Anthony Locicero, Associate Editor05.18.20
Sustainability is becoming increasingly important to brand owners, including those in the flexible packaging space.
According to the Sustainable Packaging Coalition, sustainable packaging:
• Is beneficial, safe, and healthy for individuals and communities throughout its life cycle.
• Meets market criteria for both performance and cost.
• Is sourced, manufactured, transported and recycled using renewable energy.
• Optimizes the use of renewable or recycled source materials.
• Is manufactured using clean production technologies and best practices.
• Is made from materials that are healthy throughout the life cycle.
• Is physically designed to optimize materials and energy.
• Is effectively recovered and utilized in biological and/or industrial closed-loop cycles.
“Sustainability has become the keynote in developing the creation of new products and concepts inside flexible packaging,” said Lutz Frischmann, global product director flexible packaging at hubergroup. “This is also fostered by many national and international political initiatives.
“We expect that new concepts for the flexible packaging segment will evolve along the entire value chain,” he continued. “Examples are the move towards monomaterial structures or the use of paper in completely new applications. Sustainability has many facets and many of these deal with cyclic economy solutions and end-of-life considerations.”
Sustainability takes on many forms, according to Mark Hill, senior VP of R&D at INX International Ink Co.
“From reducing migration potential, using bio-renewable content in inks, and applying technologies that help reduce food waste and enable packaging material recycling, we are looking at a very diverse set of tools to help packaging be more sustainable,” he said.
According to Joe Kubasiak, market manager – flexible packaging for Wikoff Color, Wikoff Color is working with brand owners and converters to develop inks that perform well on recyclable films and help eliminate the need for lamination, reducing the overall film structure. These inks include solvent-based, water-based and EB flexo inks, he said.
Toyo Ink is seeing brand owners and global converters make a stronger commitment to achieving certain sustainability targets in line with the Sustainability Development Goals set by the United Nations, per Yoshirou Nishikawa, GM, Business Strategy Department.
“In the flexible packaging field, the most popular trend is related to the reduction of plastic films and its suitability for recycling or biodegradation/compost,” he said. “Activities focused on the circularity of such materials, like enhancing plastic recyclability, reducing layers within flexible packaging structures and searching for substitute materials to current plastics, are the main drivers that are nowadays moving development activities aiming for increased sustainability.
“The necessity to reduce the amount of plastic being used in packaging has cast a negative light on plastic packaging,” Nishikawa continued. “However, the ongoing coronavirus pandemic has made a case for plastic packaging, as consumer demand for packaged foods has skyrocketed. Single-use plastic packaging has proven effective in protecting food from contamination and extending its shelf life.”
Recyclability and/or compostability are the focus of many flexible packaging conversations in North America, per Deanna Klemesrud, global marketing director-brand & promo, packaging inks & resins at Flint Group.
“We believe that both flexible plastic packaging and paper-based packaging have an important role to play in protecting food, reducing waste during transportation, storage and consumption, while helping to increase the health and well-being of people all over the globe,” she noted. “That said, while the conversation around the use of plastic as compromising to the environment is a common discussion, food preservation, the safety of drinking water, secure packaging of pharmaceuticals, and the ability to transport consumer goods around the world are equally important arguments and have a long-standing value that brand owners and the general public understand.
“Additionally, flexibles are more cost and resource-efficient to produce versus many other types of rigid packaging, therefore, less pollution is emitted during production and shipping due to a lighter, space optimizing packaging solution,” Klemesrud concluded.
Consumer packaged goods companies are looking for support in their sustainability, according to Anthony Renzi, VP, product management of packaging inks, North American Inks at Sun Chemical.
Sun Chemical has provided solutions that meet their goals of resource reduction, a smaller number of packaging layers, along with decreased package size: SunVisto AquaGreen, a bio-renewable ink offering a natural, cleaner, greener option for food packaging and SunSpecto SolvaGreen, a compostable, solvent-based ink for surface printing on biodegradable films, he noted.
“Through the use of SunBar barrier coating, SunSys protective coatings, and SunFuse sealants and primers, we can allow for flexible package designs with improved recyclability,” Renzi said. “Anytime a flexible package uses more than one type of substrate – for example, polyethylene film laminated to polypropylene film – that structure becomes more difficult to recycle. By using coatings to replace these layers, functional mono-material packages can be created, making recycling a reality for flexible packaging. We can also add functionality to bio-based films and even paper to enable the design of biodegradable packages.”
