Mercian Labels is to show how it can print flexible packaging with inkjet at Packaging Innovations – and is using bars of chocolate as bait.
The top quality Whitakers chocolate is packaged in a food safe recyclable paper developed by Sappi. It is printed by a Screen PAC520P, a version of its continuous feed inkjet press with food safe water based inks that can be used without further protective layers.
In what began as a proof on concept project, Mercian is handling the production of the print files with these printed off shore to begin with. As volumes build, Mercian will be installing a dedicated machine.
“We have good core competencies in handling jobs with high degrees of complexity and have been printing digitally since 2006,” says managing director Dr Adrian Steele. “We see there is a window for digital before the big runs on flexo or gravure. Screen reached out as they had developed a machine for printing packaging on paper.”
This led to the collaboration between technology provider, the paper company and printer together with the customer. The proposal also suited Whitakers. It wanted to adopt a packaging material that is fully recyclable via kerbside collection and which had no downsides in shelf life or product quality.
By opting for digital printing, the company is not committing to excessive volumes that might be thrown away before use and can respond rapidly with a spike in orders. Conventionally printed flexible packaging has long lead times and high minimum order quantities.
“We can offer all the benefits of less waste, speed to market and less product obsolescence and to enable co-packers to their film based lines with fibre based material for short runs. And there is a big demand for flexibility, which is a core strength,” says Steele.
The company is already a user of Screen’s narrow web L350 UV label press which has helped it win awards for print quality.
However, while some label printers have used existing machines to print flexible packaging, principally pouches, Mercian steered away from this approach. The 330mm web width is too narrow for flow wrap packaging, it uses UV inks which even with the low migration versions create problems for direct food packaging.
Moreover the pouch sector is well served, says Steele, and uses plastic while fibre based substrates are what customers are looking for. “The additional width is needed for flow wrap and customers want waster based inks on fibre based packaging,” he adds. “This was intended to be a proof of concept project, but has become so much more. We are taking orders and will be bringing the press in when we can.”
This underlines the potential of digital printing on the paper substrates. These will vary according to application says Sappi’s market manager for paper & packaging solutions Sibylle Hajostek. “Selecting the right paper for the right product application is crucial and our expertise in barrier coating allows us ton provide the right barrier properties for product protection.”
