Flexible packaging

Valgroup installs first HP Indigo 200K in South America

Piotr Wnuk — Wed, 29 Jan 2025 22:55:58 +0000

Valgroup has invested in the HP Indigo 200K, marking the 400th HP Indigo digital press for flexible packaging to be installed worldwide and the first in South America. The new press will streamline production, increase efficiency and expand the company’s flexible packaging portfolio.

For over 45 years in the market, Valgroup has become a reference in plastic production, transformation and recycling. It operates in Brazil, Colombia, Spain, the US, Italy, Mexico and Uruguay and has more than 7,000 employees in 41 production plants and seven logistics plants.

Installing the 400th digital press is a significant milestone for HP’s flexible packaging offering. It solidifies its position as the industry leader of choice for analog converters looking to expand their digital offerings.

The HP Indigo 200K Digital Press is specifically designed for the flexible packaging market. According to HP, compared to its predecessors, it delivers a 30 percent increase in speed and a 45 percent boost in productivity. Powered by HP’s Liquid Electrophotography (LEP) technology, it offers high-resolution printing with color vibrancy and consistency.

Acquiring the HP Indigo 200K has catalyzed innovation for the business, leading to the inauguration of a new digital vertical enabling Valgroup to scale the offering across other business areas and increase services to its customers at speed

As the only converter equipped with the technology in the South American region, Valgroup can diversify into new areas such as labels and shrink sleeves.

Designed to integrate easily into lamination and pouch-making equipment, the HP Indigo 200K will streamline Valgroup’s production, increase efficiency and expand its flexible packaging portfolio.

‘At Valgroup we always install the best machines for our business,’ said Marcus Vinicius, business manager of Valgroup. ‘One of our main drivers to collaborate with HP and install the HP Indigo 200K was the need to respond to evolving market demands for flexible packaging. Installing the new digital press means we are empowered to enter new markets and offer superior print quality that meets the needs of our customers, and, at the same time, gain expertise in digital print that will set us apart from our competitors.

‘Digital print has given Valgroup the opportunity to develop a dedicated digital business vertical, expanding into offer new diverse possibilities to our clients, increase our market approach in new special categories where service is a key importance, specially to the retail, as well as support other Valgroup’s packaging portfolio, driving business and profitability for our company.’

‘At HP Indigo, we have always been at the forefront of innovation, developing solutions that address the dynamic needs of the printing industry,’ added Noam Zilbershtain, vice president and general manager of HP Indigo. ‘The installation of our 400th flexible packaging press globally represents a historic achievement and reinforces our position as the pioneer and the only proven solution in digital flexible packaging.

‘Through our proven LEP technology, we’re helping customers enhance their operational efficiency, deliver superior quality, and advance their sustainability goals. Our commitment remains unwavering – partnering with customers to uncover new business opportunities and drive their profitability in an evolving market landscape.’

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6 days 7 hours ago

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Valgroup installs first HP Indigo 200K in South America

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The investment marks the 400th press for flexible packaging installed worldwide.

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The investment marks the 400th press for flexible packaging installed worldwide.

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South & Central America

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Eagle Flexible Packaging to add new converting plant in Waupun, WI

Piotr Wnuk — Wed, 29 Jan 2025 22:34:46 +0000

Eagle Flexible Packaging has confirmed it will construct a new 52,000-sqft facility in the Waupun Industrial Park. The facility is expected to be substantially complete by the end of 2025 and will create 30 to 40 new jobs, hired within 24 months of completion.

The Waupun Common Council approved a developer’s agreement to sell city-owned land to Eagle Flexible Packaging. The company began operations in Waupun in 2021 after acquiring a formerly shuttered production facility at 4 Taylor Street. Since then, it has added 65 jobs in the city.

In 2024, Eagle Flexible Packaging acquired 1208 Wilson Drive in the Waupun Industrial Park and has invested more than 3 million USD, including facility improvements and the addition of state-of-the-art graphics equipment.

Scott Deringer, Eagle Flexible Packaging COO, said: ‘Future expansion plans call for a doubling of the current workforce over the next five years to support planned growth.’

Waupun administrator Kathy Schlieve, added: ‘Eagle Flexible Packaging has made consistent investments in the city, bringing employment opportunities for residents and supporting community nonprofits and events since opening. The proposed project is well aligned with city goals to continue diversifying its economic base through the expansion of the Waupun Industrial Park.’

The planned expansion is expected to be substantially complete by the end of 2025 and will create 30 to 40 new jobs, hired within 24 months of the facility's completion.

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6 days 7 hours ago

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Eagle Flexible Packaging to add new converting plant in Waupun, WI

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When completed by the end of 2025 it will create 30 to 40 new jobs.

