India is moving towards more differentiated packaging in shorter runs: Peter Woods

What were the new services and technological innovations introduced by your Research & Development department in the last two years?

One of the most significant innovations has been the introduction and enhancement of Bobst Connect. This platform connects machines, customers, and processes through a digital ecosystem, creating a fully integrated environment. It offers real-time data monitoring, analytics, and troubleshooting, which results in improved machine uptime and performance. The integration capabilities have been expanded to support remote assistance and predictive maintenance, utilising IoT data to prevent breakdowns.

Meanwhile, the ever-growing trend to find new, alternative sustainable packaging structures has filled our R&D facilities and competence centres with new materials, new chemistries, and new base materials, all posing different converting challenges. On the one hand, this has been a steep learning curve, but on the other, it has paved the way for us to develop new technical innovations on our equipment and enhance our process knowhow. 

One example is the strain control to automatically manage and control web tension during converting, especially with heat-sensitive materials, such as MDOPE, which means improved performance and less waste.

Other innovative solutions that we have developed are linked to an improved coating application method, where we have developed a new coating trolley and weight control system, such as the Bobst unique Twin Roll Trolley and Reflect solution.

We also launched our high-quality hybrid coater-laminator, the Expertlam 900 offering converters greater flexibility. It is the evolution of Bobst high-end laminators with maximum versatility as it can be configured as a multi-technology laminator or in its barrier configuration when it is further equipped with Bobst coating technologies, enabling the production of barrier film and barrier paper solutions such as the Bobst OneBarrier range.

Other sustainable innovations include water-based inks and compostable substrates. Collaborating with various partners, the R&D team has optimised printing processes to use eco-friendly inks without compromising quality. These inks reduce volatile organic compound (VOC) emissions and align with the company’s broader sustainability goals.

If we look at how artificial intelligence in our workplace we have the example of our state-of-the-art, AI-driven intelligent Metallising Assistant. This solution represents a breakthrough in machine-integrated process expertise for vacuum metallising. It uses AI (machine learning) algorithms and supports the machine operator by automating the deposition process, resulting in more output and consistency of the end product and ensuring that customers always have the best operator on their machine. 

The R&D team has also been heavily focused on automating various processes within flexo printing lines. BOBST has not only improved existing robotic features but also introduced new robotic solutions to assist in plate mounting, cylinder changes, and in-line cleaning. The development of automated material handling and in-line inspection systems reduces manual interventions, thereby minimising human errors and downtime.

In 2024, Bobst launched SmartGravure, which is a game-changing leap forward for gravure printing. The complete system includes three components—oneSET, onePRINT, and oneECG (Extended Color Gamut). SmartGravure revolutionises the gravure printing process from being a highly manual operation to a fully digitalised workflow. In particular, oneSET enables users to overcome the typically lengthy set-up time and tuning and high-level operator skills required with gravure printing, as the setup is taken care of offline and the selection of the optimal process data for each new job is automatic. It, therefore, allows for more machine up-time as well as disengaging from the operator skills level, leading to overall higher productivity, and making gravure a real option for shorter job lengths. 

Gravure has also been the star of the show for oneECG printing where we are proud to have achieved the first and only gravure Pantone validation in the world on our Master RS 6003 gravure press. The examination exposed us to 2369 challenging Pantone colours where the validation test scored 92.1%. Furthermore, with standard digital Pantone solid-coated colours tested in-house, we achieved a staggering 95% of the Pantone colour library.
 
The label market in India has grown in recent years because of the increasing demand for labels across various products. The label printing industry in India is valued at USD 2.3-billion and is expected to increase to USD 3.6-billion by 2025, growing at a CAGR of 7.3%. The per capita consumption of labels in India has grown from 0.25-square metres (sqm) in 2008 to around one-sqm in 2023. What is your prediction for the label industry in 2024 and beyond? 

The Indian label industry is growing quickly.  While flexo printing continues to have the greatest share of the market, we are seeing a significant surge in demand for digital and automated packaging solutions. 

We believe India is moving towards higher quality and more differentiated packaging in shorter runs, as brand owners seek to stand out from their competitors. We believe customisation and embellishment will be utilised more and more. Sustainability will continue to be a major driver as converters need to meet the targets of their customers in 2025.  

The sectors driving growth in labels are food and beverages (55%), cosmetics and personal care (17%), home care (15%), eCommerce (10%), and chemicals (3%).  What are the key factors contributing to the significant growth of labels in the food and beverages sector?, How is the label printing industry in India gearing up to meet this growing demand? 

