What are the opportunities for wide format in packaging?

Nessan Cleary shares how the packaging sector is expanding, and while conventional methods dominate, digital printing is increasing, especially for short runs and corrugated boxes. Wide format printers are well-suited to this demand. Factors like e-commerce growth and the need for full-color, on-demand packaging contribute to this trend.

Packaging is one of the major growth areas in printing and likely to continue to grow as the global population increases and there are more people buying things. Packaging printing is still heavily dominated by conventional print technologies - typically flexography and gravure - but in recent years we’ve seen a steady increase in digital printing for packaging, including some opportunities for wide format print service providers.

The economics behind packaging printing are closely tied to manufacturing economies of scale so that it is mainly a game of very long print runs, which is best suited to conventional printing. But the growth in e-commerce with its promise of near instant consumer satisfaction means that there is always room for short runs requiring fast turnarounds, where digital print can play a role. Large format printers are a good way to meet this demand because of their ability to print to a wide range of different types of media on-demand. And large format print service providers are ideally placed to pick up such work as packaging often goes hand in hand with point of sale displays and other related marketing collateral.

The main opportunity lies in corrugated boxes, where the growth of online shopping has led to more demand for full-colour boxes as this may well be the only way that brands will have to communicate directly with their customers. Many brands have recognised through the popularity of unboxing videos that the packaging is part of the overall customer experience and are keen to enhance this. In some cases this might extend to printing the customer’s name on the box, or even printing details of each customer’s order on the inside of the box.

Even where there is no personalisation required, there may be a requirement to produce packaging complete with full colour graphics on-demand to reduce the cost of storing packaging inventories. There may also be a requirement for packaging to reflect particular short run marketing campaigns, which could be either from a large brand or a local retailer. In addition, brands often experiment with different variants of their products to check if they should expand their product mix. Those variants also require their own packaging but may never be produced in large enough runs to commission conventionally-produced packaging.

The most suitable printers will be the bigger flatbeds and hybrid printers simply because they have the size and productivity required. Some vendors have directly targeted the packaging market. Durst, for example, has developed the P5 Pack based around its P5 series of hybrid printers. The most logical of these is the P5 350 HS because of its overall productivity. The P5 Pack option includes tailoring the vacuum system on the printer to better handle corrugated boards without damaging them. It also includes a camera for more accurate automatic image adjustment. Durst has also developed the Luvera LED inkset specifically for corrugated and paper substrates. It’s said to have low odour as well as good scratch resistance and punchy colours. This ink meets the EuPIA standards for packaging inks and can be recycled on cardboard.

Given that even a short packaging run may mean printing several thousand boards, the printers will have to be matched to an automatic loading and unloading system that can handle the corrugated boards without damaging their fluting. This is relatively straightforward and could include either feeder and stacker units or even a robotic system. In any case, you will be able to see plenty of examples of such loading systems attached to printers at a Fespa show.

In some cases, press vendors have used wide format technology to develop dedicated packaging print solutions, or vice versa. Fujifilm’s upcoming HS6000 signage printer, for example, is actually a rebadged Berbaran JetMaster packaging machine. The difference between the two is partly down to the feeders used for the different substrates, but mainly a matter of the markets that the two vendors are targeting.

These packaging samples were all printed on EFI's Nozomi machines. ©Nessan Cleary

EFI originally developed its Nozomi inkjet press as a packaging solution based on large format technology. However, EFI then went on to create a Nozomi variant that specifically targeted the sign and display market.

As with most large flatbeds, the Nozomi’s use UV-curable inks, which can print to a wide range of materials. EFI has also created inksets for specific markets, such as aluminium cans for paints and similar products. However, UV inks can sometimes be a drawback in the packaging market, which has led EFI to also develop a version that uses water-based inks.

The issue with UV inks in packaging is to do with the danger of chemicals that have not fully cured within the inks migrating through the packaging to the products within. This is a particular concern for certain types of products, such as food and some cosmetics and pharmaceutical products. This problem mainly relates to chemicals used in the photo initiators within the ink, which can be carcinogenic, but only where the ink is in direct contact with those products. For this reason, many label press vendors have developed low migration UV inks that should cure more thoroughly to mitigate this issue.

Such low migration inksets are not generally available for large format printers. In any case, this issue shouldn’t affect the vast majority of products and their packaging. EFI in particular has had considerable success in selling its UV-based Nozomi to packaging printers worldwide. There is an obvious workaround of using a barrier in the packaging, such as a plastic bag, to prevent such products from coming into contact with the ink. But of course, most brands want to reduce the amount of packaging they are using, and particularly any plastic.

At the other end of the scale, thre are also several less expensive solutions that would enable a large format service provider to test out the packaging market. The Portuguese company Mtex NS, which is now part of the AstroNova group has developed a couple of short run printers that have a small footprint. These use thermal print technology with water-based pigment ink so there is no issue of UV ink migration. The flagship is the Multi 1300, which takes boards up to 1300mm wide but with a print width of 1070mm. It’s a complete solution that includes the automatic feeder along with the printer and a separate stacker unit. It will produce 600dpi print quality at 18mpm with other modes offering higher speed or better print quality. Konica Minolta also sells a version of this as the PKG-1300.
 
Xante sells the Excelagraphix 4800, which is an effective entry-level wide format packaging printer. It uses Memjet’s thermal printheads, which deliver 1600 x 800 dpi resolution. It takes boards up to 122 cm with a print width of 106.7sm. Xante says that it’s possible to print up to 338 boards per hour, assuming square boards of 122cm. The basic model relies on manual sheet feeding but there is an option to add automatic feeder and stacker units.
So in conclusion, the packaging market is as much an opportunity for wide format printers as it is for other sectors in the printing world. There are options at both the entry level and high productivity ends of the spectrum, and its a market that’s only going to grow.

Discover the latest innovations in packaging and wide format printing at FESPA Global Print Expo 2025, Europe's leading print and signage exhibition taking place from 6 - 9 May at Messe Berlin, Germany. It will showcase the most innovative products, visionary concepts, and latest developments in the future of print. Register to visit here and use promo code FESJ502 and pay only 50 euros for your entrance ticket.