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When completed by the end of 2025 it will create 30 to 40 new jobs.

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FlexiPack Packaging installs Hontec FlexiCon460-7C

Piotr Wnuk — Mon, 27 Jan 2025 23:13:23 +0000

Israeli flexible packaging specialist FlexiPack has invested in a new Hontec FlexiCon460-7C to enhance efficiency, sustainability and print quality. This investment marks Hontec’s entry into the flexible packaging market.

Israeli packaging converter has marked a milestone for the Chinese printing press manufacturer as this is the first installation of its wider web machinery.

The FlexiCon460-7C is engineered for optimal drying performance and energy efficiency. It features two long-path hot air dryers: one in the first station for primer application and another in the last station for varnish coating.

It also boasts seven LED UV-equipped stations with advanced LED UV curing systems that can significantly reduce energy consumption and carbon footprint, offering an eco-friendly alternative to conventional curing technologies.

Combining hot air drying with LED UV curing, the FlexiCon460-7C ensures proper adhesion, high-speed production and premium print quality, making it a suitable choice for high-demand flexible packaging applications.

‘This installation is a major milestone for Hontec, marking its breakthrough into the flexible packaging market with flexographic printing. It underscores the company’s capabilities in delivering high-performance, sustainable products for packaging manufacturers. Hontec is honored to support FlexiPack’s growth and is excited to expand its presence in this dynamic sector,’ said the company in a statement.

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1 week 1 day ago

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FlexiPack Packaging installs Hontec FlexiCon460-7C

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Israeli flexible packaging specialist enhances efficiency, sustainability and print quality.

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Israeli flexible packaging specialist enhances efficiency, sustainability and print quality.

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Eco Flexibles secures BRC Food Safety Grade AA certification

Selah Zighelboim — Mon, 27 Jan 2025 17:35:24 +0000

Eco Flexibles has secured Grade AA certification in the British Retail Consortium Global Food Safety Standard audit.

This certification, globally recognized as the gold standard for food safety, strengthens Eco Flexibles’ position as an end-to-end partner in the food packaging supply chain. The certification process examines over 300 operational points, including hygiene protocols, quality control, safety standards and production efficiency.

This comes during a period of growth for Eco Flexibles, which has recently expanded its production facility and enhanced its capabilities with dual Fujifilm Jet Press FP790 digital press installations and Karlville Swiss pouching machines. The food safety certification complements the company's existing BRC packaging certifications, where it has maintained Grade AA status for three consecutive years.

David Smith, general manager at Eco Flexibles, commented: 'Securing BRC Grade AA certification for food safety is another a significant milestone in our journey. As we continue to grow and evolve our business, it shows how we’re maintaining the highest possible standards across every single aspect of our operations. In an industry where quality and consistency are vital, this recognition shows we're delivering excellence at every level.

'While our focus is on revolutionizing the flexible packaging market through sustainable innovation, this certification proves we match this with exemplary operational standards. It's a powerful combination that enables us to serve as a true end-to-end partner for our food industry brand customers.'

The certification, recognized by 70 percent of the top 10 global retailers, provides additional assurance to brands partnering with Eco Flexibles for their transition to recyclable mono-material and paper-based packaging. Combined with the company's existing BRC accreditations, it reinforces Eco Flexibles' strength as a comprehensive packaging partner across the entire supply chain.

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1 week 1 day ago

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Eco Flexibles secures BRC Food Safety Grade AA certification

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The certification process examines more than 300 operational points.

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The certification process examines more than 300 operational points.

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Jindal Films installs high barrier metallizer at its Brindisi plant

Adyasha Sinha — Thu, 23 Jan 2025 13:33:02 +0000

Jindal Films has installed a new metalizer at its Brindisi plant in Italy. JFE aims to increase its metalization capacity with the metalizer, enabling the company to support the growing demand for recyclable barrier BOPP and BOPE films.

The new metalizer, with a width of over 3.7 meters, was installed in late 2024 and is now fully operational. This marks a significant milestone in JFE's ongoing commitment to meeting the growing demand for high-quality, sustainable films. With this new line, JFE will continue to grow its diverse portfolio of high-barrier metalized films, further expanding Alox-LyteTM and Ultra-High-Barrier products and broadening the range of Ethy-LyteTM metalized films.

Manfred F. Kaufmann, CEO of JFE, commented: 'We are thrilled to increase our slit metalized film capacity with a clear focus on high barrier products, now reaching 2.000MT/m. This new metalizer strengthens our commitment to providing sustainable, recyclable packaging films. Customers increasingly embrace our metalized BOPP and BOPE films and our Alox-LyteTM product range to help create mono-material, fully recyclable packaging structures.'

