Xsys joins industry partners for eco-friendly flexo

Xsys has announced the successful result of a new collaboration aimed at creating more eco-friendly flexo packaging. The project brings together the expertise of leading industry suppliers across pre-press, plates, ink, substrates, sleeves, plate mounting and printing to set a high standard in sustainable flexible packaging production.  

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

Thomas Strohe, director of commercial excellence at Xsys said: ‘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. 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 supplied plates, screening and adapters – nyloflex FTV is a versatile flat-top dot plate, suitable for bank and LED exposure. 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. The carbon-fiber rotec CFX Adapter, optimized with an Eco Xtra Ring for easier mounting and 90 percent less air usage, reduces vibrations and also promotes higher press speeds, the company said. 

Tesa SE delivered self-adhesive sleeves. Tesa Twinlock is a sustainable, reusable plate mounting system, 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. Tesa Twinlock sleeves were used in combination with rotec Hybrid TL base sleeves from Xsys, which are lighter weight. 

Bobst Bielefeld offered the Master CI flexo press offering speeds up to 800m/min. The press can work with recyclable materials. Automation being a key feature of the Master CI also streamlines operations from start to finish to minimize manual intervention and material waste. 

Follmann 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 eliminate the need for after-burners, solvent disposal, and distillation units. 

Flexicon handled prepress ensuring precise color management which is essential to achieve color results in ECG, while maintaining quality and economic efficiency. 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 arranged substrates and converting. 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. 

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.  

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.’