Many printing companies, particularly newspaper publishers, have heavily invested in expensive printing machines that are now either underused or idle. This, Bhattacharjee says, is a clear signal that it’s time to explore new opportunities.
“Newspapers already have tremendous in-house design capabilities, so why not tap into the packaging industry?” Bhattacharjee said. “Packaging is a growing industry, and it’s a natural fit for printers looking to diversify.”
Indeed, the global packaging market is booming. The total packaging market size is $1.23 trillion, growing at a CAGR of 3.16 percent. In India, the growth is even more impressive, with packaging growing at a CAGR of 8.5 percent. The Indian packaging market alone is valued at $84.37 billion, he said.
Although the packaging sector offers exciting potential, it is fundamentally different from publishing and print.
Packaging technology differs based on the substrate and the product’s end use, and it’s crucial for printers to consider these variables when transitioning into packaging.
‘Transition to packaging isn’t straightforward’
For those looking to pivot into packaging, Bhattacharjee said the importance of understanding market trends, including digital technologies, sustainability, and the ongoing debate between paper and plastic.
“Digital printing has changed the packaging game. Earlier it was only used for short runs, but now, even large players in the packaging industry are adopting the technology for bespoke packaging, special promotions, and seasonal runs,” he said.
However, sustainability is a concern for the packaging industry, particularly in Europe, where regulations around recyclable plastics are stringent.
“The real challenge isn’t just about using recyclable materials – it’s about collecting and managing waste effectively,” he said.
For many printers, the question isn’t just about entering new markets like packaging – it’s also about how to adapt existing equipment to new production methods.
While certain types of printing equipment, such as offset presses, can be adapted for packaging, the transition isn’t always straightforward, Bhattacharjee said.
Traditional presses can be adapted for package printing
“New equipment doesn’t just mean buying machine A or B. You need to consider which market segment you’re entering, what substrates you’ll be working with, and how the technology fits with your business model,” he said.
During the Indian Printers Summit, he mentioned several examples where printers have successfully adapted their existing presses to meet the demands of packaging production.
“In Europe, a traditional newspaper printer transitioned to packaging printing using an existing commercial press. They had to adapt it to handle flexible packaging substrates, but it worked,” Bhattacharjee said.
While existing equipment can be repurposed for packaging, the limitations of legacy presses can pose challenges.
“For instance, traditional coldset web presses typically have a fixed ‘cut-off’– the length of paper printed at a time – so they are limited in terms of the variable formats needed for packaging production,” he said.
“However, with the right adjustments, you can use your existing equipment for simpler packaging jobs, like printing agricultural packaging or non-food items,” he added.
Choose the right technology for the job
The question of which technology to use for packaging also depends on the scale and type of production. Bhattacharjee broke down the cost-effectiveness of various printing technologies based on production volumes.
“Digital printing is perfect for short runs – anything under 3,000 square meters,” Bhattacharjee said. “But when you’re talking about larger volumes, say 150,000 units or more, gravure is the most cost-effective. In the mid-range, however, offset printing becomes the sweet spot.”
Offset printing is especially effective for producing multiple SKUs in a single print run, something that the packaging industry requires.
He also noted that new technologies, such as extended colour gamut (ECG), are making offset more versatile.
“With ECG, you use a combination of CMYK and additional colours such as orange, green, and blue. This allows you to replace up to 22 spot colours with just seven inks, which simplifies the ink process, reduces waste, and enhances colour vibrancy,” Bhattacharjee said.
Primary reasons to consider offset
- Lower printing cost, which is mainly due to the very cheap aluminium plates. It’s lower than the cost of making cylinders for gravure and flexo clichés.
- Cost of ink: Offset EB is the cheapest. The grammage of the ink is one of the lowest because there is no solvent involved.
- Less makeready time: Gravure would be impossible to use for a quick turnaround because the cylinder-making process takes too long. Offset sleeve technology is much quicker.
Demand for short-run book printing is growing
Beyond packaging, another growth area for legacy printing equipment is flexible book production.
“The demand for smaller, flexible print runs in the book sector is growing,” Bhattacharjee said.
“With the rise of digital print-on-demand services, more books – academic textbooks or fiction – are being printed in smaller batches,” he added.
Flexible book production, especially in markets like education, is increasingly dependent on short-run printing.
“For print-on-demand services – printing 100 or 1,000 copies of a specific title – offset is an ideal solution. And with digital technologies, you can achieve batch printing with a variety of SKUs.”
A hybrid system for printing on various substrates
“Manroland’s Varioman is a hybrid offset printing machine designed for a wide range of substrates,” Bhattacharjee said.
It can print on films, paper, and cardboard, making it highly adaptable for various packaging and printing needs. The machine comes in three distinct versions:
- The F-line for film and flexible substrates: It handles substrates in the range of 10 to 300 microns, such as film and paper.
- The C-line for cardboard: It can accommodate up to 700 microns for carton and card printing.
- The B-line for book printing: The B-line is designed specifically for paper.
One of the features of the Varioman is its “variable format,” which allows the cut-off length to vary from 18 to 36 inches depending on the specific requirements of the job.
“This flexibility is achieved through sleeve technology, which enables the machine to handle different formats efficiently. This is a key advantage when dealing with diverse packaging applications, from flexible films to heavier substrates such as cardboard,” he said.
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