This installation is a crucial step in JFE's strategy to support the growing demand for high-quality, sustainable films while contributing to a circular economy. By further expanding its metalized film offerings, JFE continues developing innovative packaging products that meet performance and environmental goals.

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1 week 5 days ago

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Jindal Films installs high barrier metallizer at its Brindisi plant

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With the new metallizer, the company aims to increase Sustainable Films production capacity.

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With the new metallizer, the company aims to increase Sustainable Films production capacity.

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Flexible Packaging Association celebrates 75th anniversary

Selah Zighelboim — Wed, 22 Jan 2025 20:41:07 +0000

The Flexible Packaging Association, the leading advocate and voice of the flexible packaging industry, is marking its 75th anniversary in 2025. The FPA will begin celebrating this milestone at its 2025 Annual Meeting, which will take place March 5-7 at the JW Marriott Miami Turnberry Resort & Spa in Miami, Florida.

Since 1950, the FPA has led innovation and collaboration to tackle critical challenges and shape the flexible packaging industry, which has grown to become the second-largest packaging segment in the US, employing over 83,000 people. The FPA has advanced sustainability through material innovation, circular economy initiatives and recycling technologies while setting and surpassing safety standards and advocating for the flexible packaging sector.

'Reaching our 75th anniversary is a testament to the resilience and innovation of our members, who have continually pushed the boundaries of what’s possible in flexible packaging,' said Dan Felton, president and CEO of FPA. 'Looking ahead, we remain dedicated to driving sustainability, advancing technology, engaging on public policy and shaping a future where flexible packaging continues to meet the needs of consumers and the environment.'

As the industry moves forward, FPA is focused on seizing opportunities that maximize sustainability and achieve circular economy goals. Innovation in design and functionality will also be a major focus, as flexible packaging continues to enhance consumer convenience while reducing food and other product waste.

In honor of its 75th anniversary, FPA is creating a commemorative storybook that chronicles the progress of the flexible packaging industry over the years. This storybook will capture key milestones, innovations and the people who have shaped the industry into what it is today. Additionally, celebratory videos featuring reflections from members, leaders and board chairs spanning the decades will be unveiled during the Annual Meeting and throughout 2025.

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1 week 6 days ago

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Flexible Packaging Association celebrates 75th anniversary

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FPA is marking the anniversary by unveiling a storybook and commemorative videos.

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FPA is marking the anniversary by unveiling a storybook and commemorative videos.

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Flexible packaging market set for strong growth

Piotr Wnuk — Sun, 19 Jan 2025 22:52:55 +0000

Business intelligence firm Research and Markets has published the latest report forecasting that the global flexible packaging market, valued at 210.62 billion USD in 2023, will reach 238.91 billion USD by 2029, rising at a CAGR of 2.12 percent.

According to the report, the global flexible packaging market is set to grow due to the increased adoption of flexible packaging over rigid packaging and the increase in processed and packaged food.

The shift from rigid to flexible packaging is a major trend in the global packaging industry. It is driven by multiple factors, including sustainability, cost-effectiveness, convenience, and advancements in materials.

This shift has seen significant growth, especially in industries such as food and beverages, pharmaceuticals, personal care, and consumer goods. One of the most significant factors driving the adoption of flexible packaging is its lower environmental footprint. As it uses less material, it results in reduced waste and lighter weight, which reduces energy consumption during transportation.

The report also indicates sustainability as one of the industry growth restraints. Many flexible packaging products are made from multilayer films, where different materials (such as plastic, aluminum, and paper) are laminated together to achieve specific properties like moisture resistance, durability, or light protection.

These materials are difficult to separate during recycling processes, and most recycling facilities are not equipped to handle complex multilayer packaging.

The global flexible packaging market is primarily dominated by the APAC, Europe and North America regions, with APAC holding the largest market share.

The APAC region is poised to dominate the flexible packaging market, driven by increasing demand and the availability of cost-effective labor. These factors make the region highly attractive to producers seeking to expand their market presence and boost profitability.

In response, major players in the industry are intensifying their focus on the region by adopting strategies such as market expansions, increased investments, acquisitions, strategic agreements and the introduction of innovative products.

The flexible packaging market in the APAC region is characterized by demand across a broad spectrum of products, ranging from cost-effective sachets to high-end luxury packaging. The sector is expected to see robust growth, particularly in the food, pharmaceutical, and industrial packaging segments, driven by rising consumer demand for more convenient and protective packaging.

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2 weeks 2 days ago

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Flexible packaging market set for strong growth

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The shift from rigid packaging to flexible packaging is a major trend in the global packaging industry.

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The shift from rigid packaging to flexible packaging is a major trend in the global packaging industry.

