There may only be a matter of inches in web width between narrow and mid-web flexo technologies, but the leap it enables from label to flexible packaging production is a big one in many ways.
In the grand scheme of things, there were not many people there to witness it, but the testimony was compelling all the same. It was at Labelexpo Americas in Chicago, September 2024, that FlexoTech sat in on a conference talk given by Craig Curran, president at multi-site US label and packaging printer Nosco.
His theme was one that matched very neatly with that of the entire show: the trend of narrow web label printers moving into mid-web, flexible packaging production.
For Nosco, it was in 2019 that it started to operate in the flexible packaging arena for the first time. The main thrust of Mr Curran’s presentation was around how difficult the transition to flexible packaging has been, encapsulated in his comment that ‘you should not expect to be a master in six months; we have been doing it for four years and are just now becoming competent’.
‘It’s a highly technical product and you have to have a technical resource and align that with the sales team,’ he said. ‘You will need a lot of material expertise. You must learn all kinds of materials and learn them quickly. You need experienced operators. We were blessed to find a couple of guys that were good at laminating and slitting, whereas pouching…we had to learn the hard way. It was the school of hard knocks.’
Quality control is critical, both for incoming materials and outgoing product. Robust testing systems and processes must be put in place and used all the time, not just for the first few months. ‘If you don’t test pouches before they go out of the door, they will soon come back in the door,’ said Mr Curran. ‘It can work for 50% of the run and something changes – the heat drops on the pouching machine, for example, and you won’t have the right seal.’
Two further points stood out: firstly, that the sales team must be trained and educated to sell flexible packaging. ‘The best ones for flexible packaging are the technical salespeople,’ he said. ‘Use them to be your key, but train them all, hard and often.’
Also, the importance of building strong relationships with material suppliers. These can help with the training, but their knowledge of base materials and laminations will also be very helpful.
Technical expertise
These are themes picked up on by Patrick Graber, product and marketing director for labels at Bobst. He says the move from labels to flexible packaging in terms of printing is relatively straightforward, but it does require additional technical expertise in terms of prepress skills and process know-how, as well as application and material compatibility, particularly in regard to newer eco materials designed for recycling.
‘The biggest challenge lies in post print; in understanding brand owners’ specific requirements and ensuring seamless execution,’ said Mr Graber. ‘Each application – such as pouches, f low-wraps and shrink sleeves – has unique characteristics, and the end use may demand food compliance or the ability to withstand harsh treatment. Optimising downstream processes like coating, lamination, slitting and pouch-making is therefore essential, but often involves a steep learning curve with many new aspects to consider. Success depends on minimising waste, managing time efficiently, guaranteeing quality, and refining these processes to protect profitability.’
A common question, reports MPS Systems’ UK managing director Nick Tyrer, is ‘will my press run film?’. The answer is potentially a long one but can be summed up in seven words: yes, but be prepared for the journey.
One factor to consider is drying. If a press has UV driers on board, then direct food contact packaging is ruled out immediately. Hot air driers can be fitted for water-based packaging production. Material handling is another major consideration, with the necessity of holding accurate register position.
Ancillary equipment such as web cleaning to remove dust and static, chill drum systems, anti-static bars on all print units and before rewind, engraved idler rolls to prevent web tracking or wandering at high press speeds, and effective video inspection, can all make a big difference. ‘Any serious foray into the print and conversion of packaging film should also include a new fingerprint run so that you can properly understand what the change in material has done to the density and colour balance that you normally enjoy on other stocks,’ Mr Tyrer concludes.
Omet’s marketing coordinator Massimo Bellingardi observes that the rise in demand for mid-web printing and label printers moving to flexible packaging is due to several factors: the increase in flexible packaging and shrink sleeves; ‘greener’ thinking; and run length reduction.
‘If we analyse all those elements, it looks clear that the market is creating a big opportunity in the field of premium shrink sleeve and customised flexible packaging, where special effects, short runs and quality are the requirements,’ he said.
According to Ben Luly, product manager at Mark Andy, there are numerous challenges to contend with in moving from narrow web label to flexpack. These include technological changes in the substrates, ink, drying/ curing, run lengths and speeds, as well as the far more onerous functional demands on flexible packaging compared to labels, such as requirements around barrier characteristics, moisture resistance, light and odour, and puncture resistance. A wide range of regulations and certifications surround these issues.
There is also much to consider in terms of technology. ‘Aniloxes, doctor blades, ink formulations are all different between labels and flexible packaging, so they must be understood and their intricacies met. Drying capacity needs are very different between water-based labels and flexible packaging. Lamination in line is much more sophisticated than what is seen in the label space, and it must be understood. There might be multiple laminations of different material types.’
Mr Luly also points to the fact that many flexible packaging converters will also provide post print processing for the shrink and pouch markets, whereas labels are typically printed, converted, slit, rewound and shipped. And there are differences from a material and web handling perspective too. ‘The machine and customer must be able to run unsupported films, foils and laminates, all of which have different moduli of elasticity and therefore have different web handling characteristics,’ he said.
If running solvent inks, packaging printers must be prepared to meet facility requirements to capture VOCs, with measures such as ventilation, air changes within the room, emissions, management, electrical specifications and safety precautions, all coming under scrutiny. ‘The building, in addition to the equipment, must be certified for some organisations, and many customers require the converter to be certified,’ Mr Luly added.
According to Nilpeter’s global marketing manager Martin Fjordlund Teilberg, the switch between label production and flexible packaging requires a shift in mindset. As already mentioned, there are different materials and their behaviours to master, including what these behaviours mean for print register accuracy and drying, plus increased regulatory demands in different sectors.
‘Flexible packaging often requires barrier coatings, lamination, and cold-seal applications, adding complexity to the production process. To succeed, printers must optimise workflows, invest in automation, and rethink their processes,’ said Mr Fjordlund Teilberg.
‘Transitioning to flexible packaging is not just about adopting new substrates – it’s about redefining efficiency and quality. Automation plays a crucial role, reducing setup times and ensuring repeatability.’
Ingogroup, Spain
Spanish label operation Ingogroup launched its Ingoflex service for short and medium run flexible packaging in 2019, installing a Bobst Master M6 press with UV LED lamps and a solventless laminator from Comexi, to deliver this service to its food packaging customers.
Inigo Pons (pictured), CEO and founder of Ingogroup, explains that the main challenge lies in the combination of printing and laminating, as the technical specifications for food products in the application of printed films are very demanding.
Mr Pons told FlexoTech, ‘If I had to start over, I would try to gather much more information regarding UV low migration inks and how they affect the lamination process. Since these inks are 100% pigment-based and we use solventless lamination, a series of ‘problems’ arise that need to be solved. Specifically, I am referring to the anchoring level of UV LED low migration inks on the 12-micron PET we use and how this affects lamination, as well as the potential issues and returns from customers.
‘Another important aspect to consider is ink consumption, as it becomes one of the most significant costs—whereas in labeling, it was just another expense without standing out in any way.’
