Belgian packaging producer Vitrapack has invested in a new CI flexo press, a Bobst Expert CI, looking to boost its capacity and enhance flexibility and sustainability. It said the press will enable it to handle shorter lead times, adapt to a wider range of job requirements, and maintain consistent print quality, while keeping waste levels low.
The €32 million (£28.2 million) turnover, 100 employee business has a long history in printing, with flexo dating back to 1952 and rotogravure since 1965. It supplies major global brands in the food sector, as well as part of the non-food market, serving customers in Belgium, the Netherlands, and France.
It has partnered with Bobst for nearly 20 years, gaining advantages during that time, it said, from many automation and waste saving features afforded by the company’s technologies. Bobst’s strong technical support has also proven invaluable through the years. One of the technologies that has made a lasting impact is Bobst’s smartGPS system for registration and impression settings, first installed at Vitrapack in 2009, and followed up in 2017 with investment in two smartGPS-equipped 10-colour, 1050mm web width 20SIX CI flexo presses, complemented by a CL850 laminator.
This positive experience with smartGPS technology is cited as one of the core reasons why Vitrapack again chose Bobst for its latest flexo investment – a 10-colour Expert CI, which the manufacturer says is designed for process consistency and exceptional productivity. Its web width of 1300mm and a higher print speed means output has increased significantly, said Vitrapack.
“smartGPS technology truly sets Bobst apart from the competition,” said co-owner and delegated administrator Jan Laeremans. “It delivers the high quality our customers demand with much less unwanted downtime in production. Our first Bobst press in 2009 and the two 20SIX presses have performed exceptionally well, so we had no hesitation in choosing another Bobst press, but we needed a wider specification. The new Expert CI has a capacity that is around 25% higher.”
An important aspect of the relationship between the two companies has been the work of Co-ëfficiënt, one of Bobst’s solution partners, which has provided data-driven consulting services to help optimise production and reduce waste. In this way, Vitrapack has been able to take important steps to address macro trends such as sustainability and customisation, while at the same time optimising print quality.
Together, Vitrapack, Rask (the prepress and repro sister company of Vitrapack) and Co-ëfficiënt have laid the foundation for the “standardisation of flexo printing”, it is claimed.
“Thanks to Co-ëfficiënt’s expertise and support, we achieved a very high improvement in OEE and a substantial reduction in the press time and waste required for ink and colour adjustments. As a result, we also use much less ink and generate significantly lower volumes of residual ink,” said Mr Laeremans. “Their expertise is crucial in refining our colour matching processes to ensure precision and consistency with minimal waste.”
The new Expert CI press is running alongside the two older Bobst presses at Vitrapack, with further increased speed and enhanced print quality. The press is equipped with Full Surface Matrix intercolour drying, which Bobst says prevents substrate stretching and significantly boosts productivity.
In addition, the AV 3.0 smartGPS system on the new Expert press shortens setup time and reduces material waste, streamlining operations and minimising environmental impact. Vitrapack said this investment has significantly increased productivity, allowing it to continue growing while delivering reliable, high-quality results, and that the collaboration with Co-ëfficiënt has further amplified these benefits. By applying the suggested data-driven process optimisation strategies, Vitrapack has achieved substantial cost reductions and environmental improvements, including a notable decrease in CO₂ emissions.
The packaging producer next plans to replace one of its older flexo presses with a new Bobst machine, reflecting both the operational advantages demonstrated by the recently installed Expert CI press, and Vitrapack’s continued faith in the partnership with Bobst.