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Bobst opens Italian labels and flexpack center

Selah Zighelboim — Wed, 15 Jan 2025 17:57:19 +0000

Conventional printing 15 January 2025

Bobst opens Italian labels and flexpack center

The new Competence Center showcases Bobst narrow and mid-web portfolio across labels and flexible packaging.

Following the successful establishment of the Atlanta Competence Center in the US, Bobst has opened a new 1,200sqm Competence Center in Florence, Italy, dedicated to labels and flexible packaging. Providing access to the company’s full range of narrow and mid-web printing technologies with six complete production lines — including inline flexo, digital and All-in-One technologies — the new Italian facility is designed as a hub for collaboration and innovation.

‘The major investment in the narrow-mid web printing and converting product line demonstrates Bobst Group’s strong commitment to this segment,’ states Matteo Cardinotti, head of Bobst’s narrow mid-web printing and converting product line.

‘Bobst has experienced exceptional growth in labels in recent years and we are supporting that development by opening more local Competence Centers and hiring more staff worldwide. In Italy specifically, we have also expanded our production facilities and reinforced our service organization to match the needs of our European customers.’ Bobst employs a total of 350 employees dedicated to the narrow and mid-web inline segment.

Cardinotti said drupa and Labelexpo Americas 2024 demonstrated how the industry is ‘moving beyond innovation in hardware and software in isolation towards full integration of processes. In this respect, Bobst is leading the way with its portfolio of complete workflows designed for the future of packaging production.’

Six production lines

The production lines on show represent all Bobst’s technologies dedicated labels and short-to medium-run flexible packaging.

A Bobst Master M6 flexo press is integrated with a near-line Novolam MV mid-web laminator. This setup, in combination with oneECG printing and DigiFlexo technology, allow production of short- to medium run flexible packaging and shrink sleeves.

Bobst’s ‘All-in-One’ platform with inkjet and flexo technology inline, was represented by the Digital Master 340 press running pressure-sensitive labels for the beauty segment. For inline flexo, Bobst demonstrated its Master M5 with single-pass production of multi-layer labels, also featuring oneECG (extended color gamut) technology and DigiFlexo automation.

All presses demonstrated live were operating with direct integration to the Bobst Connect digital platform.

Acting as a central data hub, Bobst Connect integrates every aspect of the workflow, from job management and pre-press setup to printing, converting and quality control, based on collection of real-time production data.

‘The ability to capture these valuable insights allows converters to enhance their business planning and optimize the entire production process,’ says Cardinotti.

The platform is continually evolving, and Bobst recently added a new certified substrate library, job quality reports, and ‘Job and Recipe Management’, which streamlines machine integration and enables faster setup.

‘Bobst has brought into reality the idea of the closed-loop workflow, what we call “PDF to twin-PDF” concept, addressing the main industry trends with easy-to-use machines, all orchestrated by Bobst Connect,’ says Cardinotti. ‘Our main focus is to provide customers with complete workflows that help them overcome a multitude of market challenges, allowing them to deliver consistent and high-quality results much quicker and with low waste, without having to rely on highly skilled operators.’

Implementing ECG

Another issue addressed at the event was how to maintain color consistency across different types of technologies, applications and over time. This is an issue as converters move beyond labels, leveraging inline flexo technology to produce a range of short-run flexible packaging applications. With such a highly complex market, it is a great challenge for converters to maintain the consistency of brand colors from job to job.

During the event, Bobst, together with its network of partners, demonstrated how oneECG works by standardizing the colors on press and automating the color matching process, moving it from the pressroom into pre-press.

This ‘digitalizing’ of color management means operator skills will have less impact on the print outcome.

The benefits of oneECG printing on inline flexo presses also include savings on ink and plate costs, substrate waste reduction, faster setup, and a reduction in cleaning time and related consumables.

The event reinforced Bobst’s industry partnerships with the presence of Esko, Kurz, Avery Dennison, Sun Chemical, Kongsberg PCS, DuPont and Lohmann.

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Mondi shines at WorldStar Awards

Adyasha Sinha — Wed, 15 Jan 2025 10:34:34 +0000

Mondi has received 10 awards at the WorldStar Packaging Award. The awards, organized annually by the World Packaging Organization, celebrate outstanding packaging design and technology achievements worldwide.

Markus Gärtner, CEO of corrugated packaging at Mondi, said: 'We are proud to mark a milestone in 2025 with Mondi receiving more WorldStar awards than ever before. This broad recognition across our regions highlights the strength of partnerships with our customers and our teams' creativity and collaborative efforts. These awards inspire us to keep pushing boundaries and deliver even more innovative solutions.'

