Sydney-based reprographics company Kirk Group has partnered with XSYS and Hybrid Software to deliver new flexo plate innovation to Melbourne’s RollsPack.

When long-term customer RollsPack challenged Kirk Group to find a more cost-effective and sustainable way to print high value flexible packaging, it carefully considered the combination of plate and specialised screening technologies necessary to achieve the desired outcome.

It leveraged the versatility of the ThermoFlexX imaging system and Catena+ automated processing line to implement these solutions:

• ThermoFlexX Woodpecker Nano – the finest surface micro pattern available for LAMS plates, suitable for platemakers and printers who need high frequency surface screens to increase quality and efficiency while reducing costs.
• nyloflex NEF D – a high durometer printing plate for flexible packaging developed by XSYS for the efficient creation of flat-top dots and reproduction of surface screenings with UV LED exposure.
• Velvet Screening – a new screening type from Hybrid Software created to meet flexo requirements. As the successor to hybrid XM screening, it uses an advanced dot removal algorithm to reduce harsh edges, leading to smoother and higher-quality prints.

In this scenario, advanced screening technology and dedicated plate surface structures simplified the challenging task of controlling the dots and the ink behaviour on press. ThermoFlexX Woodpecker and Velvet Screening proved their individual strengths, to deliver a successful outcome for RollsPack. Both software solutions are open without any extra steps needed, meaning they can be implemented into any workflow.

The nyloflex plates with Velvet Screening and Woodpecker micro surface patterns provided by Kirk Group ticked all the boxes for RollsPack, meeting its demands for quality, sustainability and costs. A family-owned company founded in 1985, it specialises in flexible packaging production, including e-commerce, food, retail, and tamper-evident solutions.

“This solution offers a lot of potential. Set up times have been reduced significantly due to precise colour profiles, and longevity on press is comparable to other major players on the market,” RollsPack print manager Thanh Huynh said.

“There’s also a marked difference in the ink laydown on surface print; it’s one of the best I’ve seen in flexibles. Even when printing colours on a white ink base layer, where we typically experience a drop in density – the results with Woodpecker are impressive. In addition, Velvet Screening holds the dots really well, ensuring that there are minimum hard edges.”  

Huynh added that RollsPack is also firmly committed to sustainability, developing environmentally friendly products for its customers.

“We are dedicated to elevating the market by supplying innovations that benefit our customers and meet their sustainability goals. We successfully achieved the same high-quality print with water-based inks as with solvent-based inks. This drives a constant need to explore new avenues and Kirk Group plays a fundamental role in this endeavour. Together we are pushing the boundaries of brilliant flexo,” Huynh said.

Kirk Group chief operating officer Robert Selvaggio said the investment in Catena+ has been a great success story for the company.

“We were among the first in the market to realise the potential of this high performance, one-touch technology which tripled our capacity and elevated plate quality. We’re now in the process of installing a Catena+ line in Brisbane and a third one is already planned for Sydney,” he said.

According to XSYS Asia Pacific vice-president Roy Schoettle, Kirk Group has been reaping the benefits of Catena+ for a few years, and has witnessed the innovative solutions it enables, such as this special project for RollsPack Group.

“We are delighted that this partnership has been so successful and look forward to taking the next steps with the team, as they equip all their manufacturing sites with full Catena+ lines.

“Flexo is still the largest printing technology for packaging, both in terms of volume and value, but we must maximise the market opportunities and the potential of each technology on offer. This is why collaboration is crucial for the future of our industry and for our customers.”

Hybrid Software Australasia sales manager Brenton King expanded on the flexibility of Velvet Screening.

“The beauty of Velvet is that the software doesn’t require any proprietary information or special equipment, it just slots into the existing setup. Used at any resolution or ruling, it can be imaged onto the plate of your choice on any CTP device and then processed through your existing exposure frame,” he said.

“In this collaboration, Kirk Group simply applied Velvet Screening and then added the Woodpecker surface patterns during imaging. It’s a very clever combination.”