Digital technology can reduce waste, carbon footprint: Michael Matthews of Domino

The traditional 'forecast demand' printing model has long been the go-to for cost-effective flexographic printing, particularly for high-volume SKUs. However, changing consumer behaviour has led to an increase in shorter, more variable print runs, including seasonal and promotional releases. This shift has created challenges for converters, who must manage unpredictable packaging volumes while minimising waste.  

Michael Matthews, product manager at Domino, highlights the benefits of digital printing in this context: "Digital printing allows converters to adopt a 'print-on-demand' model, which is far more sustainable. By eliminating minimum order quantities and reducing overruns, converters can save energy, cut down on ink and substrate use, and lower the need for transporting and recycling excess stock."  

Integrating digital printing into existing flexo lines, either through hybrid systems or standalone digital roll-to-roll presses, enables converters to handle shorter runs more efficiently. This not only reduces waste but also aligns with the sustainability objectives of brand customers.  

Reducing waste with digital innovation  
Print waste extends beyond overstock and obsolescence. Digital printing technology offers multiple opportunities for converters to minimise their environmental impact, even when used alongside traditional flexo processes.  

One key advantage is late-stage customisation, where variable data or promotional content is added to pre-printed stock just before packaging. "This approach significantly reduces the risk of obsolescence," explains Matthews. "By printing in bulk and adding variable details later, converters can cut down on waste and improve efficiency."  

Another major benefit of digital printing is its plate-free nature. Traditional flexo printing relies on plates, which contribute to pre-press waste, including ink, media, and chemicals used during setup and proofing. "Eliminating plates not only reduces material waste but also minimises water consumption and chemical use during plate cleaning," says Matthews.  

Digital inkjet technology also ensures precise ink placement, meaning only the necessary amount of ink is used for each design. This eliminates residual ink waste commonly associated with analogue plates. Additionally, modern digital presses feature high-efficiency drying technology, which uses fewer pinning and curing lamps compared to flexo processes, further reducing energy consumption.  

Optimising workflows for greater efficiency  
Workflow optimisation is another area where digital printing shines. Automated pre-press processes, enabled by digital front-end software, streamline operations and reduce waste from hard proofs. Real-time inline RIP capabilities onboard digital presses maximise press utilisation, cutting down on idle time and lowering energy use.  

"Automation is key to improving efficiency and reducing waste," says Matthews. "By automating maintenance tasks, such as printhead cleaning and ink circulation, digital presses ensure reliable performance while minimising consumables use."  

Hardware automation also plays a crucial role in sustainability. Combining pre-press, printing, and finishing into a single, automated hybrid process reduces power consumption and material waste. "Continuous processes eliminate overrun at each stage, benefiting both the environment and the converter's bottom line," adds Matthews.  

A sustainable future for printing  
The adoption of digital printing technology is no longer a luxury—it’s a necessity for converters looking to meet the growing demand for sustainable practices. By enabling print-on-demand models, reducing setup waste, and optimising workflows, digital printing offers a clear path to reducing the environmental impact of packaging and label production.  

"Digital printing is not just about innovation; it’s about responsibility," says Matthews. "Converters who embrace this technology can significantly reduce waste and carbon emissions while improving efficiency and profitability."  

With over 60% of converters planning to invest in digital solutions within the next two years, the industry is poised for a sustainable transformation. For those looking to stay competitive and meet the sustainability expectations of their customers, the time to act is now.