Over 25 percent of visitors to Labelexpo Europe 2023 registered an interest in folding cartons.
Labelexpo Europe 2025, held in Barcelona from 16-19 September, will now include folding carton technology alongside labels and flexible packaging. This looks like a big change for the show, but in fact is more of a natural evolution based on inline and digital technologies which look set to disrupt the traditional folding carton industry in much the same way they did with flexible packaging.
As part of this move, Labelexpo has announced a strategic partnership with Brunton Business Publications Ltd, publisher of ‘industry bible’ Folding Carton Industry magazine. Through its comprehensive website ThePackagingPortal, Brunton is the leading daily source of industry news for the folding carton, corrugated and recovered fibre industries globally. The company additionally publishes International Paper Board Industry and The Packaging Portal Newsletter magazines.
This partnership will allow Labelexpo to communicate directly with the folding carton industry and brings on board the unmatched industry expertise of its Managing Director, Dan Brunton.
From labels to packaging
Labelexpo has constantly adapted to new package printing technologies. The early Labelexpo shows, starting in 1980 in Brussels, focused on what was then the new technology of self-adhesive labels converted inline on narrow web presses. As labels expanded into new formats, such as shrink sleeves, wraparound and in-mold labels, Labelexpo adapted to showcase these technologies. The next big evolution for Labelexpo was the addition of flexible packaging, which happened around a decade ago with the launch of the 30-in wide HP Indigo 20000 Digital Press.
Flexo press manufacturers then developed wider ‘mid-web’ presses in the 26-30in/670-800mm range better adapted to handling these larger packaging formats. Label converters who diversified into flexible packaging – typically stand-up pouches – found this opened up new market opportunities which strengthened their label businesses. We are now seeing a similar convergence of print technologies between labels and folding cartons with the potential to open up new markets for label converters and other market disruptors.
Converging technologies
Folding cartons are today overwhelmingly printed on sheetfed presses followed by further off-line operations such as creasing and die cutting, hot stamping and embossing. These multiple process steps add to lead time and create a lot of work-in-progress (WIP) as pallets are moved between workstations. The technologies which could revolutionise this traditional workflow are core Labelexpo technologies: inline flexo and rotary offset, digital and hybrid.
Inline flexo, rotary offset and hybrid presses allow the processing of folding cartons in a single pass from printing and coating to cut-crease and sheeting. As with any label press, additional processes can be added in-line, such as screen printing, foiling and embossing and VDP/numbering. The finished cartons are immediately ready for shipping or further processing on folder-gluer machinery.
Digital printing has huge potential for short run and personalized folding cartons. In 2013 HP Indigo demonstrated a folding carton line built around a Tresu coater, 30000 digital press and with partner Kama demonstrating half-size cut/creasing. Since then there have been interesting developments in water-based inkjet for folding cartons, and Mark Andy’s executive vice president Tom Cavalco says the company is actively looking at how to apply its hybrid UV inkjet platform to the folding carton market.
Labelexpo could speed the adoption of digital printing for folding cartons, just as it did for labels and flexible packaging. The addition of folding cartons to Labelexpo is also likely to galvanise developments in short-run converting systems and digital embellishment. We should also not forget that by far the biggest volumes of wet glue labels and in-mold labels are printed on sheetfed offset presses. One result of bringing folding cartons into Labelexpo will be an increased focus on the high levels of automation on these presses as well as new in-line coating and foiling systems.
Common themes
As well as overlapping print technologies, there are wider themes which unite labels, flexible packaging and folding carton converters at Labelexpo. Sustainability is a key one, driven by the EU’s looming PPWR initiative. Labelexpo Europe 2025 will examine these trends at a feature area on the show floor, with daily presentations and interactive exhibits.
One consequence of PPWR is that many brands are looking to move from plastics to technical paper and fibreboard-based packaging formats. Topics covered in the Labelexpo PPWR feature will include the potential replacement of laminated cartons and flexible packaging with technical coatings to make recyclable mono-material packaging. Automation is another common theme. Labelexpo exhibitors are already demonstrating process automation software and robotics systems, particularly focused on end-of-line material handling. The addition of folding cartons will no doubt expand this area of the show.
The future
What might persuade a folding carton converter to visit Labelexpo? I suspect the same reasons flexible packaging converters now visit the show: a general interest in visiting co-suppliers; and a general interest in new print and decorative technologies. Also, with the entry of Private Equity finance into the packaging sector we are seeing more big groups which include labels, flexible packaging and folding carton operations. This is reflected in a growing visitor interest in both flexible packaging and folding cartons. At Labelexpo Europe 2023 over 25 percent of visitors registered an interest in folding carton technology and 40 percent in flexible packaging. This demonstrates that Labelexpo has transformed into a package printing show, albeit with labels at its core.
Labelexpo Europe 2025 is already shaping up to be an exciting show for folding cartons. Edale, now owned by Canon, has confirmed it will bring its FL5 Carton Production Line to the show. Actega will demonstrate its barrier coating technology, Tec-ni-Fold launches an inline creasing module and Rotatek shows a print station from its Universal 850 rotary offset press specificed for folding cartons. There are also a wide range of existing exhibitors like Omet who also supply to the folding carton market.
Labelexpo Europe 2025 will be a ‘soft launch’ for folding cartons. By 2027 we expect folding cartons to be fully integrated into the show.
Folding Carton Masterclass
The Label Academy will host a half-day Master Class at Labelexpo Europe 2025 in Barcelona. The Master Class is targeted at label converters who are looking at diversifying into folding cartons using in-line flexo/rotary offset, digital or hybrid presses.
The class covers an introduction to the folding carton market; production challenges and possibilities with in-line flexo, digital and hybrid presses; developments in materials including barrier coatings; converting technology for cutting and creasing and folder gluers.
The Master Class finishes with a case study of a label converter making the transition to folding cartons on an inline flexo press.