To that end, hubergroup – a CEFLEX member – has a wide range of certified bio-compostable inks and many of its products are C2C certified, Frischmann said.
“From reducing migration potential, using bio-renewable content in inks, and applying technologies that help reduce food waste and enable packaging material recycling, we are looking at a very diverse set of tools to help packaging be more sustainable,” INX’s Hill said.
Wikoff Color’s initiatives include new product formulations across multiple chemistries, developing industry partnerships with like-minded companies and reducing its environmental impact at its manufacturing operations, according to John Pettus, director – corporate sales and marketing.
Toyo Ink joined several workgroups – including CEFLEX in Europe and CLOMA in Japan – to “ensure we stay up-to-date of the rapidly evolving flexible packaging market,” Nishikawa said.
“We have launched a broad lineup of inks, coatings and adhesives made with a ‘biomass’ or plant-based resin,” he continued. “We are developing de-inking systems that allow inks to be removed from plastic packaging films before they are to be recycled. We are also developing barrier systems that would allow or help to reduce the layers in flexible packaging structures while maintaining the same level of packaged content protection.”
Flint Group is also a CEFLEX member and an active member of the Flexible Packaging Association.
“Being a member of CEFLEX means that we focus on existing solutions for the recycling of plastic packaging materials and we work collaboratively to develop new markets for materials which today have no viable recycling solution,” Klemesrud said.
“Flint Group is involved with and has access to many sustainability initiatives and collaborations, such as the Materials Recovery for the Future Collaborative, which has a simple vision that flexible packaging is recycled curbside and the recovery community captures value from that,” Klemesrud said.
According to Renzi, Sun Chemical is increasing the number of raw materials sourced from bio-renewable sources.
“One example is using soya bean oil that comes from already existing soya bean crops in fields that have been certified as not replacing other pre-existing natural biodiversity,” he said. “Plastic packaging can be difficult to recycle because it is made up of multiple materials. Eliminating packaging layers and reducing complexity make the recycling and, in some cases, composting process easier.”
Advantages of flexible packaging
Benefits for flexible packaging include, according to Renzi, reduced packaging weight and increased shelf life.
“With consumers being more environmentally aware, flexible packaging allows for light-weighting, which plays a critical role in reducing the carbon footprint by decreasing raw material consumption or the number of truckloads of product that need to be delivered, resulting in reduced fuel costs and lower emissions,” he said.
“Utilizing SunBar barrier coatings allows transparent windows while still providing high oxygen and UV barrier resistance,” said Rick Stokes, director - coatings group at Sun Chemical. “These barrier coatings extend the shelf life of a product in a flexible pouch while also keep migration to a minimum. Barrier coatings provide a smooth, homogenous, pinhole-free layer that can be easily overprinted with inks and laminated to a variety of secondary films.
“They are also cost-effective and can improve the recyclability and biodegradable of the package,” he continued. “Coatings and inks can make packaging change colors when meat or vegetables pass their expiration date. These technologies help retailers and consumers know when food may no longer be fresh.”
hubergroup’s Frischmann cited lightweighting, user convenience, shelf visibility, shelf life extension and flexibility in packaging design as advantages.
“The trend towards smaller households and consumer flexibility can also be served by smaller pack sizes or ‘ready meals’ or ‘boil in the bag meals,’” Frischmann said.
Flexible form factor allows for easy and more cost-effective packaging and shipping, Hill said.
“Package weight is a key factor in transportation costs. Since flexible packaging is lightweight and minimizes space, it’s more affordable to ship domestically and internationally,” he added. “Another benefit is the extended shelf life. By utilizing the right barrier materials, products provide resistance to light, contaminants, moisture and oxygen, keeping products fresh for a longer period of time.”
One of the best advantages of flexible packaging is the efficiency gained during shipping, according to Kubasiak.
“Flexible packaging is both lighter and more compact than glass, metal and rigid plastic containers, which leads to space and energy savings,” he said.
Nishikawa cited lower weight compared to glass or rigid containers.
“Low cost of flexible packaging is another reason why packaging converters and brands find this type of packaging attractive, as less material and energy are used in forming flex packs than rigids,”
he said.
As Klemesrud pointed out, it’s all about convenience.
