Flexo Printing System Expands Packaging Converter Capabilities

The European packaging and label industry is facing increasing pressure to adapt. Brand owners are reducing the number of suppliers they work with while simultaneously demanding more variants, more frequent artwork changes and support for a wider range of substrates and packaging formats. For converters, this means that traditional specialization in a single application area is becoming less sustainable.

As a result, companies are increasingly investing in printing and converting systems capable of handling multiple applications on a single platform. In addition to self-adhesive labels, shrink sleeves, flexible packaging, multilayer labels and specialty applications such as lamitubes are becoming more important.

Flexo Printing System for Multiple Substrates and Applications
The MASTER M5 inline flexo press from BOBST was developed to address these requirements. The system processes a wide range of materials, including films, paper, foils and labelstock, in both short and long production runs.

Its modular configuration allows the integration of different printing and finishing technologies, including flexo printing, screen printing, gravure, hot and cold foil, lamination and converting operations within a single production line. This enables complex applications to be produced in a single pass.

Another important factor for converters is support for Extended Color Gamut (ECG). Using the oneECG color management system, different applications can be produced with a standardized seven-color ink set. This reduces the need for spot colors and simplifies switching between different jobs and substrates.

Automation Reduces Setup Times and Operator Workload
In addition to substrate flexibility, users highlighted the level of automation as a key reason for selecting the system. Technologies such as DigiFlexo automate print registration and pressure settings, while DigiGap controls die-cutting pressure adjustments.

For companies handling changing job mixes and operators with varying levels of experience, this reduces setup effort and shortens changeover times. Productivity can therefore be maintained even for shorter production runs.

Expanded Production Capacity Through New Applications
Slovak label converter Bóna LABELS invested in the press to enter the market for coupon and multilayer labels, applications the company was previously unable to offer.

By combining printing and converting in a single production pass, bottlenecks were reduced and time-to-market improved. According to the company, monthly production output doubled after the installation of the system.

“Thanks to the MASTER M5, we have doubled our monthly output and can produce applications that we were previously unable to offer our customers,” said owner Bertalan Bóna.

Production Increase Across Multiple Packaging Formats
Haitoglou Graphic Arts in Greece also implemented the machine to improve production efficiency for packaging applications in the food, cosmetics and wine sectors.

According to the company, printed output increased by 35 percent after installation, while sales increased by 15 percent. The company attributes these results to higher automation levels, reduced waste and simplified machine operation.

“Its intuitive setup and operation helped our operators adapt quickly to the machine and contributed to process reliability,” said CEO Denise Haitoglou.

High Process Stability for Complex Job Structures
North American converter Label Specialties required a system capable of handling high product variation and short lead times. The objective was to process different jobs without compromising quality or productivity.

According to the company, the press delivered consistent production quality and operational stability in daily production environments.

Examples from Slovakia, Greece and North America indicate that packaging converters are increasingly investing in flexible printing and converting systems to economically expand into new applications while standardizing production processes.

Edited by Sucithra Mani, Induportals editor – adapted by AI.

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