Thomas Ott, CEO of flexible packaging at Mondi, commented: 'These awards underline Mondi’s commitment to driving innovation and sustainability in packaging. By closely collaborating with our customers and partners, we ensure our products and designs deliver on functionality while keeping materials in circulation and avoiding waste. The recognition by the World Packaging Organization is a testament to the dedication of our teams and our collective focus on creating value through packaging that supports a circular economy.'

The WorldStar 2025 Awards ceremony will occur on May 30 in Milan, Italy. The awards are among the most prestigious accolades in the packaging industry, recognizing innovation that addresses critical challenges and delivers high value. Mondi’s success in 2025 underscores its role as a pioneer in sustainable packaging designs.

Mondi’s 2025 WorldStar Award winners:

Paper bag without free film, other category: Mondi’s paper bag without free film layer is an innovative technology in industrial packaging designed to protect filling goods like building materials, chemicals and feeds. It significantly reduces the plastic content by replacing the free film layer with a coated barrier paper. The bag is certified recyclable based on tests conducted in Mondi’s recycling laboratory in Frantschach according to the CEPI v.2 test method and 4evergreen’s fiber-based packaging recyclability evaluation protocol and scored 19 out of 20 points in the certification of Interseroh+.

Eco-cage, food category: Eco-cage is a basket made of corrugated packaging designed to reduce plastic waste and enhance fruit freshness through ventilation holes. Its lightweight yet strong design ensures durability, making it suitable for supermarkets, farmers' markets and homes. A significant advantage of Eco-Cage is its flat transport capability, allowing for over 2,000 baskets per pallet. The carrying handle is reinforced with tape to ensure sufficient load capacity.

Lunch box, food category: The Lunch Box has security seals that break when the package is opened. This feature prevents accidental openings and provides consumers with confidence that their meal has remained untouched and unopened from preparation to delivery. The lunch box has a handle that allows the consumer to lift and carry the meal easily, but it can also be folded to stack a few packages during delivery. The Lunch Box also has an integrated waste basket so that waste can be placed and easily disposed of when sorting waste after eating. This product is formed without the use of glue, tape or staples.

Doorbell guard, electronics category: Doorbell Guard is an innovative packaging product made from corrugated material, designed for premium electronics, combining functionality and aesthetics. The outer body of the packaging ensures optimal transport protection, while the intelligent inner insert securely holds the product and its accessories and ensures a sleek product presentation. The packaging, custom-made for high-quality doorbells, is versatile, serving in-store displays and eCommerce shipping. Its compact design efficiently stores all components, keeping all parts securely in place. The multiple inserts showcase the main product and neatly conceal accessories. The box is quick and easy to assemble, saving time in packaging and eliminating the need for plastic bags.

Bumperpac, transit category: Bumperpac is a new lightweight corrugated packaging for transporting bumpers sustainably and efficiently. The innovative packaging offers good protection, easy handling and excellent ergonomics in a packaging that folds and unfolds instantly. The sturdy cardboard that makes up the corrugated sleeve is glued with water-resistant adhesive that withstands the humid conditions of overseas transport. The packaging is placed on a customized wooden pallet that requires less wood than a standard pallet.

Product protection for premium parasols, transit category: To enhance sustainability, the redesigned packaging for premium parasols completely replaces the previously used Expanded Polystyrene (EPS) padding. With this new packaging product, 65 parasol variants can now be packed effectively. With about 4,000 parasols dispatched annually and two EPS pads per parasol package, Mondi’s customer can eliminate around 8,000 kg of EPS per year, replacing it with 100 percent recyclable corrugated board.

BeerCoolBox, packaging materials and components category: This innovative beer bottle packaging, made of fully recyclable corrugated cardboard, combines functionality, aesthetics and sustainability requirements. The design consists of a sturdy box and a specially designed insert covered with barrier paper, ensuring water resistance. The insert transforms into a practical ice container, cooling beer bottles to the perfect temperature. The water from the melted ice remains in the insert due to its waterproof properties, eliminating the risk of leaks and keeping the surroundings clean.

Display-guard, point of sale category: Display-guard features a reinforced construction with double-walled panels, which increases the durability of the box and ensures safe transportation and storage of products. Triangular corner structures provide additional support during transportation and storage, helping the box to maintain its form and minimizing the risk of damage. This ensures that the box remains stable even under hefty loads. Its design makes it suitable for display on pallets and on shelves, allowing a variety of products to be stored safely. The easily foldable structure saves space during transportation.

TopLockBox, e-Commerce category:

TopLockBox is an innovative alternative to traditional plastic eCommerce bags and standard boxes. It is specifically designed to prevent theft and ensure product security during shipment.

