Visitors at drupa 2024 in Düsseldorf, Germany, were able to inspect a colorful flexo-printed zipper bag, produced with the support of tesa, Bobst, Follmann, Flexicon and Petroplast. The innovative project has been established in response to the accelerating demand from brand owners and consumers for more sustainable manufacturing processes and high-quality products.

“At XSYS, we understand the importance of driving innovation also through collaboration, so we continuously work with leading industry partners to future-proof flexo, being the printing process of choice,” said Thomas Strohe, Director of Commercial Excellence at XSYS. “Showcasing the power of unity, this groundbreaking project promises to deliver significant benefits to our industry and our customers. To reach individual sustainability targets, every step counts, and through the right strategies and partnerships, they can be achieved faster and more effectively.”

The zipper bag project utilizes seven-color extended gamut (ECG) process backed with white. Both the print and lamination substrates are made from polyethylene (PE), creating a complete mono-material construction. As well as facilitating easier recycling, this PE construction leverages different innovations and expertise from all the participating parties:

• XSYS Germany GmbH supplied plates, screening and adapters – nyloflex^® FTV is a versatile flat-top dot plate, suitable for bank and LED exposure, which delivers best-in-class performance, helping to reduce the cost of processing and printing. The ThermoFlexX imager in combination with Woodpecker surface screening Nano was used for the ECG process colors, and Nevis for printing white with enhanced coverage and opacity. Woodpecker surface screening supports highest quality while reducing ink transfer; besides cost-in-use reduction, this enables faster drying and increased press speeds. The carbon-fiber rotec^® CFX Adapter, optimized with an Eco Xtra Ring for easier mounting and 90% less air usage, reduces vibrations and also promotes higher press speeds.
• tesa SE delivered self-adhesive sleeves – tesa^® Twinlock is a more sustainable, reusable plate mounting solution, featuring a compressible sleeve with a self-adhesive layer that can be reactivated for each run. As the plate is mounted directly onto the sleeve, no mounting tape is required, avoiding waste and improving the carbon footprint of the process. tesa^® Twinlock sleeves were used in combination with rotec^® Hybrid TL base sleeves from XSYS, which are lighter weight for more efficient and safer handling.
• Bobst Bielefeld GmbH offered the Master CI flexo press –With speeds up to 800m/min, the Master CI combines advanced technologies and smart innovations in CI flexo printing to enable the highest productivity, process stability and flexibility independent of the operator’s skill level. The press is engineered to deliver superior print quality, meeting the high demands of modern packaging, with faster setup times and reduced downtime. In this collaboration, the focus on taking steps to more sustainable flexo printing, aligns well with this press’s ability to work with recyclable materials and its contribution to reducing the environmental footprint of packaging. Automation being a key feature of the Master CI also streamlines operations from start to finish to minimize manual intervention and material waste.
• FOLLMANN GmbH & Co. KG provided inks – the Folco range of high-quality, water-based inks is designed for printing flexible packaging and specially optimized for efficient drying to support high production speeds. Produced, transported, and processed without solvents (VOCs), the inks offer significant safety, environmental, and health benefits, enabling a more sustainable printing process by eliminating the need for after-burners, solvent disposal, and distillation units.
• FLEXICON AG supported prepress – Flexicon handled prepress ensuring precise color management which is essential to guaranteeing brilliant color results in ECG, while maintaining quality and economic efficiency. Detailed ECG separation makes prints more sustainable, with perfect quality outcomes as the result. For this project, the design even incorporates a fake gold, printed with ECG colors only without the use of any metallic spot colors. Plates were produced utilizing a ThermoFlexX TFxX 80-D imager, ThermoFlexX Catena-E 80 exposure unit, and Catena-WDLS processor from XSYS.
• PETROPLAST GmbH arranged substrates and converting – Petroplast is a family-driven company specializing in all types of flexible packaging, offering tomorrow’s sustainable solutions today. Combined with an extensive partner network and stock capabilities, the company was able to meet the project requirements at short notice. The substrates chosen were Jindal Ethy-Lyte™ 25HD200 + LD-PE materials, laminated on a Bobst Nova SX 550 laminator, and converted to zipper bags at SN Maschinenbau GmbH.

These components and the deep process know-how of the partners provide a complete end-to-end workflow capable of supporting customers’ quality demands. Reducing the environmental impact through the use of more eco-friendly methodologies and materials, this combination establishes the benchmark for the future of flexo.

Thomas Strohe concluded, “While each company brings unique strengths and perspectives, the collaboration shows how coming together with a single purpose can drive innovation and achieve exceptional results in flexo. The overall impact of our collective efforts demonstrates true industry leadership and unwavering commitment to creating more sustainable solutions. This is the gold standard of innovation.”