Why System Integration is the Next Step in Printing Operations

By Erwin Busselot, Director Business Innovation & Solutions, Ricoh Graphic Communications, Ricoh Europe Versatile digital inkjet print production is now easily accessible as we saw at drupa 2024. High quality, colour rich and luxurious results can be achieved quickly, efficiently, and cost effectively.

While productivity remains the number one priority in 2025 for 82.7% of respondents in the 2024 PRINTING United Alliance State of the Industry Survey (SOI), strengthening core services by focusing on business fundamentals is next. In fact, 65.4% of American commercial printers surveyed planned to “pay closer attention to everything that affects profit” from maintaining accurate budgeted hourly cost rates to capturing more positive sales.

In highlighting the buoyant outlook for digital inkjet printing Smither’s global The Future of Inkjet Printing to 2029 report identified a number of ways the technology can positively impact business fundamentals.

These include:

• Enhanced connectivity through web to print portals for smooth job ordering.
• Seamless integration with conversion processes compared to alternative systems.
• Optimised workflows for inkjet that drive cost competitiveness.

It is clear digital inkjet printing’s ability to easily integrate with hardware and workflow processes has the power to drive growth and profitable success.We will be exploring how to harness that power at next month’s Hunkeler Innovationdays 2025.

The event’s theme is ‘Connect’ and we will demonstrate how commercial printers can create a more joined up approach. We will:

• Show what can be achieved when they link every step of the end to end process to streamline their operations. We will share how efficient and profitable order to dispatch production begins with software solutions including RICOH TotalFlow BatchBuilder, that simplifies and automates many steps in short run digital production, and RICOH ProcessDirector, that captures, transforms, and manages production information and print processes with precise tracking.
• Expand on how up to the minute data can aid understanding about operational efficiency. RICOH Predictive Insight uses Artificial Intelligence and Machine Learning capabilities to provide data driven insights into device utilisation and operator productivity.
• Discuss how a highly connected approach can be further enhanced with new automation protocol Print Line and Finishing Interface (PLF-I). This open source interface provides a step change in communication between web fed technology and pre- and post-processing equipment.

The integration of connected systems also fosters creative co-innovation. For instance, Graham Lycett, CEO of Green Gift Cards, partnered with Ricoh to disrupt the gift and loyalty card market. By using Ricoh’s technologies, his company now provides fully recyclable cards with an associated carbon impact of just 4.28gCO2e per card, a dramatic reduction compared to the 46.97gCO2e impact of non-recyclable PVC cards.

Discover how a connected approach can transform your operations and power growth and profitability at Hunkeler Innovationdays 2025, taking place from February 24 to 27 at Messe Lucerne. Register here to visit Ricoh in Hall 2, Stand P6.

https://www.ricoh.com/

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Technical and Economic Challenges Hinder Bioplastics Growth, Says Aquapak

The number of new bioplastic firms that have appeared on the market in recent years is significant. They are promising to revolutionise the industry with their bio-developed polymer platforms, claiming sustainable, renewable resources – the answer to the World’s plastic problem. It all sounds so easy, and ‘bio’ certainly has cache with investors and appears to be gaining traction with the end user. However, in truth, bio plastics are at the beginning of a very long and, often, frustrating journey.

Of course, bioplastic makes perfect sense against the backdrop of increasing concerns about plastic waste and the environmental impact of traditional plastics. In response to these concerns, consumers, businesses, and governments are seeking alternative materials that are more sustainable and have a lower impact on the environment. Bioplastics, which are made from renewable resources such as corn starch, sugarcane, vegetable oils and even seaweed, offer a more sustainable solution to traditional plastics. They are mostly biodegradable and compostable, meaning they can be broken down by natural processes and do not pose a long-term threat to the environment.

However, the bioplastics market is still in its infancy and growth remains stubbornly slow. According to trade body European Bioplastics, global production capacity of bioplastics is set to grow from around 2.23 million tonnes in 2022 to approximately 6.3 million tonnes in 2027.

By far the largest application remains packaging, which consumed 48% of the total market in 2022. Industries such as automotive and transport, agriculture and horticulture, electrics and electronics also use bioplastics, with their relative share in the overall market expected to increase moderately, according to the trade body.

However, the penetration of bioplastics in the overall plastics industry remains minute, at around 0.5%.

