Corrugated Re-Envisioned: Part 3
As a refresher, this a multi-process method of printing on a top sheet (liner) which is then laminated to the corrugated material. This is currently the most widely used method for printing high color graphics (three or more colors) on corrugated. If you haven’t read the previous articles in the series, in my first article of the year we looked at the recent Karstedt study on high graphics corrugated growth, and in Part 1 of this series, we looked at some analog technologies for corrugated post-print. In Part 2, we looked at digital solutions for post-print.
Preprint (Print and Laminate)
Printing Technologies
Prior to the introduction of production inkjet post-print (direct to corrugated) printing solutions for high color graphics, this was and actually still is the primary production process—for obvious reasons. If you recall from previous articles, printing on the soft, dirty and uneven surface of corrugated is not easy for any direct contact printing process. Offset is pretty much out of the question, but very tightly controlled flexo like Bobst MASTERFLEX-XL THQ and Koenig & Bauer CorruFLEX can work. Which is why printing on a liner or clean smooth paper first and then laminating it to the corrugated has been the process of choice. After all, most printing processes including offset, flexo, gravure, EP and inkjet print on a variety of papers really well all the time.
Flexo still has the lion’s share of the market, primarily due to its lower cost and higher productivity. Next in line would be offset, some gravure, up and coming inkjet, and even a little electrophotography (EP). Historically, offset and gravure have been selected to achieve a higher quality than flexo; however, with some of the newer flexo plate and equipment solutions, that may no longer be the case. The biggest growth opportunities are expected with inkjet since it is very much in a startup position. According to IT strategies, inkjet for corrugated growth rates between 2018 and 2023 will approach 35% CAGR, while analog will maintain a fairly steady but still attractive 3%.
Selecting the method is really based on a lot of factors, including your market opportunities, capital investment, production costs and internal skills, although making that determination also involves run size, as well. Both analog and digital presses are and will continue to be in the mix and grow. Here are some representative examples.
The Koenig & Bauer Rapida Large Format sheetfed offset presses have been a staple in packaging due to their size, quality and productivity.
© Koenig & Bauer
Other great examples are the XL presses from Heidelberg. In fact, they just introduced a new version of Heidelberg Speedmaster XL presses. These updates have focused on a new level of “Push to Stop” automation and a newly added “Plate to Unit” automated plating logistics system. These new features will undoubtedly help them compete against other offset presses and some of the new inkjet offerings.
© Heidelberg
Looking at inkjet offerings, in 2015, HP and KBS (Koenig & Bauer) unveiled the PageWide T1100S (shown below) with a web width of 110 inches designed specifically for printing large volumes of high color corrugated liners for corrugators. In 2016, HP followed up with the introduction of the PageWide T400S with a 42-inch print width press targeted at shorter run preprint liner production.
©HP
Not to be outdone, the KBA RotoJet L-Series inkjet presses are also targeted at packaging in general and are ideal for high color corrugated liners.
© Koenig & Bauer
This is only the beginning. We have seen the corrugated market growing and the interest in manufacturing new presses to producing high color corrugated growing in tandem. Xeikon has already “hinted” at offerings in this space for drupa, and we can expect many more as we head toward the event.
Size and Productivity
Let me be frank (no, not Romano). Almost any digital or analog press can print high color preprint liners for corrugated. The real issue is going to be the physical size of the flat board, the quantity, and finding a corrugator that can laminate it. From a cost and productivity standpoint, larger presses printing larger liners better match the size of the corrugating machines, thereby making it easier and more cost effective to laminate. However, I would also expect to see an increase in litho-laminator machines to handle the increased demand for shorter-run corrugated packaging. Litho-laminator machines are already available from Bobst, C-Tec and others. Drupa will be a great platform for more introductions.
In Summary
High color corrugated packaging is growing and will continue to grow. The run sizes are getting smaller to adapt to the new market requirements, and the opportunities for print service providers to jump on this moving train abound. This series was meant to present an overview and whet your appetite in advance of drupa. You can expect that there will be lots of new introductions in this space leading up to, during and after the event. As we hear of them, we will present them to you.