Optimized for quick and easy assembly, TopLockBox helps to save valuable time and effort. Its user-friendly closure system guarantees that packages can be securely sealed with minimal effort, improving operational efficiency. Security is the top priority; the unique lock system makes unauthorized access to the box contents difficult. For added convenience, TopLockBox features a tear strip that allows recipients to open the package without additional tools, enhancing the user experience while maintaining packaging integrity. The strong sealing tape ensures the box stays securely closed throughout its journey, guaranteeing that products arrive safely and securely.

Bottle protector, other category: The Bottle protector’s robustness, durability and design not only enhance product security during transport and storage but also align with the brand's sustainability goals. Its user-friendly design simplifies assembly and handling, increasing operational efficiency and business cost savings. The aesthetically pleasing design boosts brand visibility and helps create a stronger connection with consumers. Bottle protector is shipped flat, offering less storage space and easy assembly. It acts as a carrier and a separator, enhancing the box's durability for safe transport and storage. The design includes folding tabs that reinforce corners, maintaining the box’s structure and reducing the risk of damage. The packaging is made of 100 percent recyclable materials, and printable surfaces allow for effective brand promotion.

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2 weeks 6 days ago

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Mondi shines at WorldStar Awards

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The company wins 10 awards for innovative packaging designs.

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The company wins 10 awards for innovative packaging designs.

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Marzek Etiketten + Packaging grows business across Europe

Piotr Wnuk — Sun, 05 Jan 2025 21:29:43 +0000

Flexible packaging 13 January 2025

Marzek Etiketten + Packaging grows business across Europe

Marzek Etiketten + Packaging produces labels, flexibles and cartons with high levels of creativity and a strong sustainability focus.

Marzek Etiketten + Packaging is unique as a family-owned business for producing labels, flexibles and cartons with high levels of creativity and a strong sustainability focus.

Marzek Etiketten + Packaging remains unique in the European labels market. Not only is the company still fully family-owned – by the fourth and fifth generations of three families – but it covers the full range of package printing applications, from roll and sheetfed labels to flexible packaging and folding cartons, in plants spanning Austria, Hungary and Ukraine. The company has over 700 employees and a turnover of 87M USD (80M EUR).

CEO Dr Johannes Michael Wareka says the Marzek Group is big enough to benefit from cooperation between multiple production sites and international sourcing while at the same time being more agile than bigger, PE-owned labels and packaging groups.

The success of the company can be measured not only in its employee numbers and turnover but also in the multiple Finat and World Label awards it has won for superbly creative label and packaging designs. All these award-winning designs originated from the company’s own in-house creative department.

“In the future, it will be the people who prepare the data who are responsible for quality control, not the machine operator. This is a change in the mindset”

Going forward, Marzek Group is committed to a major ongoing investment program, with a current commitment to invest 17.5M USD (16M EUR) across the group in 2024/2025.

Greenfield flexibles

When L&L last visited Marzek, the company had purchased the flexible packaging operations of Mondi group in Kner, Hungary, and was planning to develop a new greenfield site. That has now been realized.

The flexibles plant operates under the name of M-Flexilog Kft, located in Békéscsaba, close to the existing Marzek Kner Packaging Kft factory. The 25,000sqm site includes 8,500sqm of factory space dedicated to the manufacturing of flexible packaging, pouches, sleeves and wraparound labels. Overall, the value of the four-year investment project exceeded 12.9M USD (11M EUR).

Financing of the M-Flexilog Kft plant was strongly supported by the Hungarian government, which saw it as a major strategic investment for the country. The government not only supported Marzek financially but also sent high-ranking representatives to the inauguration ceremony from the Hungarian Ministry of Foreign Affairs and Trade, as well as the Minister of State for Economic Diplomacy. High-ranking Austrian diplomats, including the Austrian commercial deputy attaché, also attended.

ECG printing wet glue labels on Heidelberg Speedmaster

The centerpiece of the M-Flexilog Kft plant is an 8-color solvent-based Windmoeller & Hoeslscher (W+H) Miraflex CI flexo press, installed in 2017. The press runs at speeds up to 400m/min.

The W+H press is complimented by a Nordmecanica Combi 4000 solvent laminator and Soma Venus III slitter-rewinder and a fully automated color mixing system.

The workflow includes an automated 14m-high rack warehouse with induction loops for over 8,000 pallet spaces.

Construction of the M-Flexilog Kft plant was designed to meet high environmental protection standards with state-of-the-art energy recovery systems. The operation complies with BRC/IOP hygiene standards essential for servicing the food and pharmaceutical packaging industries.

“Labels and packaging are all about communicating the product to the consumer. Packaging is a piece of communication”

A short drive across town is Marzek’s folding carton plant, Kner Packaging, housed in a communist-era multi-story building with floor upon floor of state-of-the-art carton printing and converting equipment.

