effective expansion
Alongside hardware developments, it is important to look at other aspects of the market and consider how advancements here can also help improve production. Premier has a carton board portfolio that offers both market newcomers and existing companies in this area options for packaging.
Recent additions to its range include CKB Carrier, a strong kraft back board developed for use as carrier multipacks and Rochperle, a fully coated, grease resistant folding boxboard with a cream back. David Arnold, sales director of graphical and packaging boards at Premier, says these two products aim to help companies with the transition from single-use plastic to fibre based recyclable packaging alternatives.
“Premier’s extensive carton board portfolio is one that offers newcomers and existing customers the choice of reliably sourced, high quality, consistent products to match a wide range of end-uses,” Arnold says.
He adds: “However, Premier’s service offer is where newcomers will really benefit as they look to diversify.
Customers can order as little as 100 sheets for next day delivery on the majority of carton board products and therefore Premier can help customers start off in this market.
“Carton board has a wide range of end-uses and applications from greetings cards to food packaging. With the growth of cottage industries and the move away from single-use plastics, there are many markets with relatively low barriers to entry that newcomers to the market could look to target.”
O Factoid: Research from Future Market Insights estimated that the global printed packaging market could be worth as much as $17.14bn (£12.32bn) by the end of 2021 O
Arnold goes on to say that this wide-reaching use of carton board has led to a huge spike in demand for these products over the past 18 months, driven by the increase in online retail and the growing demand for plastic-free packaging alternatives.
“Packaging is probably the nearest and potentially most cost-effective expansion market that a commercial printer could undertake, depending on the capabilities of its current kit,” Arnold comments.
While packaging does indeed offer a realistic and potentially profitable expansion option to print companies, as is the case when moving into any new market, they must first ensure they have enough demand from customers to warrant a move and also the right kit in place to produce high quality work.
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