Labels and Packaging

Even with all of its problems, 2020 was a transformative year for labels and packaging, and 2021 will bring the learned lessons to the forefront. Much of this has to do with a combination of new digital and hybrid equipment introductions and packaging procurement models.

The void of consolidated introductions left by the absence of drupa combined with the pandemic-driven shift in consumer behavior has created a more fragmented view of what is here, what is coming, and more importantly, what is needed. With a little research I believe we can see the trends and how they will be driven. So, with that, what can we expect?

Digital Packaging, the Next Wave

Early adoption of digital packaging production was relegated to prototypes, short run and variable data applications that supported marketing campaigns. It is now gaining mainstream acceptance as a result of the successful implementation of digital label printing, which now represents in excess of 25% of total label production globally. We are now seeing an expansion of available digital packaging solutions, that can be used to support other packaging applications including folding carton, flexible packaging and corrugated.

Folding Carton

Folding carton has long been in the purview of offset printing. This year we expect to see more of that shifting. The introduction of the Edale FL5 flexo hybrid press is only one of the solutions that will affect that shifting. I wouldn’t be surprised to see the integration of an inkjet unit by Edale or another solution provider to bring variable data capabilities down the line.

Edale FL5

While digital production of folding carton has been happening, it really hasn’t transitioned the next level of adoption. This is primarily attributed to the lack of a good selection of larger format cut sheet digital solutions. It looks like 2021 is going to be the year that finally changes. In the inkjet space, in addition to increased penetration of the B1 Landa S10, and the release of the Koenig & Bauer VariJET 106, the groundbreaking MGI AlphaJET Industrial Print Factory brings a unique approach to high-quality folding carton and corrugated print applications and is almost ready for prime time.

MGI AlphaJET

B2+ cut sheet press installations have also been growing. While Konica Minolta has been increasing their market share with the KM-1e, and Fujifilm has been placing more JetPress 750s, others are preparing for their entry into the market. Ricoh has announced their long awaited Z75 sheetfed inkjet press, which will most likely go to beta this year, and I would expect a few other surprises later this year as well.

In the EP space, after their product line upgrade in 2020, HP Indigo has been placing their 90K roll fed B1+ and sheetfed B2+ 15K and 35K digital presses for folding carton production.

HP Indigo 35K

In the smaller format and footprint category, 2020 saw the introduction of more extended format size support as well as support of heavier media in a3+ presses like the Canon ImagePRESS C10010VP, Ricoh C9210 and the Xerox Iridesse.

Canon C10010VP

Flexible Packaging

The continued growth of flexible packaging replacing rigid containers in the form of stand-up pouches is another of the growth applications for digital print. Pouches, which are easier and less costly to ship, actually use anywhere from 40-70% less plastic than rigid-container and label combinations, which are increasingly attractive to brands and sustainability-conscious consumers alike. One of the more interesting applications can be found in a solution by V-Shapes, an Italian technology company. They have developed technology that provides easy opening single portion packets that can be used for pharma, cosmetics, chemicals, food, etc.

This year will also see the release of some flexible printing technologies previously announced and soon to be announced. These include EP solutions from HP and Xeikon, as well as inkjet solutions including the Uteco/Kodak, Sapphire Evo W, Screen PacJet FL830, Miyakoshi, MJP30AXF, Rigoli MVZ Powered by Memjet and players yet to be announced.

Rigoli MVZ 1000

Corrugated

Preprint and postprint corrugated applications are already gaining market traction, and the digital production of folding cartons is starting to see increased growth with the introduction of many new cut sheet digital press solutions. These include the previously introduced HP C500, the updated EFI Nozomi C18000 Plus, as well as Xeikon’s IDERA and Domino X630i to mention just a few.

Labels

While digital label production is not new, it is going through a new growth spurt with the introduction of more hybrid flexo/digital solutions that provide a complete print-through-finishing solution at speeds that shift the cost crossover point. These include solutions from Mark Andy, Canon, Bobst and many others.

The Best of Both Analog and Digital

All of these digital and hybrid solutions are being used in place of flexo and offset as they are increasingly available to satisfy the requirements of shorter “on-demand” runs. Granted, the digital solutions currently available may be a bit slower, although that is starting to change, and the output even a little more costly than some of the flexo solutions. However, digital production allows you to create focused and more optimized processes based on specific requirements instead of trying to fit work with different requirements into the same production processes. Designed well, that could provide more cost-effective and timely solutions with fewer setups and less handling. 

We can expect much more development as a result of Memjet, Dimatix, XAAR and other printhead manufacturers and their OEMs like Colordyne, Konica Minolta, PCMC, etc. They are increasingly integrating printheads into a variety of different inkjet and hybrid machine configurations to support rapid development of packaging print applications. These types of solutions will find their way into a variety of different machines to support a variety of stand-alone print applications, as well as print as a function of product manufacturing. 

It's more than just printing.

Converting is still an important part of packaging production. Folder gluers, inline die cutting, and increasingly laser die cutting are now being introduced into the end-to-end based application solutions. Ultimately, brand identity and shelf appeal are still the key attributes of packaging, and digital embellishment technologies are providing the solutions needed to support the needs of on-demand package printing. Increasingly they are all being integrated into complete inline production solutions.