Certainly, the food and beverage market in India is booming. India now has a very dynamic and young population, with 65% of Indians under 35 years old. There is more disposable income and consumer lifestyles are changing. These factors and others are driving this boom. 

The labels industry will need to produce shorter runs, more efficiently and sustainably, reaching the market in shorter times. To do so, converters need more agility, more on-demand production, and more sustainable operations, all of which are possible by adopting digitalised, automated, connected and sustainable technology, which Bobst provides.

Another key consideration for label manufacturers in India is changing regulations. For example, food and beverage manufacturers in India must now increase the boldness and font size of the nutritional information on their product labels to help consumers make healthier choices.  

Label production comprises pressure-sensitive labels (70%), shrink and stretch sleeve labels (12%), wet glue labels (10%), and in-mould labels (8%) and is manufactured by around 700 label printers that run one or more six- to eight-station flexo presses. There are about 1,800 flexo presses, 40 of which were installed in 2023. Similarly, there are 77 digital presses, 37 of which were installed in 2023, and one hybrid press (Gallus Labelfire) installed in 2023. What are the key factors driving the increasing installation of digital and hybrid presses in label production, and how do they compare to the traditional flexo presses in terms of efficiency and quality? 

The rise of digital and hybrid presses is due to changing market dynamics – specifically, the need to produce shorter runs in shorter timeframes. 

Both digital and analog flexo systems have their place. Flexo may be the better option for larger label orders, whereas digital printing works well for smaller projects with a faster set-up and turnaround time and lower upfront costs. 

A key trend, certainly at Bobst, has been the digitalisation and automation of the flexo process. For example, our oneECG technology which enables flexo to achieve 100% color repeatability with consistent and high-quality output.

In addition, India’s label market is growing considerably, in volume, quality and diversity of labels, shrink sleeves and flexible packaging applications. Digital solutions are also finding their place alongside analog equipment for customisation and short runs, even though run lengths are still high compared to other world regions. High-quality differentiated packaging in short runs will become even more important as brand owners seek to stand out from their competitors, an increase in digital solutions is a must, however we believe that due to the market characteristics in India, highly automated, let’s call them digitalised inline flexo machines will still dominate the label segment in the short term.

Bobst’s digital and all-in-one (AIO) presses are designed to deliver advanced automation, superior print quality, and seamless end-to-end processes, including multilayer labels in a single pass. These features set our customers apart from their competitors. By integrating multiple processes into a single machine, our all-in-one solutions significantly reduce the need for additional equipment and labor, leading to lower production costs. 

The user-friendly interfaces and advanced automation features also reduce the need for highly skilled operators, minimizing human errors and ensuring a smoother production process.

According to WhatPackaging? magazine, the flexible packaging market in India was valued at USD 8.4 -billion in 2020 and is expected to reach USD 12.3 billion by 2025, growing at a CAGR of 8.0%. Gravure continues to dominate. However, in the last five years, we have seen a linear growth of CI flexo machines. This has translated into approximately 15 CI flexo presses being installed every year. Experts opine that the key to investment is CI flexo's sustainability quotient compared to other processes. With flexible packaging runs becoming shorter, do you see technologies such as CI flexo and digital gaining popularity in the Indian market? 

The printers of tomorrow will be in a more comfortable position to choose the printing technology based on more than just run lengths. Until now, CI flexo has been the preferred choice for shorter runs as setup times are faster, and the speed and cost of preparing clichés are more advantageous for fast-changing SKUs. In addition, recent advancements in CI Flexo, such as extended colour gamut printing and improvements in plate-making technologies, have bridged the quality gap that used to exist. 

However, gravure presses are evolving too. In particular, the brand new SmartGravure package from Bobst revolutionises the gravure printing process from being a highly manual operation to a fully digitalized workflow, as outlined previously. It also enables multi -obs to be engraved on one set of cylinders and therefore done on the same run.

The flexible packaging market in India is undergoing a significant shift towards shorter runs, driven by increased customization, brand diversification, and faster product cycles. While on the surface this trend aligns well with the key advantages of CI Flexo and digital printing technologies, gravure is adapting too. The future therefore will be a preferred printing choice rather than something dictated merely by speed of set-up time, operator skill levels, and fast-changing designs. The shift from gravure to flexo is certainly a reality, but with the latest innovations coming to gravure printing, we see the gap narrowing. Printers have options, and that’s a good thing. 

However, gravure printers attempting to use flexo presses have stated that it is challenging to replicate the quality of gravure samples on flexo. Furthermore, when they are successful in doing so, brands expect their other converter suppliers to achieve the same level of quality using flexo, which may not always be feasible. Given this situation, how can printers expand their capabilities with flexo and other emerging technologies? 

