Köstlin Prepress Services has invested in Flexcel NX flexo plate technology from Miraclon, enhancing its production capacity, efficiency, and sustainability. The company, based in southwest Germany, supplies flexographic printing plates to packaging printers specialising in flexible packaging.
According to managing director of Köstlin, Marc Talmon Gros, the surge in demand was driven by new product launches, updated designs from brands, and a growing customer base with diverse SKU portfolios. “Our central repro service model, supported by high-quality Flexcel NX plates, continues to resonate with customers,” he said.
Köstlin has used Flexcel NX technology for over 12 years, producing both solvent-based Flexcel NXH and water-wash Flexcel NX Ultra plates. These now make up more than 75% of the company’s plate production. Mr Gros said that in 2024, production of Flexcel NX plates rose by over 10%, while demand for plates from other suppliers remained flat. “Flexcel NX remains the gold standard for high-demand flexible packaging print jobs where efficiency and quality must go hand-in-hand,” Mr Gros added.
In November 2024, Köstlin replaced its older NX Ultra 35 system with a larger Flexcel NX Ultra 42 Processing System, enabling plate production up to 1067 x 1524mm. “With 50% more surface area, we’re using plate material much more efficiently. It’s especially helpful for large-format jobs like garden soil bags,” said Mr Gros. The upgrade allows the team to produce up to 16 plates per shift while reducing solvent use, and the company aims to grow its Flexcel NX Ultra plate share from 20% to over 30% of its total Flexcel output in 2025.
The company also reports that nearly 70% of its plates now use PureFlexo Printing, a Miraclon innovation that optimises ink transfer and reduces dot gain variability.
Additionally, Köstlin has installed a Shine LED Lamp Kit to replace its UV fluorescent exposure unit, a move that it says has reduced energy consumption, improved exposure consistency, and saved production time. “We’re saving around ten minutes per plate,” stated Mr Gros. “Over time, that adds up to major gains.”
