FlexPack@Labelexpo, co-located with Labelexpo Americas 2024, will focus on the complete production chain from materials selection to print, laminating and pouch-making. Andy Thomas-Emans reports.

Flexible packaging will be a key focus at Labelexpo Americas 2024 next month as label converters continue to diversify their product offering and wide web converters seek solutions for the increasing amount of short run work coming their way.

This is a trend we are now seeing across Labelexpo shows around the world. Labelexpo Asia 2023 was the first Labelexpo show to feature a dedicated flexible packaging hall, being effectively a ‘show within a show’. This takes nothing away from Labelexpo’s core focus on label technologies. Rather, these two sectors of the package print industry are entirely complementary.

Why this growing interest from label converters in flexible packaging?

The last decade has seen a quiet revolution in packaging formats as brands have moved more of their premium products into high-value, small-format laminated stand-up pouches as an alternative to labeled containers.

At the same time, label press technology has been evolving towards wider web widths and the ability to handle extensible films. Mid-web presses – defined as in the range 26-30ins - will be a standout machine category at Labelexpo Americas 2024, and for many label converters these are becoming the main gateway into flexible package printing and converting. These presses can be configured with both UV and extended hot air drier units for water-based inks and coatings.

At Labelexpo Americas 2024, Mark Andy stages the global launch of its 26in-wide P Series S9 press for label and flexible packaging markets. Show attendees can also see the US debut of Nilpeter’s 26in-wide FA-26 following its highly successful launch at Labelexpo Europe 2023 when multiple presses were sold off the show floor. Lombardi shows a print unit from its mid-web Invicta press.

Digital printing of flexible packaging has been dominated by HP since the launch of its 30in-wide HP Indigo 20000-series presses at Labelexpo ten years ago. At Labelexpo Americas 2024, HP marks the US launch of the latest press in this series, the HP Indigo 200k, which greatly increases productivity over previous generation machines.

Flexpack Ecosystem

Entering the flexible packaging market requires much more from a label converter than simply installing a press, either digital or flexo. It requires acquiring a wide range of knowledge about the flexible packaging ecosystem, which is a different world from labels. Put shortly, labels are secondary packaging, not in direct contact with the product, while flexible packaging is the primary container of the product.

This means it is essential to come to grips with the required properties of flexible packaging: burst resistance, moisture and light resistance, structural properties, and, increasingly, sustainability profile. Flexible packaging requires an understanding of lamination, multi-layer structures, barrier properties and surface and reverse printing. The finished pack needs to be tested for a range of properties including leakage and pack integrity.

Following printing and laminating, the pouch needs to be formed ready for filling. And depending on the end use, a filling/dispensing spout may need to be incorporated.

To help converters understand all aspects of the flexpack workflow, Labelexpo Americas 2024 has introduced a dedicated ‘exhibition within an exhibition’ called FlexPack@Labelexpo. This will allow show visitors to focus on materials, lamination technology and pouch manufacturing machinery, supported by a half day deep dive flexible packaging masterclass organized by the Label Academy.
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FlexPack@Labelexpo will be located in Hall F of the Donald E Stephens Convention Center. Exhibitors will be present to talk about everything from materials - films, zippers, thermal laminates, overprint varnishes for example - to curing technology, laminating technology, slitting machinery, pouch-making and spouting equipment.

Companies currently confirmed in the FlexPack@Labelexpo zone include Karlville, Gonderflex, S-One LP, ABG, Mamata, Protect-All, Novaflex, Bonset American Corporation, Sanzip re-closable zipper and Nobelus. In addition, three times a day, visitors will have the chance to attend a short introduction to flexible packaging presented by HP.

Flexpack equipment

Focusing on the equipment on show, Gonderflex will demonstrate its P-8009 GFXW single pass thermal laminator-coater-embellishment-slitting machine. The Labelexpo machine configuration includes lamination, a single flexo unit for either surface or reverse print and textured cold foil application with an integrated JetFX print bar system, followed by slitting and rewinding.

Karlville Converting and Karlville Swiss partner to demonstrate post-print flexible packaging machinery for pouch making, lamination and slitting in partnership with HP Indigo. The company will showcase its compact thermal laminator for surface print application running a Protect-all MET PET with Nobelus Soft Touch thermal laminate.

Alongside is the Karlville Swiss Compact D, a quick change pouch making machine running Charter MDO PE Mono Material.

S-OneLP demonstrates the Cellcoat Systems T-14 thermal laminator, for which the company is exclusive US and European distributor. S-OneLP also displays its range of flexible packaging films and related primers, including Michelman in-line and off-line primers and water-based varnishes.

Attendees can also see a range of overprint varnishes and coatings helping to achieve bespoke surface effects and protection for printed materials. Available OPVs include water-based, UV, LED, and eBeam varnishes and topcoats.

Companies providing information on different aspects of the flexpack supply chain include, Protect-All, which demonstrates printable barrier films and laminations; Novaflex promoting its laminating systems; and Mamata promoting its pouching machines and Form, Fill, Seal (FFS) equipment.

FlexPack@Labelexpo is also set to attract conventional wide-web flexible packaging converters interested both in meeting existing suppliers and deciding how they will tackle the challenge presented by increasing requests for short run packaging.

It is worth noting that the wide web converting industry generally regards shrink sleeves as flexible packaging – as one more unsupported film application. FlexPack@Labelexpo will follow this categorization, so shrink sleeve materials and converting equipment will be in included in the exhibition zone going forward.

At Labelexpo Americas 2024, ABG will demonstrate new and shrink sleeve systems in the FlexPack@Labelexpo zone. The Turret Seaming Rewinder (TSR750) ensures a weld that conforms to any container shape. Alongside this will be ABG’s Doctoring machine (DR450).

Karlville Converting shows its Plus series shrink sleeve seamer running a Bonset CPET as well as a film printed with Siegwerk inks demonstrating a de-inking application.

Equipment launches at the show continue to grow, so make sure you continue to check www.labelexpo-americas.com.