Flexible packaging consists of materials such as foils, films and papers commonly constructed as mono or multilayer substrate. These materials are converted into different shapes and sizes to hold and protect the package contents. Flexible packaging also provides a cosmetic marketing value for products.
A wide number of products make use of flexible packaging, including fresh produce, pet food, candy, cookies, bread, flour, cake mixes, dried fruit, fertilizer, frozen vegetables, and snack food. The food industry accounts for 50% of flexible packaging sales.
The term flexible packaging embraces the manufacture, supply and conversion of plastic and cellulose films, aluminum foils and papers which are used separately or in combination.
Flexible packaging materials combine functional and aesthetic properties that afford protection to a wide range of food and other consumer and commercial products.
Flexible packages are printed for 3 main reasons:
- To sell the product and promote it by catching the eye of the buyer with attractive colors and images.
- To supply needed information about the product such as ingredients list, content and end of life date.
- For product security or tracking reasons, especially in high end products, such as expensive seeds and pharmaceuticals, to prevent product forgery and counterfeiting.
Usage of flexible packaging types is affected by:
- Regulatory affairs and environmental aspects
- Consumer protection needs (health and hygiene)
- Retail and brand owners’ responses to consumer preferences
- The direct cost of packaging production and costs that enable packaging to differentiate between competing products.
The digital opportunity
Digital printing suggests relatively high break even point compared to Flexography or Gravure printing where high costs for plates and long preparation times are needed.
Market trends are generally moving towards the digital opportunity. There is a growing need for ever shortening versions of flexible packaging due to:
- Cutting the supply chain - smaller inventories
- Private labels gaining popularity
- Product samples
- Prototyping for market testing
- Targeted products that address smaller segments with more focus
- Advertisements on packages
Variable Data Printing (VDP) is a form of on-demand printing in which elements such as text, graphics and images may be changed from one printed piece to the next without stopping or slowing down the press, using information from a database. VDP enables the mass customization of documents via digital print technology, as opposed mass-producing a single document using conventional printing. VDP is a direct outgrowth of digital printing, which harnesses computer databases and digital presses to create high-quality, full color documents, with a look and feel comparable to conventional printing.
Workflow trends are towards more sophisticated packaging design and use of high quality color. Short run flexible packaging applications include: Pre-production samples, test markets, prototyping, exhibition materials, promotional packaging, high-priced packaging, variable language and others.