The plant houses nine offset presses, both Heidelberg and KBA, including a short-inking Anilcolor press for shorter runs. Printed sheets go to a fleet of Bobst cut-crease machines and a Gietz 740 foiling machine.

Sheetfed labels

A sheetfed wet glue label plant also operates from the Kner Packaging site.

The plant houses six Heidelberg and two KBA printing machines, each 6-color plus coater, one of which prints with an extended color gamut (ECG) ink set. This means that over 95 percent of Pantone colors can be simulated using the same seven inks (CMYK+OGV), so there is no wash-up of spot color units between jobs.

This brings offset color management into line with digital, where brand owners have shown themselves prepared to accept a 7-color simulation of brand colors. It also means multiple jobs with different Pantones can be ganged across the same sheet, greatly improving efficiency on shorter-run, multi-SKU work.

Running ECG does require that everything about the workflow is standardized, including fingerprinting the press with each different substrate.

Printed sheets are sent to a Polar finishing line, where they are either square cut or die punched and bundled.

Marzek’s wet glue model is to produce at maximum efficiency and allow brand owners to call off stock when required. The company has built its own management information system (MIS) to allow this to happen.

Miraflex AM CI flexo press

The humidity-controlled warehouse stores some 1,500 SKUs. As soon as an SKU reaches a set minimum quantity, the MIS automatically re-orders a new production run.

‘This means we are free to schedule printing and finishing for maximum efficiency, and our customers are assured of consistent levels of stock at a price set once annually,’ says Wareka. ‘Customers anywhere in Europe can call off their order on Friday, and the next Thursday, they have everything they need. This is our key advantage.’

The sheetfed division processes around 20,000 tons of label materials a year, of which 15 percent is filmic material.

Pressure-sensitive labels

Marzek’s pressure-sensitive label converting operation is based in Traiskirchen, Austria, a short drive from Vienna airport.

The plant runs a mixture of printing processes, mainly offset but also flexo and digital.

For short-run and customized work, Marzek has installed two HP Indigo 6K presses. In fact, the company has been a digital pioneer, installing the first HP Indigo 6000 press in Europe in 2009 and the first 6K press in Austria.

Marzek’s internal label design team has used that experience to push the boundaries of digital print.

An example of this is the ‘Flying Bird’ project, which uses HP’s Mosaic software to generate an animated flying sequence when labels are viewed side by side.

Further creative possibilities are added by the SEI Laser Label Master laser die-cutter.

“PPWR is coming, and it will be relevant to everything we do. Packaging will finally be required to become more sustainable”

The laser die-cutter has been faster than we expected,’ says Wareka. ‘It is also very versatile. It not only eliminates the need to change tooling, but it allows for a vast range of possibilities like security marking, micro-perforation and creating unique and variable label designs, which would be impossible with standard die-cutting techniques. We can score through an ink onto a metallic substrate to create fine embellishments or cut out complex shapes. This in itself is a security feature as it makes the label harder to copy.’

Applying the laser to hot foil creates hologram-like effects that cannot be replicated with a photocopier.

‘The counterfeiter would actually need the same equipment,’ says Wareka, ‘Digital can do so much more than just copying conventional printing. Each collection of labels can be different, and not just the design but the shape. There are endless possibilities. And digital today matches offset quality.’

The multiple ABG Digicon finishing machines add further possibilities for creative design.

The latest Digicon 3 includes two Big Foot hot foil/embossing stations and flatbed silk screen. Marzek has perfected micro-embossing that gives an additional layer of security protection.

Add to this the ability to create a huge range of metallic shades with digital overprinting, and Marzek has a formidable resource for brands looking for truly innovative and secure packaging systems.

Marzek’s offset press fleet consists of three Rotatek Brava presses, which can be switched between semi-rotary and full rotary operation. Additional modules installed since L&L’s last visit include a Pantec Rhino embossing unit, Kocher+Beck automated unwind and ABG turret.

In addition, a 11-color + varnish Omet Varyflex V2 offset press with extended hot air dryer on the varnish station has been transferred from the Kner Packaging site in Hungary.

Marzek Vienna also runs an MPS EFA 530 flexo press equipped with K+B non-stop unwind.

In-line booklet and multi-layer label production is a specialty on these machines.

Offset plates are made in-house with a Kodak CTP system, along with flatbed and rotary silk screen production. Flexo plates are produced on an Esko CDI XPS Crystal 4835.

Automation will be a key component in Marzek’s investment plans. ‘In the future, it will be the people who prepare the data who are responsible for quality control, not the machine operator,’ notes Wareka. ‘This is a change in the mindset.’

