Flexibility gives the edge

5 July 2011



Maureen Byrne joined Muller Martini’s study group seminar recently to see how offset can be combined with other types of print methods to achieve excellent quality of flexible packaging and labels.


Held in May this year at Muller Martini’s training centre in Maulberg, Germany, the study group seminar was a lively mix of presentations and demonstrations of the presses that have been developed and acquired.

The day was made even more interesting with presentations on shrink film materials and their characteristics from packaging company Bilcare Staufen; materials characteristics from Treofan Germany; inks from Zeller + Gmelin; EB curing from ESI Energy Science; and UV curing from IST Metz. There was also a video presentation from Hammer Packaging, USA on the topic of the transition to web offset printing; and one from Nestlé on its packaging requirements and their implications for the printer.

Stars of the show, however, were the live demonstrations of an Alprinta V and a Variable-Size Offset Printing (VSOP) press, the model series patents of which were acquired from Drent Goebel last year.

The Alprinta V is used typically for flexible packaging and labels. The combination of flexo and offset units along the press allows for maximum variety of print colours and finishes. Flexo, for example, can be used to print white opaque or metallised ink; or gravure can take the place of an offset unit for particularly thick layers of ink. Two runs were demonstrated; between which the change-over from one size and substrate to another was carried out. Both substrate and cylinders were changed over quickly and easily from 24 inch shrink printed with 6 colours on clear substrate to 26 inch, 4-colour in-mould labels with an opaque white backing. “The image and sizes can be changed in one step,” said David Townend, Business Development Manager, Presses.

One big advantage of this press is that virtually any print length can be produced. To change the printing size, it is not necessary to change the whole printing insert; but only the carbon fibre cylinders. Paper, film and composite materials work just as well as self-adhesive label stock.

The other press demonstrated was the VSOP, which can be used to print flexible packaging, labels, films and cartonboard, thanks to its new design. For maximum flexibility, sizes can be changed quickly and easily without changing all the print inserts. The plate and rubber blanket cylinders are designed as handy sleeves. Due to their low weight, they are easy to handle, and can be changed quickly and easily. Visitors saw a change-over on this press that took only a few minutes.

Again, other printing processes can be added, such as flexo, screen, rotogravure and digital; as well as finishing stations such as foil stamping, laminating, punching and sheeting. When the VSOP is used in food packaging manufacture, electron beam or UV drying can be used to harden the printing ink in an inert and therefore low oxygen atmosphere; and odours are almost completely eliminated.

Proof that these presses have impressed customers, many have opted for one or other of the options detailed above. For example, for the first time in its 58-year history, cartonboard packaging and wet adhesive label printing house Läser in Switzerland decided on a web-offset press. It is now using the Alprinta 74V to produce label rolls (wraparound) and shrink sleeves. Previously the company was using sheet-fed presses.

Company owner Jürg Läser chose the new roll-fed hybrid solution with offset and flexo printing units: “It allows us to print on plastics as well as paper, and I am confident that film packaging is the future,” he commented.

Shrink sleeves printed by Muller Martini are used by Swiss beverage manufacturer Rivella. According to Matthias Roth, Strategic Buyer at Rivella, the increasing number of brands has a major impact on packaging. “Products bought straight from the shelf are almost always chosen for their packaging,” he said.

Ten years ago, Rivella only sold two products that used shrink sleeves. Now that number has risen to 13. Its range has become more sophisticated, with its Michel brand now sold in varieties such as Tinga, Beauty Colada and Power Coffeeberry, rather than plain orange or pineapple.

“Shrink sleeves convey emotions better,” said Tatiana Giorgi, Project Manager, Marketing. “In such a hard-fought market as fruit juices, this is critical, particularly among the younger generation.”


From the roll to the bottle: highly automated shrink sleeve processing at Rivella. Rivella

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