“Consumer studies show that convenience is critical to people with increasingly busy lifestyles,” she said. “In the past, people would prepare dinners using fresh foods and ingredients. More and more people purchase pre-cooked or pre-prepared food for simplicity and speed. Flexible packaging is perfect for brands that offer these convenient options.
“Additionally, there are more and more single households who use smaller portion sizes, and many of these ‘right-sized’ meals use a variety of flexible packaging structures,” Klemesrud continued. “And, for these households, maintaining the freshness of larger items is important; therefore, re-sealable packages are also increasingly popular.
From a safety perspective, flexible packaging pouches or shrink sleeves can be designed with transparent (window) areas that allow consumers to see what’s inside, she noted.
“Food waste is a growing global concern. Brand owners are pressured to find ways to keep food fresh longer,” Klemesrud said. “Flexible packaging provides options that can retain food freshness over longer periods of time. With longer and longer shelf life, food can be distributed further afield and remain fresh.
Aesthetics also play a vital role.
“More than 70% of purchase decisions are made at the shelf and brand owners have limited time to make their impact,” Klemesrud said. “If you consider shrink sleeve packaging, brand owners have a much larger area to fill with graphics and branding – 360° graphics are a reality and continue to grow in popularity. Additionally, providing more surface area for nutritional and safety information required in certain regions of the world.”
Low migration inks
The low migration ink market was valued at $300 million in 2018, according to Global Market Insights.
“Low migration inks are already established for many years in many regions of the world as a standard,” Frischmann said. “At hubergroup the Gecko brand represents this maximum level of product safety for solvent-based inks for the flexible packaging market. “
hubergroup introduced its Gecko brand for food packaging in India in 2014 with great success, according to Frischmann.
“Now low migration inks have become globally available following the same quality standards,” he said.
hubergroup also developed the MGA Corona, the first low migration ink series in offset packaging with certified migration controls.
“Wikoff Color has developed a variety of low migration energy-cure ink systems over the last several years in response to this growing demand,” Kubasiak said. “Traditionally, UV- and LED-cure were the technologies that converters turned to when looking for inks suitable for food packaging, but we are now seeing a lot of promise in EB flexo. Through our licensing agreement with Technosolutions, Wikoff Color has the capability to manufacture Gelflex inks, which are 100% cured at the end of the press with no migration.”
“Apart from the European market where low migration inks are already required for compliance, there is a growing demand for these inks in markets like India or China,” Nishikawa added. “This demand is being driven by new, tighter regulations that address increased safety in food packaging in several countries. To meet with increased regulatory requirements, Toyo is continually re-formulating our inks so that they comply with the latest regulation.”
Flexible packaging growth
Flexible packaging has been a strong growth area in printing in recent years.
“Consumer behavior, safety, hygiene, sustainability and pack aesthetics have played a large part in the growth of flexible packaging and we see this trend continuing,” Klemesrud said.
The global flexible packaging market is anticipated to reach $335 billion by 2026 according to research published by Polaris Market Research. The increasing disposable incomes and growing demand for fast-moving consumer goods drive the growth of the flexible packaging market, according to Polaris Market Research.
Growing urbanization has resulted in urban citizens spending most of their time at work and everyday commute, which has increased the demand for convenient packaging for on-the-go consumption, thereby supporting the flexible packaging market growth, the research showed.
“Since it tends to be a food-related packaging choice, and convenience is a key trend consumers are looking for, it’s logical to see this segment growing,” Hill said.
“Among all the sectors in the printing industry, flexible packaging is the one with a higher growth rate,” Nishikawa added. “Increased convenience and portability match perfectly with the needs of on-the-go modern consumers. The demand for flexible packaging is growing faster in developing countries, with the Southeast Asia region showing the most promising opportunities in the near future.”
According to the FPA, the flexible packaging industry is valued at 19% of the total packaging industry, with an average CAGR of around 2% since 2008.
“Based on the data presented by the FPA, we predict flexible packaging to continue to grow at a steady rate,” Kubasiak said. “The functional use of pouches instead of glass, cans or rigid plastics for food packaging to prolong freshness is key to the upward trend.”
“There are three key trends driving the growth in flexible packaging – sustainability initiatives, convenience and smart packaging,” Renzi added. “From a sustainability standpoint, these market trends include key changes in the package itself, such as better barrier protection, light-weighting and recycling/compostability. Convenience packaging has been on the rise since younger single households don’t cook huge meals.”