While quality associated with gravure is generally considered more premium, the gap between gravure and flexo over the years has narrowed considerably. Advancements in CI Flexo, such as Extended Gamut Printing and improvements in plate-making technologies, have helped to bridge the quality gap. 

Both technologies have evolved in recent years. For printers and converters, making the switch from one technology to another is sometimes the most challenging element. To do so requires a change in mindset throughout the entire company, from management to sales to machine operators, a clear and gradual implementation plan with key milestones and awareness that it will not happen overnight, and securing the right support in the pre-press and process preparation. Bobst can provide the support and solutions required.

Has the pace of new capacity addition been different pre and post-covid (three years before vs three years after)? 

Yes, there have been some noticeable changes. In the years before Covid, we saw steady but cautious investments, with a preference for gravure and a focus on high-volume production and cost efficiency. Post-Covid, we have seen rapid investments in capacity addition, driven by demand shifts, supply chain concerns, sustainability, and shorter run lengths. This period saw a significant push towards CI Flexo and digital printing technologies to meet evolving market needs.

Overall, the post-Covid period marked a more dynamic phase of capacity additions and technological transitions, compared to the relatively stable and traditional growth trajectory seen in the pre-Covid years.

You have interactions with customers from different parts of the world. What are the top challenges the Indian label industry faces? 

In India, as in other markets, we have seen supply chain issues in recent years, which has impacted the price of raw materials and reduced margins for converters. But things appear to be improving. 

The demand for more sustainable packaging solutions is growing in India and regulations are increasing in this area. Companies will need to invest in more sustainable processes, materials, and circular economy practices. Regulations are also evolving around the need for clearer nutritional information on labels and around the need to reduce the impact of counterfeit products.

Many of the converters from India that we meet are looking for technologies that could enhance productivity, reduce waste, and simplify operations, helping them to meet the increasing demands for shorter print runs, faster delivery, and more sustainable practices.

Sustainability involves decisions made in daily life and business. The actions we take, or choose not to take, today, will significantly affect our environment in the future. How do you think businesses can incorporate sustainability into their operations? 

Environmental and sustainability issues are at the top of the agenda of governments, companies, and individuals all over the world, including in India. 

There are many ways that businesses can become more sustainable. At Bobst, we are helping converters to be more sustainable in their operations, for example by reducing the environmental impact of our machines, and reducing energy consumption by 20% for the machines we will sell in 2030 vs our baseline of 2022. We are also improving equipment sustainability through the reduction of ink, waste, and substrate. For example, oneECG – our extended colour gamut technology, which digitalizes and automates colour management – creates no ink waste, uses 30% less ink, and reduces make-ready time and make-ready waste by up to 90%. And we have made zero-fault labels a reality through innovations like Accucheck, which automates all the machine setup and corrections, allowing downtime reduction, and provides 100% quality inspection at full speed, guaranteeing perfect production quality from the first to the last label, without compromise, regardless of width or speed.

Tackling global environmental challenges may seem daunting, but there are steps all brand owners and converters can take to rapidly improve the sustainability of their packaging operations.

How do papers/films and embellishments influence the perception of a product? What elements of a label can visually express and summarise its essence? 

Embellishments can take a label from ordinary to extraordinary. Modern technology allows creatives to fulfil their vision, as labels can take almost any shape, texture and format, across multiple job lengths around the globe. 

Special embellishing techniques and extended die-cutting capabilities create unique ways for brands to present their products, with colours, use of foils and striking imagery offering a high degree of customisation and potential.

Machines like the Bobst Master DM5 ensure there are no limits to creativity, with all embellishments and custom solutions possible. The machine features both UV inkjet and flexo, delivering a full range of added value capabilities, such as varnishing, tactile effects, holographic effects, cold foil glue applications, and inline UV lamination.

We are seeing more and more personalised, customised and embellished labels in the Indian market now as brand owners seek to stand out from the crowd, making technology like this even more important. 

Label converters have increasingly sought automation for different stages of the product life cycle in recent years. With a shortage of labour in the industrial sector, human involvement has become a bottleneck in the production process. Automation and connectivity have shifted from being a cost-saving measure to a crucial requirement for industrial survival. What specific types of automation have label converters been implementing to address the challenges in the production chain? 
 
Automation is enhancing the label production process at every stage. And it is data that drives effective automation. 

