Hot on the heels of being awarded ‘Best Flexible Packaging Press’ a by the European Digital Press group (EDP), SCREEN and Chiyoda Gravure of Japan announce the installation and collaborative development is complete and that the Truepress PAC 830F is in full-scale production of flexible, sustainably-printed packaging at its Itako factory 2.

The flexible packaging market has experienced a growing requirement to expand high- mix, lower-volume production as consumer needs have diversified and product life cycles have become shorter. As societies, especially in Australia and New Zealand, push to become more sustainable, there is a growing demand to reduce the environmental impact of manufacturing processes and optimise resource utilisation. Because it uses water-based inks, the PAC 830F is uniquely positioned to address these sustainability issues.

The PAC 830F also eliminates the need for photopolymer platemaking and gravure cylinders, with associated chemicals. Capable of very short runs and multiple versions, it also greatly reduces wastage and package redundancy. Set-up times for jobs have been reduced by an incredible 70% over conventional methods.

The much-awarded Truepress PAC 830F digital inkjet flexible packaging press uses aqueous inks and is now in full production at Chiyoda Gravure Corp.

Furthermore, the industry is facing an urgent need to address challenges such as rising raw material costs, faster time to market, and emerging procurement risks, as well as social issues including shortages of human resources.

Based on these challenges, Chiyoda has completed the setup of equipment and quality verification for commercial production. The company can now accept orders for production using digitally-printed flexible packaging, focusing primarily on small to medium runs on standard PE and PP films. 

Delivering new value with Truepress PAC 830F

Thanks to its plateless digital process, the PAC 830F significantly reduces material waste and the cleaning and setup work required during job changeovers compared to gravure or flexography. Both of these conventional processes will continue to dominate very long print runs, but brands are demanding more and more shorter runs.

Chiyoda Gravure intends to use the new press to promote the delivery of value-added factors, eg:

• Improve brand value through the provision of a diverse product range Chiyoda will provide a wide variety of design options while using standardised package sizes and support the planning of limited time and region-specific products as well as test market items.
• Produce runs to flexibly accommodate small lot orders and the need for a diverse product line, thereby helping its clients to build their brand value.
• Optimise SKUs and reduce inventory - Chiyoda will establish a production system capable of supplying the necessary quantities at the required times, enabling its clients to optimise their packaging material inventory and reduce the number of SKUs.
• Improve productivity and create a more worker-friendly production environment Chiyoda will reduce operator workloads by minimising plate changeovers and cleaning tasks while maintaining highest quality.

Strengthen efforts to reduce environmental impact - Chiyoda will seek to drive a comprehensive reduction in environmental impact by leveraging the benefits of water-based, solventless inks and plateless printing.

Eco Smaart – Chiyoda’s new smart branding

Chiyoda’s printed products and related services using digital technology as a solution named are now branded “Eco Smaart.” This is an initiative to deliver new value through digital, solvent-free printing and it is designed to meet market needs such as those for high mix, low volume production, shorter lead times, optimised inventory, and reduced environmental impact. SCREEN’s Truepress PAC 830F is part of the Eco Smaart initiative.

Looking forward, the plan is to establish an optimal production model that effectively combines digital and traditional gravure printing, with a goal of achieving a digital printing output of around 10% by 2030. The two companies will work to build a production system that is capable of meeting diverse client needs while contributing to the sustainable development of the flexible packaging industry.

Chiyoda Gravure Corp. President Hiroyoshi Sato with SCREEN President Hiromi Sakurai

Hiroyoshi Sato, President of Chiyoda Gravure Corporation says: “We are working to upgrade our production capabilities in response to the trend toward high mix, low volume

production and the growing demand for environmental sustainability. Our introduction of the Truepress PAC 830F has enabled us to establish a flexible production system complementing our existing gravure printing operations. Going forward, we aim to leverage the unique advantages of digital printing to offer new value. We believe this will make a significant contribution to the growth of our clients’ businesses.”

Hiromi Sakurai, President of SCREEN Graphic Solutions Co., Ltd. Says: We are delighted that Chiyoda has begun full-scale operation using our Truepress PAC 830F. We specifically developed this press as a solution to support digitalisation and environmental sustainability in the flexible packaging market. Moving forward, we will continue to collaborate with our clients to create new market value and contribute to the realisation of a more sustainable printing industry.”

Examples of flexible packs printed using aqueous inks on the PAC830F

Locally, Screen GP Australia Managing Director Peter Scott notes: “I have monitored the co-development of the PAC 830F at Chiyoda for some time and already we have had Australian flexible packaging printers travel to Japan to see this press in action. The interest is high, as we are certain to emulate Europe’s industry transition toward solvent-free, water-based and food-safe inks, as converters face tightening rules on traditional VOC-heavy chemical usage.”

SCREEN packaging presses are sold through Jet Technologies in Australia and New Zealand.

www.screenaust.com.au

www.jet-ap.com.au

www.chiyogra.co.jp