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15.02.2021 Flexible packaging

Flexible packaging can easily be referred to as adaptable packaging. Due to its adaptable properties, it offers the possibility of packaging a wide range of solid items, liquids, gels, powders, fats, and even gases.

Flexible packaging is used in various industries such as food and beverage, cosmetics (personal care, health and beauty), healthcare/medical, automotive, and agriculture to package a wide range of products.

It comes in various flexible shapes, such as pouches, sachets, bags, wraps, and shrink films. It allows different sealing and opening methods, is lightweight and easy to carry, provides storage and re-sealing capabilities (zipper pouch), preserves freshness, and extends the shelf life of products, especially food. Along with its ability to carry and protect the packaged product, packaging also offers numerous sales, distribution, sustainability, marketing, and promotional advantages.

The new HP Indigo digital technology, recognized as one of the most sustainable printing technologies on the market, has replaced traditional flexo and gravure (copper plate) printing techniques. These two traditional methods require the production of plates or copper cylinders that transfer ink onto the material, whereas digital printing does not require such tools. Digital printing is also an excellent alternative in terms of color quality compared to traditional methods. The ink system in cartridges is fully enclosed, and no harmful chemicals or solvents need to be added – VOC free. A significant advantage of HP Indigo inks is that during recycling, they break down easily, meeting environmental standards such as ROHS (Restriction of Hazardous Substances) and are biodegradable.

Flexible Packaging - HP Indigo

HP Indigo technology ensures exceptionally high print quality, and with the HP IndiChrome+ (CMYK+OVG) printing option, up to 90% color matching with Pantone colors can be achieved. It also allows double-sided printing on various materials (paper, PET, BOPP, LDPE, etc.), adjusts the print format, prints variable data (serial numbers, barcodes, QR codes, etc.), and handles small to medium production runs with various designs and finished shapes.

Flexible packaging is made using a wide range of materials (substrates), including paper, polymer, metallized, cellulose, and bioplastic films (PET, BOPP, LDPE) ranging from 12 - 350 microns in thickness and with print widths up to 740 mm. Various factors influence the choice of material: the role of permeable and impermeable sides in the packaging construction (barriers), mechanical strength and load capacity, printability, heat resistance, sealing, final appearance, recyclability, and manufacturing costs.

The most commonly used materials for flexible packaging include LDPE (low-density polyethylene), BOPET (biaxially oriented polyethylene terephthalate), BOPP (biaxially oriented polypropylene), BOPA (biaxially oriented nylon), Kraft paper, aluminum foil, cellulose, and biodegradable materials.

When the packaging material is made from a single type of material or plastic, it is referred to as single-layer material. When it is made or composed of several layers (of the same or different types), it is referred to as multi-layer packaging material. Multi-layer materials are used to package more complex products, where several different parameters and barriers must be considered for product protection. Each layer has a specific function, such as preventing contamination, preserving freshness, protecting against mechanical damage (impact, scratches, tears), and ensuring tensile strength and sealing of the packaging.

As mentioned, flexible packaging commonly appears in the form of bags, pouches, sachets, wrappers, or wrap films, typically made from flexible and adaptable materials such as polymer and metallized (aluminum) films or paper.

With state-of-the-art technology for flexible packaging printing, we enable faster production, personalized printing, smaller print runs, various designs and executions, eco-friendly printing, and cost-effective solutions.

Flexible packaging provided by our technology includes promotional personalized packaging for brands, packaging for energy bars, various pouches and sachets with or without zipper technology, sticks packaging (oil, vinegar, mayonnaise, etc.), packaging suitable for retort packaging, coffee, spice, and other food packaging, compostable packaging (decomposes up to 80% within 90 days with the help of bacteria), packaging that can be 100% recycled with known recycling procedures (re-newing), LDPE, BOPP, and BOPET.

We are focused on producing high-quality products that are both environmentally friendly and user-friendly.

Pouches – Stand-up Bags

Pouch – Stand-up bags are one of the most recognizable trend products in the world of flexible packaging, used for packaging a variety of products. They come in various shapes and designs such as: three-side-seal pouch, gusseted pouch (with an expansion fold), stand-up pouch, spouted pouch (with a straw or spout for pouring), zipper pouch (with a resealable closure), vacuum-sealed pouches, microwaveable pouches.

The shape of the pouch allows easy transportation, can be reopened and resealed, is relatively resistant to mechanical damage, provides good product protection, and extends its shelf life. Pouches are most commonly used to package powdered products, ready-to-drink liquids, coffee, powdered milk, etc.

Sachets
Small flat bags, often referred to as small pouches, the difference being that sachets typically package a single product, often sealed on all four sides. They offer excellent opportunities for branding and marketing, as their entire surface can be printed. Sachets come in various sizes and shapes and can package a wide variety of products such as powders, soaps, shampoos, coffee sugars, tablets, liquids, and more.

Wraps and Twist Wrappers
Wrapping is a process in which a product is wrapped in clear or printed film, creating a tight-fitting flexible package (wrappers). They are typically made of cellophane or twist BOPP and are ideal for wrapping and packaging square, elongated, oval, and round-shaped products such as dragées, candies, chocolate balls, toffees, and various types of sweets. Regular wrappers are used for packaging biscuits, chocolates, sweets, vegetables, hard soaps, medical products, etc. Since the wrap can be fully printed, it provides excellent branding opportunities and visibility for the product on the shelf.

Pack-ready technology allows for fast printing and packaging solutions, enabling quick product placement on the market.

Lamination aims to improve the appearance, quality, and barrier properties of the packaged material. The lamination process combines two or more base materials, which are fused together by heat and pressure, without the need for conventional polymerization of adhesives or hardeners (which usually takes 7-14 days), and does not require solvents, adhesives, polyurethane, or ethyl acetate, but only pure EVA material. The EVA resin is directly incorporated into the material itself, so the weight and thickness of the material remain constant after lamination (10µ).

With Pack-ready lamination technology, we can quickly bring a product to market in high-quality packaging.

Lamination of Flexible Packaging