Outlook
By all indications – from market reports to responses from industry professionals – the outlook for flexible packaging over the next few years is positive.
“Changes by new sustainability topics will have a tremendous impact on flexible packaging but this is more seen as an opportunity for new solutions,” Frischmann said. “Flexible packaging has many important positive aspects like hygienic food packaging and extended food shelf-life. These positives need to be combined with sustainable concepts and here we are on a good track.”
“We expect to see the growth of recyclable films, EB flexo, and new methods to recycle plastics as the main contributors to the success of flexible packaging in the future,” Kubasiak said.
Increased awareness of the health risks of chemicals, especially food contact chemicals, will continue to drive regulatory change in many countries, according to Nishikawa.
“Packaging is ultimately affected by the substances and materials that are allowed or restricted in its manufacturing,” he said. “In the next few years, we expect to see the flexible packaging industry transition to a new packaging economy that addresses the need for greater sustainability, recyclability, biodegradability in packaging materials.
“Governments and their regulating bodies will need to decide which is the best, most feasible way to achieve their sustainability commitments – whether to promote a circular economy where plastic can be reused or recycled, or whether to opt for an alternative material to replace plastic, such as paper, aluminum or glass. Regardless of which packaging economy is chosen, the ink industry will need to be ready to deal with the impact of a transition.”
Flint Group reported continued shifts from gravure to flexography and continued and growing adoption of expanded gamut printing (EGP) as reasons for positive growth, along with a consistent and growing interest in water-based inks for flexible packaging applications.
“Of course, the sustainability topic will continue with a focus on laminate simplification, down-gauging to thinner films, and a strong focus on design for circularity,” Klemesrud said. “Along with this will be the continual need for increased efficiency to ensure cost reduction – less waste used and improved productivity.
“Aesthetics and functionality will remain a key topic as well – improved print fidelity and high color strength along with easy open and re-sealable packaging, intelligent packaging, and excellent resistance properties to protect package design and ensure clear content information of the products within the package are important for both the brand owner and consumers,” she concluded.
“In addition to the functional requirements that are required for packaging, such as coatings that provide the durability needed to help the package survive filling and shipping, standout has always been an important quality that brand owners demand from their packaging,” Stokes said.
According to the Sustainable Packaging Coalition, sustainable packaging:
• Is beneficial, safe, and healthy for individuals and communities throughout its life cycle.
• Meets market criteria for both performance and cost.
• Is sourced, manufactured, transported and recycled using renewable energy.
• Optimizes the use of renewable or recycled source materials.
• Is manufactured using clean production technologies and best practices.
• Is made from materials that are healthy throughout the life cycle.
• Is physically designed to optimize materials and energy.
• Is effectively recovered and utilized in biological and/or industrial closed-loop cycles.
“Sustainability has become the keynote in developing the creation of new products and concepts inside flexible packaging,” said Lutz Frischmann, global product director flexible packaging at hubergroup. “This is also fostered by many national and international political initiatives.
“We expect that new concepts for the flexible packaging segment will evolve along the entire value chain,” he continued. “Examples are the move towards monomaterial structures or the use of paper in completely new applications. Sustainability has many facets and many of these deal with cyclic economy solutions and end-of-life considerations.”
Sustainability takes on many forms, according to Mark Hill, senior VP of R&D at INX International Ink Co.
“From reducing migration potential, using bio-renewable content in inks, and applying technologies that help reduce food waste and enable packaging material recycling, we are looking at a very diverse set of tools to help packaging be more sustainable,” he said.
According to Joe Kubasiak, market manager – flexible packaging for Wikoff Color, Wikoff Color is working with brand owners and converters to develop inks that perform well on recyclable films and help eliminate the need for lamination, reducing the overall film structure. These inks include solvent-based, water-based and EB flexo inks, he said.
Toyo Ink is seeing brand owners and global converters make a stronger commitment to achieving certain sustainability targets in line with the Sustainability Development Goals set by the United Nations, per Yoshirou Nishikawa, GM, Business Strategy Department.
“In the flexible packaging field, the most popular trend is related to the reduction of plastic films and its suitability for recycling or biodegradation/compost,” he said. “Activities focused on the circularity of such materials, like enhancing plastic recyclability, reducing layers within flexible packaging structures and searching for substitute materials to current plastics, are the main drivers that are nowadays moving development activities aiming for increased sustainability.