John Williams, Chief Technology Officer, Aquapak says: “The bioplastics industry faces several different challenges – none of them mutually exclusive. The first is feedstock – where is it coming from and is there enough of it? There has been criticism for incentivising land use change, as forests are cleared for feedstock production and do we fully understand the potential impact on biodiversity if there is an increase in marine derived feedstock, for example? Interestingly, the impact of an increased use of agricultural and related feedstock, according to independent reports, is minimal but there is still a widespread concern driven by this misunderstanding.

“The second challenge is the waste management system. The sector must contend with the limitations of existing waste management system in order to be circular. Being biodegradable or compostable counts for nothing if collection and processing is insufficient to recover the material. All materials must be reused, recycled or composted to reduce end-of-life impacts and ultimately end soil and marine pollution.“The third is the high manufacturing cost of bioplastics. Bioplastics are more expensive to produce compared to traditional petroleum-based plastics, and this increased cost is often passed on to consumers in the form of higher prices for bioplastics products. This can make it difficult for bioplastics to compete with traditional plastics, especially in price-sensitive industries such as packaging.

“The fourth challenge – and arguably the greatest – is developing solutions that can be commercialised at scale. There’s a reason polypropylene and polyethylene have become so incredibly dominant. When they were developed, there was no awareness of environmental issues as they became dominant because of their functional benefits. The process of refining crude oil is highly efficient and has much greater carbon density per unit of conversion in comparison to the conversion of plant feedstocks through biorefineries.

“For many of the bio offers on the market, despite significant investor support, they are still very much work in progress. Despite claims from some quarters, there is no one biobased material solution. The target end products are complex and new biobased products must meet functional and regulatory requirements. There’s a very real risk that if the industry continues to operate in silos, development will remain painfully slow. Collaboration between industry partners will be key to success.

“We have learnt many lessons from the development of Hydropol which can be shared with the bioplastics sector – indeed, many in the sector are now working with us but the more collaboration between us all the better. However, it takes time and money to develop a new polymer – a lot of time, and many of the challenges faced are out of your control. You must operate in an environment set up for materials like PP and PE and face increasingly complex combinations of materials. Moving the world away from them is not a straightforward task. The only way to

accelerate the transition to a truly circular economy supply chain and improve the environmental situation is to ensure the industry collaborates, combining new materials with existing ones and merge new materials together to maximise functionality and end of life.”

https://www.aquapakpolymers.com/

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Uflex Partners With IIP Delhi To Promote Recycling Awareness And Sustainable Innovations

UFlex, India’s largest multinational flexible packaging and solutions company, has partnered with the Indian Institute of Packaging (IIP) Delhi to promote recycling, circular economy, and sustainability. As part of this collaboration, UFlex has set up the Ideation Zone on the IIP campus, which will serve as an interactive space for students, professionals, and the public to learn about sustainable practices. The Ideation Zone was inaugurated by Mr. Jeevaraj Pillai, Director – Sustainability, UFlex Limited, today, marking the beginning of a series of educational initiatives aimed at advancing a circular economy.

The partnership between UFlex and IIP Delhi aims to bridge the gap between industry and academia, fostering a deeper understanding of the environmental impact of packaging and the role of innovative technologies in driving recycling efforts. The initiative is designed to encourage young minds to explore sustainability challenges and find solutions that can shape a greener future.

The Ideation Zone is made using recycled materials, including multi-layer plastic and aseptic packaging waste, exemplifying the practical application of circular economy principles in sustainable infrastructure, and transforming flexible plastics into a sustainable future. UFlex currently recycles nearly 30,000 MT of plastic waste across Poland, Mexico, and India.

As part of this collaboration, UFlex will engage industry leaders and sustainability experts in workshops and seminars to educate students on recycling, advanced technologies, and the role of R&D in driving sustainability within the packaging industry. These sessions will also emphasize the importance of integrating R&D into academic curricula to prepare future professionals for leadership roles in sustainable packaging innovations.

Mr. Jeevaraj Pillai, Director – Sustainability, UFlex Limited, said, “UFlex’s partnership with IIP Delhi is a significant step in promoting the importance of recycling and sustainability. At UFlex, we recognize that education is a powerful tool in driving change within the packaging industry. Through this collaboration, we aim to inspire future packaging leaders and professionals to adopt the principles of the circular economy and sustainable innovation, helping to create a more sustainable and responsible future.”Dr. Tanweer Alam, Addl. Director and RO, IIP Delhi, stated, “We are excited to partner with UFlex to provide our students with the opportunity to engage with industry experts and learn about the latest in recycling and sustainability. This collaboration aligns with our mission to equip students with the knowledge and tools needed to address the evolving demands of the packaging industry and make a lasting impact.”