Automation requires that machine and process data be captured, analysed, and used for optimisation in real-time across fully digitised processes. Bobst has developed its cloud-based digital platform, Bobst Connect, to meet these requirements. All machines connected to it can transfer their production data to the cloud and receive data from it – from the setup process through adjustments during ongoing production to quality reporting during and at the end of the production. 

There are then many examples of the benefits of automation throughout the production process. For example, tasks previously performed at the machines can now be moved to the prepress stage, particularly the setup processes. An example is recipe management for quality control with our Accuchek system. A single click is all it takes to transfer the recipes to the Accuckeck systems, which then configure themselves automatically.

This brings several advantages: the setup process is accelerated, the work of machine operators is significantly simplified, and input errors are eliminated. 

Label manufacturers using Bobst’s digital printing machines are already familiar with the convenience of automatic machine settings. They simply need to import their customers' PDF files into Bobst’s Digital Front End, define the setup data for the machines, and send the jobs to them. Immediately afterwards, the printing machines start running. 

Such automation enables quick setup and changeover times, allowing customers to efficiently manage short runs and quick turnarounds. The user-friendly interfaces and advanced automation features also reduce the need for highly skilled operators, minimizing human errors and ensuring a smoother production process.

The Bobst Master M6, a productive and automated label and flexible packaging press

Manufacturing at Bobst

Worldwide industry boldly focuses on robotics and automation of production processes. Do you see the Indian label and packaging industry also being part of a trend of 4.0 Industry and investing in the latest technology? What is the time frame you see? 

Yes, absolutely. India is already starting to go down this path, and this will only accelerate. It is estimated that USD 5.5 to USD 6.5-billion was spent in India on Industry 4.0 in 2021  – a number which is likely to have increased significantly by now.

The converters from India that we speak to are looking for technologies that enhance productivity, reduce waste, and simplify operations, helping them to meet the increasing demands for shorter print runs, faster delivery, and more sustainable practices. By embracing digitalization and automation, converters can fulfil all their unmet needs. 

What advancements are you making to reduce setup times and minimise waste in flexo printing? 

All of our solutions are designed to reduce setup times and minimize waste. Take the Master M5 for example, a press for converters willing to automate their production line, with systems and solutions that reduce downtime and waste. With its digital workflow with integrated printing and converting technologies, it enables 1-minute job changes, with very high-quality consistency at very low operating costs. 

Or our range of CI Flexo presses, which offer fast job setups and changeovers, crucial for shorter print runs. The Vision CI Flexo Press features rapid setup and changeover, and technical innovations and automation that ensure repeatable process consistency, minimum waste and easy manufacturing. 

What solutions do you offer for short-run jobs to compete with digital printing? 

The digitalisation and automation of the flexo process have seen a rise in hybrid and all-in-one machines, transforming these presses from hybrid to truly all-in-one systems. These can compete with digital for short-run jobs. Take the Digital Master series, modular and upgradable All-in-One hybrid solutions that provide the flexibility and agility to address a wide range of applications with a single equipment. With full integration between UV flexo and digital printing, they enable effortless switching from short to long runs with minimum ink and material waste.

In addition to Bobst gravure and CI flexo presses, the Master M6 is the most suitable press for mainstream short-to mid-run flexible packaging and shrink sleeve applications, as digital doesn’t provide yet the productivity and cost required for this segment. 

What are the latest advancements in your flexo printing technology that can improve speed and efficiency for medium-sized businesses? 

Bobst is helping customers to simplify label production, including through improved speed and efficiency.

Earlier in 2024, we introduced a closed-loop ecosystem from pdf to twin pdf to boost productivity, ease of use and sustainability. The features will allow label converters to accelerate job preparation, with faster job completion less dependent on operator skills, and with a more connected production floor, thanks to a range of new Bobst Connect and pre-press features. 

Many of our machines enable optimal productivity. For example, our Digital Expert 340 enables high printing speeds of 65-m/min upgradable to 100-m/min for the highest digital productivity with any run length up to 8,000 linear meters.

What kind of support or maintenance services do you offer post-purchase, especially for companies operating in India? 

Bobst has an entire portfolio of services available for its customers, supporting all steps of the production workflow. MyBobst is our secure, dedicated customer web portal for everything our customers need for their Bobst machines and equipment. Bobst helpline provides fast and easy access to technical experts who can identify issues and in most cases solve them remotely, ensuring that machines are up and running again as quickly as possible.

Anytime that’s not quite enough, we’re available for a technical inspection and assessment of equipment and preventative or corrective maintenance on request. If spare parts are needed for machines, we have three global distribution centres – including one in Asia to serve our customers in India – which ensure optimal delivery times, even on the same day if urgently required.