“The necessity to reduce the amount of plastic being used in packaging has cast a negative light on plastic packaging,” Nishikawa continued. “However, the ongoing coronavirus pandemic has made a case for plastic packaging, as consumer demand for packaged foods has skyrocketed. Single-use plastic packaging has proven effective in protecting food from contamination and extending its shelf life.”
Recyclability and/or compostability are the focus of many flexible packaging conversations in North America, per Deanna Klemesrud, global marketing director-brand & promo, packaging inks & resins at Flint Group.
“We believe that both flexible plastic packaging and paper-based packaging have an important role to play in protecting food, reducing waste during transportation, storage and consumption, while helping to increase the health and well-being of people all over the globe,” she noted. “That said, while the conversation around the use of plastic as compromising to the environment is a common discussion, food preservation, the safety of drinking water, secure packaging of pharmaceuticals, and the ability to transport consumer goods around the world are equally important arguments and have a long-standing value that brand owners and the general public understand.
“Additionally, flexibles are more cost and resource-efficient to produce versus many other types of rigid packaging, therefore, less pollution is emitted during production and shipping due to a lighter, space optimizing packaging solution,” Klemesrud concluded.
Consumer packaged goods companies are looking for support in their sustainability, according to Anthony Renzi, VP, product management of packaging inks, North American Inks at Sun Chemical.
Sun Chemical has provided solutions that meet their goals of resource reduction, a smaller number of packaging layers, along with decreased package size: SunVisto AquaGreen, a bio-renewable ink offering a natural, cleaner, greener option for food packaging and SunSpecto SolvaGreen, a compostable, solvent-based ink for surface printing on biodegradable films, he noted.
“Through the use of SunBar barrier coating, SunSys protective coatings, and SunFuse sealants and primers, we can allow for flexible package designs with improved recyclability,” Renzi said. “Anytime a flexible package uses more than one type of substrate – for example, polyethylene film laminated to polypropylene film – that structure becomes more difficult to recycle. By using coatings to replace these layers, functional mono-material packages can be created, making recycling a reality for flexible packaging. We can also add functionality to bio-based films and even paper to enable the design of biodegradable packages.”
To that end, hubergroup – a CEFLEX member – has a wide range of certified bio-compostable inks and many of its products are C2C certified, Frischmann said.
“From reducing migration potential, using bio-renewable content in inks, and applying technologies that help reduce food waste and enable packaging material recycling, we are looking at a very diverse set of tools to help packaging be more sustainable,” INX’s Hill said.
Wikoff Color’s initiatives include new product formulations across multiple chemistries, developing industry partnerships with like-minded companies and reducing its environmental impact at its manufacturing operations, according to John Pettus, director – corporate sales and marketing.
Toyo Ink joined several workgroups – including CEFLEX in Europe and CLOMA in Japan – to “ensure we stay up-to-date of the rapidly evolving flexible packaging market,” Nishikawa said.
“We have launched a broad lineup of inks, coatings and adhesives made with a ‘biomass’ or plant-based resin,” he continued. “We are developing de-inking systems that allow inks to be removed from plastic packaging films before they are to be recycled. We are also developing barrier systems that would allow or help to reduce the layers in flexible packaging structures while maintaining the same level of packaged content protection.”
Flint Group is also a CEFLEX member and an active member of the Flexible Packaging Association.
“Being a member of CEFLEX means that we focus on existing solutions for the recycling of plastic packaging materials and we work collaboratively to develop new markets for materials which today have no viable recycling solution,” Klemesrud said.
“Flint Group is involved with and has access to many sustainability initiatives and collaborations, such as the Materials Recovery for the Future Collaborative, which has a simple vision that flexible packaging is recycled curbside and the recovery community captures value from that,” Klemesrud said.
According to Renzi, Sun Chemical is increasing the number of raw materials sourced from bio-renewable sources.
“One example is using soya bean oil that comes from already existing soya bean crops in fields that have been certified as not replacing other pre-existing natural biodiversity,” he said. “Plastic packaging can be difficult to recycle because it is made up of multiple materials. Eliminating packaging layers and reducing complexity make the recycling and, in some cases, composting process easier.”
Advantages of flexible packaging
Benefits for flexible packaging include, according to Renzi, reduced packaging weight and increased shelf life.
