By Felip Ferrer, Offset Technical Sales Director, Comexi

The Future of Flexible Packaging: Why the Comexi Offset CI Evolution is a Game-Changer

Sustainability should not be viewed as a luxury. The Comexi Offset CI Evolution proves that it is possible to achieve peak print quality and high operational speeds while simultaneously lowering costs and protecting the planet. As a solvent-free hybrid printing press, it combines offset and flexo technology with a central impression (CI) cylinder, utilizing Electron Beam (EB) curing inks.

This system encompasses the advantages of offset printing and the safety of low-migration EB inks and coatings, which contain no photoinitiators. This makes it an ideal choice for producing a wide range of materials for both food and non-food packaging. The new Evolution model specifically delivers higher automation, unmatched print quality, and superior color consistency. With 30 installations worldwide—including four recent repeat orders—this technology has proven itself as a reliable, high-performance solution. It is currently attracting significant interest from brand owners who prioritize speed-to-market and environmental responsibility.

Why Is It a Game-Changer?

1. Sustainability & Regulatory Compliance (PPWR Ready)

The Comexi Offset CI Evolution is designed to meet the rigorous demands of the Packaging and Packaging Waste Regulation (PPWR).

  • Eco-Friendly Curing: Electron Beam (EB) curing eliminates the need for solvents and recovery equipment.
  • Reduced Emissions: This process significantly reduces energy consumption and CO? emissions.
  • VOC Removal: It effectively removes Volatile Organic Compounds (VOCs) from the printing process.
  • Heat-Free Processing: Unlike other methods, EB Offset does not apply heat to the substrate.
  • Material Stability: Combined with the CI cylinder, this allows for high-speed, perfect-register printing on heat-sensitive materials like thinner MDOPE.
  • Circular Economy: EB inks and coatings provide surfaces highly resistant to chemicals and scratching.
  • Advanced Recycling: Cross-linked EB inks can separate as solid flakes during industrial hot washing.
  • Contamination Prevention: This separation prevents the discoloration of wash water and contamination of recycled polymers.

2. Unmatched Efficiency & Cost Savings

The operational efficiency of this press translates directly into significant economic advantages.

  • Low-Cost Tooling: The process uses recyclable aluminum plates costing less than $10 each.
  • Ink Efficiency: EB inks feature 100% solid content, requiring lower consumption for high-quality results.
  • Reduced Maintenance: Because the inks do not dry in the printing units, press washings and changeover times are drastically reduced.
  • Smart SKU Management: Converters can combine multiple SKU designs into a single run to increase efficiency.
  • Setup Time Savings: Printing five designs together can save four changeovers and massive amounts of setup time.
  • High Productivity: The press reaches speeds of 300 m/min with a 1100 mm width.

3. Digital Agility at Scale

Comexi offers a “digital way” of working but at an industrial scale.

  • Speed-to-Market: Transition from a marketing file to a complete set of plates in under 20 minutes.
  • Automated CTP: The streamlined Computer-to-Plate process ensures rapid turnaround.
  • Print On-Demand: This agility allows for high-volume production with operational costs comparable to conventional flexo or gravure.

4. Superior Quality

Quality remains a cornerstone of the Offset CI Evolution.

  • High-Definition Resolution: Achieve quality levels of 80-100 l/cm or 200-270 lpi.
  • Color Versatility: These results are attainable using either an extended gamut process or spot colors.

A Pivotal Shift in Flexible Packaging

The Comexi Offset CI Evolution represents a pivotal shift in the flexible packaging industry, harmonizing environmental mandates with high-speed industrial performance. By reducing the reliance on solvents and heat, and lowering tooling costs significantly, it provides converters with a future-proof platform for growth. This technology not only ensures compliance with upcoming regulations but also delivers the premium quality that global brands demand.

If you want to test the Comexi Offset CI Evolution, contact us!