LOUPE Americas 2026 (formerly Labelexpo Americas) is opening the door to in-line folding carton technology. Andy Thomas-Emans, Strategic Director at Informa Markets Labels & Packaging Group, explains how LOUPE is evolving from its labels core.
In-line flexo printing of folding cartons is now firmly established as part of the wider LOUPE universe, opening up new opportunities for label converters in the booming folding carton space.
The key difference between in-line production and traditional sheet-fed offset is that finished printed and embellished folding carton pieces are produced in a single pass from a roll of cartonboard.
A range of print and decoration processes can be added to the same press line – in exactly the same way as on a narrow web label press.
In-line processes typically include web treatment, reverse-side printing, cold foil, UV flexo (or offset) printing, coating and cast-and-cure lamination. Additional units might include silkscreen, extended driers for water-based flexo and gravure coatings, digital print bars and more.
After print and decoration, the folding carton is die-cut and creased in the same machine pass.
This can be achieved either with in-line rotary die stations, one for creasing and one for through-cutting, or with an in-line flatbed die-cutting station. In-line flatbed technology was demonstrated on a Canon/Edale CartonLine press at Labelexpo Europe 2025 (now LOUPE Europe), a UV flexo press configured with cold foil and cast-and-cure lamination.
Semi-rotary flatbed uses the same kind of inexpensive tooling found in an offline cut-and-crease machine, so is ideal for shorter runs. Press speed is slower compared to fully rotary cut-and-crease, so the chosen configuration will depend on the kinds of work the converter is expecting.
Individual die-cut blanks are delivered onto a shingling conveyor with automatic waste removal, with options for fully automated packing if the cartons are shipping directly to customers.
Going forward, we expect to see not only flexo, but also hybrid machine platforms producing folding cartons in a single pass, powered by inkjet with flexo coating and other modular decoration processes.
Sweet spot vs sheet-fed
Traditional sheet-fed folding carton production accounts for the overwhelming volume in today’s global packaging market.
Sheet-fed carton conversion involves multiple production steps, including printing, die-cutting/creasing and foiling/embossing. This involves a lot of work-in-progress (WIP), is labour-intensive and creates additional lead time for each additional process step.
Label converters moving into folding carton production using in-line presses can offer a more agile service as they are printing and finishing in a single pass. Multiple decoration processes can be offered as part of the same press pass. This suggests how label converters can find niche markets in folding cartons.
Firstly, where is the wrong place to compete? It is impossible to compete on price alone against highly efficient and automated sheet-fed converters.
Also, the narrow/mid-web in-line press width places limits on the format size that can economically be offered.
So the niche is to be found in short-run, fast-turnaround, multiple-SKU work on smaller-format folding cartons; or in longer runs of highly embellished small-format folding cartons.
Steve Haedrich, President of New York Labels + Box Works, and LOUPE Americas 2026 Folding Carton Ambassador, explains:
“The growth in new product launches, seasonal packaging, limited editions, and SKU proliferation is driving demand for short-run and more flexible folding carton solutions. Customers want to test products and enter new markets without committing to extremely large quantities. In-line folding carton technology currently can allow the printer to perform six steps at once – roll to press, back print, front print, foil stamp, film laminate and emboss and die-cut at the same time.”
Folding cartons at LOUPE Americas 2026
As with flexible packaging, we expect in-line folding cartons to grow steadily in importance at future LOUPE Global shows. Already at LOUPE Americas 2026, suppliers have started showing these specialised products.
Tamarack Products launches its Fusion in-line label application system developed for applying RFID labels to folding cartons on folder/gluer lines. The system is compatible with any pre-die-cut material and is engineered for high-speed application with tight registration accuracy.
PouchMark Automation demonstrates systems to stack, feed and print variable information directly onto prime and secondary folded kit boxes, “eliminating the need for physical compliance or product information labels.”
Looking to folding carton embellishment, Gietz-Vinfoil demonstrates in-line cold foil modules and Breit Technologies shows how to produce embellishments on carton materials, with both samples and equipment options.
SAPA Intelligent Technology exhibits the DMS sheet-fed digital embellishment line for folding cartons. Featuring a vision registration system with accuracy to 0.1 mm, this targets premium packaging applications including cosmetics, wine packaging and luxury goods.
Turning to converting systems, Kocher+Beck US demonstrates flexible dies to produce rotary folding cartons and Schober USA shows its RSM Offline Die Cutter and static die-cutting and punching modules. Beta Industries shows its BetaFold crease and fold analyser.
For materials, Sappi is promoting its LusterFSB SBS paperboard for food service packaging applications.
Kett exhibits near-infrared moisture and composition analysers alongside portable thickness gauges for folding carton applications.
Integration of folding carton workflows into wider factory MIS systems is demonstrated by a range of suppliers including CERM, eProductivity and HiFlow.
The future
A key advantage of introducing in-line folding carton technology to LOUPE is the presence of so much of the surrounding ecosystem, including inks, coatings and materials.
This allows us to focus on folding carton sustainability issues at LOUPE, particularly the replacement of non-recyclable laminated structures with recyclable barrier coatings for bakery and confectionery applications.
The ability to specify sustainable alternatives to existing non-recyclable folding cartons is a particularly powerful USP for label converters moving into this new segment.
It took around 12 years for flexible packaging to become a key part of Labelexpo, now LOUPE. We expect in-line and hybrid folding carton production to become a key part of the LOUPE global portfolio in considerably less time than that.