The inauguration ceremony was attended by management and leadership team of UFlex, academic team, and sustainability advocates. This event marks the beginning of a long-term commitment by both UFlex and IIP Delhi to foster education, awareness, and innovation in the realm of recycling and sustainability.

www.uflexltd.com

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Brückner, FP Corporation And The Really Big Thing

• Contract conclusion for a new stretching line
• for ultra-thick simultaneously stretched film applications

Japanese FP Corporation (FPCO), a leading manufacturer of food containers, has made a groundbreaking advancement in film technology with the development of the world’s first ultra-high-rigidity biaxially oriented polypropylene (OPP) sheet. This innovation is the result of a collaboration with many different companies and Brückner Maschinenbau with their advanced film stretching technology – and has now culminated in a contract for a new stretching line.

A decade of innovation and collaboration

Over the past 10 years, FPCO has conducted extensive research and testing at Brückner’s technology center and pilot line. This partnership has optimized FP Corporation’s material as well as Brückner’s simultaneous stretching technology LISIM  to produce high-class thick BOPP films for a variety of applications, ranging from food containers to industrial uses such as for the automotive industry.

1. The world’s first ultra-high-rigidity biaxially oriented polypropylene sheet for various applications

Innovative food trays

The new BOPP sheet has pioneered a new category of food tray used for “frozen to microwave” due to superior cold & heat resistance. Namely, meeting the growing demand of frozen foods in the field of food trays, the newly developed BOPP sheet can be used for production of a food tray for frozen food and can also be used for microwave oven cooking as it is.

Industrial applications and home furnishings

• Inherent characteristics as PP: Light weight, chemical resistance, recyclability
• Characteristics from biaxial stretching: Transparency & high gloss, high rigidity & toughness, cold resistance
• Remarkable characteristics: Excellent formability, decorativeness, mono-material

The new OPP sheet with a thickness of 150-300 micron, exhibits excellent mechanical features such as high rigidity and high toughness, when utilized as a sheet for “In-Mold Labeling” (IML), rigidity and toughness of the molded article can be significantly enhanced. Therefore, compared to a conventional IML article, the amount of injection resin can be decreased to 20% by mass in order to attain the same level of mechanical strength of the conventional IML article. Moreover, if the sheet is decorated with printings on injection side, it can be produced a decorated IML article that contributes to paint-free system. This makes the IML article suitable for automobile parts and other industrial parts, and this advancement contributes to reducing environmental impact.

2. A laminated OPP sheet

• Features: High rigidity, impact resistance, toughness, light weight, thermo-formable, and excellent decorative properties due to superior transparency

• Applications: Automotive, home furnishings, solar cells, and as a partial replacement for materials like steel, aluminum, and carbon-fiber-reinforced plastics

The laminated OPP sheet with a thickness of 1-3 mm is suitable as building material, including windows, waist-high walls, carport roofs and solar panels, supporting materials due to its transparency, mechanical strength, and light weight. Furthermore, when arranged as a decorated sheet, it can be used in several fields such as automobile exterior, automobile interior, housing & furnishings. In particular, when used as exterior material for automobile, it also enables paint-free system, and significantly contributes to the reduction of environment impact.

Boris Pasternack, Brückner Maschinenbau’s Head of Sales East Asia says: “After more than 10 years of intensive collaboration with FP Corporation, we are thrilled to see this innovative development move into production – a remarkable example of German-Japanese partnership and pioneering spirit.” Yoshihiro Nishie, FP Corporation’s General Manager of Comprehensive Research Institute and Basic Technical Engineering Dept. adds: “Over a decade since the commencement of foundational research, the world’s first BOPP sheet technology has been successfully developed, thanks to a fruitful partnership with Brückner. This achievement can be attributed to the culmination of both companie’s technical expertise.”

Future Prospects

The new OPP sheets have already received positive recognition across various industrial fields. FP Corporation is currently designing a new plant to start production in late 2027, with plans to market these products through alliances with related industries. This collaboration not only highlights the innovative capabilities of both companies but also sets a new standard for sustainable and high-performance materials in the industry.

https://www.brueckner-maschinenbau.com/en

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