Servicing brands

The Traiskirchen operation specializes in designing and printing wine labels, which can be produced either in self-adhesive or sheetfed offset formats. The company currently has over 3,000 different wine label projects open.

The Traiskirchen facility hosts an in-house creative design agency and artwork department that uses Esko WebCenter software to proof 3D virtual prototypes to customers. ‘We have a big emphasis on storytelling when we work with brands across all food and drink sectors,’ says Wareka. ‘Labels and packaging are all about communicating the product to the consumer. Packaging is a piece of communication.’

Michael Wareka with Stephanie, Oliver and Marie

Marzek can leverage its multi-format capabilities to provide brands with coordinated sets of packaging – for example, premium decorated cartons and labels for promotional wine, spirits and beer brands.

The company has made a heavy investment in e-labels, which means linking a QR code or RFID on the bottle label to extensive online information about the product. Marzek provides this as an end-to-end service to brands, including online database management.

As part of its wider service offering, Marzek supplies dispensing systems and thermal transfer printers for point-of-sale and logistics/warehouse labeling.

Sustainable business

Sustainability has become a central topic when discussing new projects with brand customers. This is a core value for Wareka personally, and it has deep roots. ‘I define sustainability as: You should leave for the next generation a better company than you found it. This is the only way to be sustainable, and family-owned companies have always done this effectively.’

Wareka sees the EU Packaging Directive (PPWR), with its three-pronged approach to Reduce, Reuse and Recycle, as the ‘big topic’ in Europe. ‘It is coming, and it will be relevant to everything we do. Packaging will finally be required to become more sustainable.’

The company is developing a range of more sustainable packaging products, including alternatives to non-recyclable multi-layer flexible packaging.

Marzek reports on a wide range of sustainability metrics.
‘We subscribe to SBTI – Science-based target initiatives - which is a reporting system currently very few companies follow,’ says Wareka.

SBTI targets show businesses how much and how quickly they need to reduce their greenhouse gas (GHG) emissions to prevent the worst effects of climate change. The Marzek Group has a wide range of sustainability certifications, including ISO 14001 and FSC.

Marzek also subscribes to the CSRD (Corporate Sustainability Reporting Directive) and the GRI (Global Reporting Initiative), which involve standardized reporting on a wide range of diversity, equality and social responsibility metrics.

The big brands and retail chains are doing this themselves and they are looking for suppliers who also do this reporting, even smaller ones,’ says Wareka. ‘It is an administrative burden for small companies when you add it to ISO and BRC and so on, so this is an advantage for larger companies which have more resources to meet the criteria.’

Sustainability also means reducing inefficiency and waste in the production process.

In conclusion, Marzek is, in many ways, a remarkable company. It has managed to grow into a multi-plant, multi-national scale business while retaining the core values and characteristics of a family-run business, with the next generation fully engaged in the process.

Marzek history

The Marzek company was established by Dr Johannes Michael Wareka’s grandfather in 1879, making Michael the fourth-generation CEO. His three children are now fully involved in the business: Oliver in customer relations, Marie in accounts, and Stefanie in marketing. On a day-to-day basis, the Marzek Group is run by a board, and a new COO has just been appointed, taking up position in January. Michael Wareka will remain as CEO centrally involved in Marzek’s future strategy.

Center of the storm

During the eastward expansion from its base in Vienna, Marzek has found itself at the center of historic European events.

The Hungarian packaging operation was originally a communist-era state-controlled business with 1,500 employees. After the collapse of the Soviet Union, the operation was privatized and broken up. When Marzek acquired the business in 2005, there had been literally no investment since the early 1990s and only 120 employees remained.

Today, there are 500 employees in Marzek’s Hungarian business; there has been a major investment in modern equipment. Production volume has expanded by more than six times.

Then there is Ukraine.

Marzek started manufacturing in Ukraine in 2009. The Marzek Dnipropack plant is situated in the east of the country, worryingly close to the front line of the conflict with Russia.

Marzek Ukraine employees’ children

‘In Ukraine, we are still producing, even under very challenging circumstances,’ says Michael Wareka. ‘If there was stability there, the growth rate would be in double figures.’

To help provide some relief, Marzek arranges for groups of its employees’ children to be brought across the Hungarian border to spend two weeks resting and recuperating in Békéscsaba, close to where Marzek’s packaging plants are located.

Marzek’s employees, led by Wareka and his family, arrange parties and excursions and the children all stay together in a hostel donated by local people.

‘It is challenging making all the arrangements to bring the children over the border. The Hungarian government can be hostile towards Ukraine, but the people of Hungary are amazing and welcome the children with open arms to their country,’ says Wareka.

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Andy Thomas

Strategic director

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