Is offset really an alternative to flexo and gravure

For those who have never investigated web offset as a solution for their flexible packaging production, the suggestion that it can actually work out to be significantly more cost-effective than gravure and flexography is often greeted with surprise or disbelief.

The two major challenges in flexible packaging printing and converting today are the demands for shorter runs and faster job changes. These can be bottom-line killers. Previously, such jobs were taken on by converters to retain regular, longer-run business, but were rarely profitable, Today, those once- exceptional jobs are becoming the norm, and are now beginning to threaten the ongoing viability of some converting businesses. In understanding why web offset can be a solution to many production conundrums, it is helpful to tackle one of the key confusions in the market: “short-run”. The term short-run is used to mean significantly different things by different segments of the converting and general printing markets. The rise of digital presses for flexible packaging printing moved the term “short-run” far below what conventional flexible packaging converters have traditionally done. At present, the largest digital press on the horizon has a one-meter web-width and a four-color printing speed of 300 fpm. Flexo and web offset presses are clearly in a separate category with speeds five times higher, or more, as well as wider web-widths and more colors possible.. It is more useful to think of digital run lengths as “micro runs”. At present, the number of these micro runs and the total percentage of digitally. printed flexible packaging are very small, Even the double- digit growth forecast for digitally printed flexible packaging over the next decade will not materially change the balance. Losing micro runs to digital is not what’s putting pressure on flexo and gravure printers. It is the runs that are too long for digital, but too short for profitability and their increasing popularity that are causing the real problem.

Offset’s strengths

Today’s web offset presses offer capabilities that can turn marginal short-run jobs into sustainable, profitable ones. With high productivity and fast, low-cost plate production and makereadies, web offset is far more capable than flexo to address short lead times and run lengths, Other capabilities that reinforce the case include: print quality, greater color control and a standardized process, as does the ability to handle a wide variety of substrates, including those as fine as nine microns, at high speeds. The Goss Sunday Vpak series builds on these inherent advantages through innovative variable sleeve technology featuring quick-change blanket and plate cylinder sleeve adapters that make “infinitely variable repeat lengths even easier and more affordable. With options for integrating flexo, gravure and digital stations into a Vpak press configuration to form a hybrid production line, it delivers flexibility without compromise as printers continue to benefit from a wide range of coating and finishing options. The traditional flexible packaging sector is under great pressure, Accurately identifying the factors that are causing this pressure and addressing them is what will separate those who preserve their margins – and their businesses from those who remain wedded to the way things have always been done, At present, the whole packaging market is in a state of change driven both by brands and consumers, but it is an exciting market with a bright future for those able to embrace that change.

Follow-up interview with David Muncaster

In this article it is mentioned that web offset isn’t readily associated with flexible packaging. Why do you think is that?

Historically, flexible packaging has been dominated by the gravure and flexo printing processes. While sheetfed offset is huge in other forms of 24 25 26 Technical Feature packaging, it hasn’t been able to handle most flexible materials or roll fed print, In addition, historically, there have been very few web offset. suppliers and for those suppliers that did use web offset, they predominantly used cassette based systems. where repeat changes are often very expensive and time consuming. The fast decline in average run-lengths has forced converters to focus on reducing image and setup costs, which previously were less important on long runs. This need to reduce setup time and costs is making web offset a far more interesting option, A focus on print quality, shorter run lengths and just in time/enough ordering are all good reasons for a shift to offset, Any seasoned visitor to the LabelExpo show couldn’t fail to notice the growing presence of offset modules integrated into what would previously have been exclusively flexo based systems, offsets increasing popularity is further demonstrated by the number of traditional flexo suppliers now offering web offset based solutions.

What are the most suitable applications for a web offset press, and where do you think flexo and gravure are still the more suitable technology?

All print technologies, including flexo and gravure, have their strengths and weaknesses with gravure suited to printing heavy coatings and special effects, such as metalics, and mostly associated with very long runs, Flexo gives high coverage for opaques and laquers and is associated with higher plate costs so would be more suitable for medium to long run lengths. flexibility without compromise as printers continue to benefit from a wide range of coating and finishing options.. Combining a wider array of technologies into a single integrated system provides the converter with flexibility in terms of designs and effects, economics in terms of image costs (offset’s big advantage), print quality in terms of both image detail and effects.