“With consumers being more environmentally aware, flexible packaging allows for light-weighting, which plays a critical role in reducing the carbon footprint by decreasing raw material consumption or the number of truckloads of product that need to be delivered, resulting in reduced fuel costs and lower emissions,” he said.
“Utilizing SunBar barrier coatings allows transparent windows while still providing high oxygen and UV barrier resistance,” said Rick Stokes, director - coatings group at Sun Chemical. “These barrier coatings extend the shelf life of a product in a flexible pouch while also keep migration to a minimum. Barrier coatings provide a smooth, homogenous, pinhole-free layer that can be easily overprinted with inks and laminated to a variety of secondary films.
“They are also cost-effective and can improve the recyclability and biodegradable of the package,” he continued. “Coatings and inks can make packaging change colors when meat or vegetables pass their expiration date. These technologies help retailers and consumers know when food may no longer be fresh.”
hubergroup’s Frischmann cited lightweighting, user convenience, shelf visibility, shelf life extension and flexibility in packaging design as advantages.
“The trend towards smaller households and consumer flexibility can also be served by smaller pack sizes or ‘ready meals’ or ‘boil in the bag meals,’” Frischmann said.
Flexible form factor allows for easy and more cost-effective packaging and shipping, Hill said.
“Package weight is a key factor in transportation costs. Since flexible packaging is lightweight and minimizes space, it’s more affordable to ship domestically and internationally,” he added. “Another benefit is the extended shelf life. By utilizing the right barrier materials, products provide resistance to light, contaminants, moisture and oxygen, keeping products fresh for a longer period of time.”
One of the best advantages of flexible packaging is the efficiency gained during shipping, according to Kubasiak.
“Flexible packaging is both lighter and more compact than glass, metal and rigid plastic containers, which leads to space and energy savings,” he said.
Nishikawa cited lower weight compared to glass or rigid containers.
“Low cost of flexible packaging is another reason why packaging converters and brands find this type of packaging attractive, as less material and energy are used in forming flex packs than rigids,”
he said.
As Klemesrud pointed out, it’s all about convenience.
“Consumer studies show that convenience is critical to people with increasingly busy lifestyles,” she said. “In the past, people would prepare dinners using fresh foods and ingredients. More and more people purchase pre-cooked or pre-prepared food for simplicity and speed. Flexible packaging is perfect for brands that offer these convenient options.
“Additionally, there are more and more single households who use smaller portion sizes, and many of these ‘right-sized’ meals use a variety of flexible packaging structures,” Klemesrud continued. “And, for these households, maintaining the freshness of larger items is important; therefore, re-sealable packages are also increasingly popular.
From a safety perspective, flexible packaging pouches or shrink sleeves can be designed with transparent (window) areas that allow consumers to see what’s inside, she noted.
“Food waste is a growing global concern. Brand owners are pressured to find ways to keep food fresh longer,” Klemesrud said. “Flexible packaging provides options that can retain food freshness over longer periods of time. With longer and longer shelf life, food can be distributed further afield and remain fresh.
Aesthetics also play a vital role.
“More than 70% of purchase decisions are made at the shelf and brand owners have limited time to make their impact,” Klemesrud said. “If you consider shrink sleeve packaging, brand owners have a much larger area to fill with graphics and branding – 360° graphics are a reality and continue to grow in popularity. Additionally, providing more surface area for nutritional and safety information required in certain regions of the world.”
Low migration inks
The low migration ink market was valued at $300 million in 2018, according to Global Market Insights.
“Low migration inks are already established for many years in many regions of the world as a standard,” Frischmann said. “At hubergroup the Gecko brand represents this maximum level of product safety for solvent-based inks for the flexible packaging market. “
hubergroup introduced its Gecko brand for food packaging in India in 2014 with great success, according to Frischmann.
“Now low migration inks have become globally available following the same quality standards,” he said.
hubergroup also developed the MGA Corona, the first low migration ink series in offset packaging with certified migration controls.
“Wikoff Color has developed a variety of low migration energy-cure ink systems over the last several years in response to this growing demand,” Kubasiak said. “Traditionally, UV- and LED-cure were the technologies that converters turned to when looking for inks suitable for food packaging, but we are now seeing a lot of promise in EB flexo. Through our licensing agreement with Technosolutions, Wikoff Color has the capability to manufacture Gelflex inks, which are 100% cured at the end of the press with no migration.”
