BOBST smartGPS delivers precise registration and impression settings during the plate mounting process

The key to success in flexible packaging production hinges on maintaining full control over each element in the process. End-to-end process control and high levels of automation throughout the entire value chain ensure consistent and predictable high-quality print results. BOBST One complete solution is one of the most productive and cost-effective ways to deliver packaging excellence.

The many market challenges faced by converters in the flexible packaging sector require constant vigilance and strategic investment in the most innovative technologies to stay competitive. The global packaging industry is grappling with escalating cost pressures amid sustained political and economic unrest. The lack of skilled labor continues, putting the onus on equipment manufacturers to increase automation, while emerging legislative initiatives amplify the imperative for more sustainable solutions proven by full life-cycle analyses.

End-to-end productivity
One of the main objectives of implementing process control measures in flexible packaging production is to ensure excellent, consistent, and repeatable print quality. Any variations in quality, whether in the accuracy of colors, ink density, or print registration, can have far-reaching consequences. For converters, mistakes erode profitability, generate unwanted waste, and disrupt delivery schedules. Furthermore, subpar print quality not only risks rejection by the customer but also jeopardizes consumer trust in the product and may tarnish the overall brand reputation.

With the aim to deliver a highly cost-effective, productive, and less wasteful workflow, BOBST’s ‘One complete solution’ leverages the company’s expertise in flexible packaging. This holistic approach brings together advanced technologies for each stage: platemounting in prepress with smartGPS, flexo printing on the VISION CI press, quality inspection via a Digital Inspection Table (DIT), solventless lamination on the NOVA SX 550, and connected services via the BOBST Connect portal. The process can be further augmented by deploying BOBST oneECG (Extended Color Gamut) printing technology.

Automation in setup and changeovers
The first element in BOBST One complete solution is press preparation. Setting up a CI flexo press for printing requires meticulous attention to detail, precision in adjusting all parameters, and a keen understanding of the unique requirements of each job to ensure optimal print quality and the highest production efficiency. With the smartGPS Graphic Positioning System, BOBST has shifted these registration and impression setting procedures to the plate mounting stage. This frees up significant amounts of active press time and allows operators to prepare the next job while the first one is still being printed.

Best in class price-performance value
Balancing the cost of equipment with its effectiveness is a key factor in ensuring operational efficiency and maximizing the value of an investment. The printing phase of BOBST One complete solution is executed by the VISION CI flexo press to guarantee optimal print quality across a wide range of substrate types at a highly competitive cost level.

Tackling various production lengths at up to 400 m/min, the VISION CI offers consistent and repeatable print quality with solvent-based and water-based ink in 8 to 10 colors. To maximize efficiencies further, it can be set up to run BOBST oneECG technology with a fixed set of colors that cover up to 95% of the Pantone book. In terms of uptime, ink consumption, and waste, oneECG is the most efficient process in flexible packaging, only possible when mastering full process control.

Protecting the product
Once the printing is completed, the job is transferred to the laminator where the final multilayer material structure is created. Lamination adds mechanical properties that improve the strength of the material, making it resistant to tearing and punching so the product is fully protected; it adds barrier properties that protect the product inside from the effects of light, moisture, oxygen, pathogens and other spoiling agents, keeping it intact and fresh for longer (in the case of food); and it ensures that the substrate can be perfectly sealed on the packaging line.
This critical stage in the One complete solution workflow is handled by the BOBST NOVA SX 550 solventless laminator, a highly modular, automated, and compact machine. One of the main advantages that make this 450 m/min laminator suitable for both shorter and longer runs is the toolless job changeovers, which can be completed in minutes, meaning unproductive downtime can be kept to a minimum.

Taking flexible packaging to a higher level
Several other process control innovations from BOBST complete the picture. A new solution for quality control is the Digital Inspection Table (DIT), which has recently been made available for flexible packaging following success in the corrugated and folding carton sectors. Offering digital connectivity and automatic reporting, the DIT Flexpack introduces a new level of precision and efficiency to proofing and quality control, significantly minimizing waste while bolstering customer confidence.

Finally, the overarching mechanism in the One complete solution is BOBST Connect, a user-centric online portal that offers live progress reports and remote assistance, gathers accurate performance data and automatically calculates OEE, handles shift management, and much more. BOBST Connect allows converters to take full control of their production and use in-depth workflow analysis to optimize all processes for maximum quality, productivity, and sustainability.