What are the obstacles for offset to overcome in order to be a viable alternative? i.e. substrates, and the substrate thickness

Substrates are not an issue for offset, it can print on anything that flexo or gravure can, both in terms of substrate characteristic and thickness, The two main obstacles for me are: 1) A lack of understanding of the offset process, there is a pre-conception that offset is complex compared to the relative simplicity of existing processes. 2) Capital investment for web offset would be considerably higher than for equivalent flexo and gravure machines, however ROI for web offset is relatively easy to show, Folding carton and corrugated preprint applications may also be more profitably produced on web offset systems even when compared to sheetfed offset. Goss Vpak presses can handle films and foils down to 9pm and achieve up to 98 percent of the PANTONE Color range by using extended color gamut, without the need for PMS inks and associated changeover costs. They also benefit from photo-realistic image quality utilizing fine line screens down to 150 l/cm and stochastic/FM screening, Inline finishing options and hybrid configurations, including flexo, Sleeves facilitate fast Sunday Vpak systems, with offset as the core technology, meet the needs of short, medium and long-run applications, With options for integrating flexo, gravure and digital stations into a Vpak system to form a hybrid production line, it delivers

gravure and digital units, ensure that Vpak systems provide optimum productivity, efficiency and flexibility to meet the requirements of a wide range of applications. Although there’s no one-size- fits-all solution, web offset makes an ideal base for a combination printing system, delivering low-cost image changes and high print quality, while easily integrating the inherent advantages of flexo, gravure or digital stations. With sustainability high on the agenda for most organizations, web offset offers a more efficient continuous and streamlined production process reduced material wastage and the elimination of VOC’s. with flexo and gravure, It also ensures far greater flexibility and control, and allows. converters to offer their customers later artwork deadlines.

Isn’t digital printing the more suitable solution for short runs?

For selected short/micro run jobs, personalization and on certain substrates, yes, digital has its place but for the vast majority of FMCG packaging the breakeven point in terms of run-length is still too short for digital. Flexo and gravure operations. are feeling the pinch from run length reductions most acutely not from the niche micro volumes that are purely the domain of digital printing. Previously, such jobs were often loss-leaders, taken on to retain regular, longer-run business. Today, those once- exceptional jobs are becoming the norm, and are beginning to threaten the ongoing viability of some converting businesses.

Next to investing in a web offset press, and train your staff, what else does need to be considered when switching from flexo or gravure to offset. Think peripheral equipment, logistics, etc. And what are the approximate total costs (including the press) of this on average?

One key change is that of platemaking, the relative simplicity of offset plate making allows converters to manage the process in-house rather than buying plates or engraved cylinders from external suppliers. It has the distinct advantage of delivering plate costs that are a fraction of those associated Today’s hybrid web offset systems offer capabilities that can turn marginal short-run jobs into sustainable, profitable ones.

In which direction will the flexible packaging market develop within the next 5- 10 years?

The market will continue to grow with particular growth in pouch and retort packaging, we see an increased interest in bio based flexible substrates to help companies meet sustainability targets and improve ‘green’ credentials, Average run lengths will continue to drop as SKU’s rise and digital will continue to grow at a fast rate in terms of revenue but will remain a small percentage in terms of volume, Hybrid systems, integrating flexo, gravure and digital will become more common as brand owners put ever-increasing demands on converters for quick responses to changes in market demand. while increasing design complexity. In an ever-evolving market the ability to easily adapt printing systems to meet a change in market requirements is critical to ensure the long term profitability of a business. The Vpak range has been designed with this need for future proofing in mind. As their equipment ages, flexo and gravure converters have some difficult investment decisions ahead, They must decide whether international brands will continue to pursue competitive strategies in line with current trends: whether run lengths will continue to drop and SKUs multiply, if ‘mass customization’ will take over the world, or if these practices are marketing fads that will pass.