“Apart from the European market where low migration inks are already required for compliance, there is a growing demand for these inks in markets like India or China,” Nishikawa added. “This demand is being driven by new, tighter regulations that address increased safety in food packaging in several countries. To meet with increased regulatory requirements, Toyo is continually re-formulating our inks so that they comply with the latest regulation.”
Flexible packaging growth
Flexible packaging has been a strong growth area in printing in recent years.
“Consumer behavior, safety, hygiene, sustainability and pack aesthetics have played a large part in the growth of flexible packaging and we see this trend continuing,” Klemesrud said.
The global flexible packaging market is anticipated to reach $335 billion by 2026 according to research published by Polaris Market Research. The increasing disposable incomes and growing demand for fast-moving consumer goods drive the growth of the flexible packaging market, according to Polaris Market Research.
Growing urbanization has resulted in urban citizens spending most of their time at work and everyday commute, which has increased the demand for convenient packaging for on-the-go consumption, thereby supporting the flexible packaging market growth, the research showed.
“Since it tends to be a food-related packaging choice, and convenience is a key trend consumers are looking for, it’s logical to see this segment growing,” Hill said.
“Among all the sectors in the printing industry, flexible packaging is the one with a higher growth rate,” Nishikawa added. “Increased convenience and portability match perfectly with the needs of on-the-go modern consumers. The demand for flexible packaging is growing faster in developing countries, with the Southeast Asia region showing the most promising opportunities in the near future.”
According to the FPA, the flexible packaging industry is valued at 19% of the total packaging industry, with an average CAGR of around 2% since 2008.
“Based on the data presented by the FPA, we predict flexible packaging to continue to grow at a steady rate,” Kubasiak said. “The functional use of pouches instead of glass, cans or rigid plastics for food packaging to prolong freshness is key to the upward trend.”
“There are three key trends driving the growth in flexible packaging – sustainability initiatives, convenience and smart packaging,” Renzi added. “From a sustainability standpoint, these market trends include key changes in the package itself, such as better barrier protection, light-weighting and recycling/compostability. Convenience packaging has been on the rise since younger single households don’t cook huge meals.”
Outlook
By all indications – from market reports to responses from industry professionals – the outlook for flexible packaging over the next few years is positive.
“Changes by new sustainability topics will have a tremendous impact on flexible packaging but this is more seen as an opportunity for new solutions,” Frischmann said. “Flexible packaging has many important positive aspects like hygienic food packaging and extended food shelf-life. These positives need to be combined with sustainable concepts and here we are on a good track.”
“We expect to see the growth of recyclable films, EB flexo, and new methods to recycle plastics as the main contributors to the success of flexible packaging in the future,” Kubasiak said.
Increased awareness of the health risks of chemicals, especially food contact chemicals, will continue to drive regulatory change in many countries, according to Nishikawa.
“Packaging is ultimately affected by the substances and materials that are allowed or restricted in its manufacturing,” he said. “In the next few years, we expect to see the flexible packaging industry transition to a new packaging economy that addresses the need for greater sustainability, recyclability, biodegradability in packaging materials.
“Governments and their regulating bodies will need to decide which is the best, most feasible way to achieve their sustainability commitments – whether to promote a circular economy where plastic can be reused or recycled, or whether to opt for an alternative material to replace plastic, such as paper, aluminum or glass. Regardless of which packaging economy is chosen, the ink industry will need to be ready to deal with the impact of a transition.”
Flint Group reported continued shifts from gravure to flexography and continued and growing adoption of expanded gamut printing (EGP) as reasons for positive growth, along with a consistent and growing interest in water-based inks for flexible packaging applications.
“Of course, the sustainability topic will continue with a focus on laminate simplification, down-gauging to thinner films, and a strong focus on design for circularity,” Klemesrud said. “Along with this will be the continual need for increased efficiency to ensure cost reduction – less waste used and improved productivity.
“Aesthetics and functionality will remain a key topic as well – improved print fidelity and high color strength along with easy open and re-sealable packaging, intelligent packaging, and excellent resistance properties to protect package design and ensure clear content information of the products within the package are important for both the brand owner and consumers,” she concluded.
“In addition to the functional requirements that are required for packaging, such as coatings that provide the durability needed to help the package survive filling and shipping, standout has always been an important quality that brand owners demand from their packaging,” Stokes said.
