Dr. Dieter Niederstadt, Technical Marketing Manager at Asahi Photoproducts, during his presentation at the Next-Generation Sustainable Flexo Symposium in May 2026.
The packaging industry is entering a new phase of circularity. Increasing recycled content is only one part of the challenge. To create packaging that can truly move within a circular economy, materials must be recyclable, functional, printable and commercially viable.
This is changing the discussion around packaging print. PCR-based films, thin mono-material structures and new substrate combinations behave differently from conventional materials. They may show haze, varying surface characteristics, lower thickness or higher flexibility. As a result, the question is no longer only whether a material can be recycled, but also which printing process can reliably convert it into high-quality packaging.
From this perspective, flexographic printing is becoming an increasingly important enabler of circular packaging. With the right combination of substrate, plate technology, ink system, process control and workflow expertise, flexo can help expand the use of recycled and lightweight materials without compromising the visual and functional role of packaging.
In this interview, Dr. Dieter Niederstadt, Technical Marketing Manager at Asahi Photoproducts, shares his perspective on Circular Economy, print quality, and the role of integrated flexographic solutions in supporting the packaging industry's sustainability goals.
Q1. Circular Economy is often discussed from a material and recycling perspective. Why should packaging print be part of this discussion?
Dieter Niederstadt:
Because packaging only becomes truly circular if it remains functional, recyclable and marketable. Increasing recycled content alone is not enough. A package still has to protect the product, run efficiently through printing and converting processes, and communicate the brand at the point of sale.
This is where print becomes highly relevant. New circular packaging materials, such as PCR-PE films or thin mono-material structures such as MDO, often behave differently from conventional substrates. They can be hazier, more flexible, less uniform or more sensitive in processing. The printing process therefore becomes part of the Circular Economy discussion, because it determines whether these materials can be used for demanding consumer packaging applications.
Q2. What makes mono-material and PCR-based substrates particularly challenging from a printing perspective?
Dieter Niederstadt:
Many circular packaging concepts rely on mono-material structures, thinner films or recycled polymer streams. These materials can be more difficult to print because they may have different mechanical properties, surface characteristics or show elongation of the material compared with conventional laminated structures.
In some printing processes, very thin or uneven substrates can create additional challenges, especially when high print quality and stable register are required. Flexographic printing, particularly in central impression configurations, can offer advantages here because it is well suited to handling thin, flexible or more demanding filmic substrates.
This does not mean that one technology will replace all others. But it does mean that flexo can play a very important role in enabling packaging designs that reduce material use, increase recyclability and still meet brand owner expectations.
Q3. During the recent Next-Generation Sustainable Flexo Symposium, high-quality print results on PCR-based substrates attracted considerable attention. Why is this development significant?
Dieter Niederstadt:
To meet the recycled content requirements for packaging materials set by the PPWR, we see material variation in surface energy or the amount of impurities coming from high levels of post-consumer recycled content. These materials are often associated with compromises in print quality. Variations in material quality, visible haze and inconsistent surface characteristics could affect the final appearance of the package.
As a result, many of these materials were primarily used for relatively simple applications rather than packaging designs where brand presentation and visual impact are critical.
The print results presented during the symposium suggest that this situation is beginning to change. Even on substrates containing more than 90% PCR content, it was possible to achieve results that exceeded what many industry experts would previously have expected.
This is important because brand owners increasingly want to combine ambitious sustainability targets with strong shelf appeal. If high levels of recycled content can be combined with reliable print quality, entirely new packaging applications become possible.
Q4. What does this tell us about the future relationship between Circular Economy and printing technology?
Dieter Niederstadt:
One of the most important lessons is that Circular Economy is not simply a material issue.
To create packaging that is truly circular, recyclable materials, printing technologies and process knowledge must work together. A highly recyclable substrate alone does not create a successful packaging solution if it cannot be processed efficiently or if the final package fails to meet performance and branding requirements.
This is why the discussion is increasingly moving beyond recycled content percentages. The industry must consider how new materials behave during printing, converting and recycling, and how the entire value chain can work together to optimise these processes.
In many cases, flexographic printing is particularly well positioned to support this transition because it can help converters process lightweight films, mono-material structures and challenging PCR substrates while maintaining process stability and print quality.
Q5. If Circular Economy requires materials, printing technologies and process expertise to work together, what does this mean for solution providers such as Asahi Photoproducts?
Dieter Niederstadt:
The challenges facing the packaging industry today are becoming increasingly interconnected. Recyclability, material reduction, print quality, process stability and operational efficiency all influence one another.
This is one of the reasons why we increasingly talk about ecosystems rather than individual technologies. Sustainable packaging production depends on the successful interaction of multiple elements across the workflow.
At Asahi Photoproducts, we see our role as contributing to this broader collaborative approach. Plate technology is one part of the equation, but equally important are imaging technologies, screening methods, ink systems, substrates, press technologies and process automation. Only when these elements work together can converters fully realise the potential of new packaging concepts.
Q6. How does the Asahi AWP™ Ecosystem support this transition towards more circular packaging production?
Dieter Niederstadt:
The Asahi AWP™ Ecosystem was developed around the idea that sustainability and productivity should support each other rather than compete with each other.
The ecosystem combines water-washable plate technology, dedicated processing equipment and water recycling solutions into an integrated workflow. The objective is to help converters improve resource efficiency while maintaining reliable production performance and high print quality.
What makes this particularly relevant for Circular Economy is that it addresses several aspects simultaneously. It supports more efficient use of resources, contributes to reduced process waste and helps simplify parts of the platemaking workflow.
As sustainability requirements continue to increase, we believe that integrated solutions of this type will become increasingly important throughout the industry.
Q7. Water is becoming an increasingly important resource across many industries. What role does AWP-LOOP™ play within this ecosystem?
Dieter Niederstadt:
Circular Economy is fundamentally about keeping valuable resources in use for as long as possible. Water is no exception.
AWP-LOOP™ was developed to recover and reuse process water within the platemaking workflow. By creating a closed-loop approach, the system helps reduce overall water consumption while supporting a stable and predictable production environment.
This becomes increasingly important as converters look for practical ways to improve resource efficiency without adding unnecessary complexity to their operations.
The technology recently received the FIA Operational Environmental & Sustainability Gold Award 2026. While industry recognition is always appreciated, we see this award primarily as confirmation that resource-efficient process solutions are becoming increasingly important for the future of flexographic printing and circular packaging production.
Q8. Asahi recently received an EcoVadis Silver Medal for its Photoproducts plant in Japan. What does this recognition mean for the company?
Dieter Niederstadt:
The EcoVadis Silver Medal is an important recognition because it reflects sustainability performance beyond individual products and technologies.
For us, this is directly connected to our broader sustainability DNA. Product innovation is essential, but sustainability must also be reflected in how a company operates, manages resources and drives continuous improvement.
The assessment recognizes progress across multiple areas and supports our commitment to developing solutions that combine environmental responsibility with long-term operational value.
Q9. Looking ahead, what do you see as the most important opportunity for the packaging industry?
Dieter Niederstadt:
I believe the greatest opportunity lies in proving that more sustainable packaging can also be high-performing packaging. Regulations such as the PPWR may be costly and challenging to implement, and they are not always welcomed by every stakeholder in the value chain. However, by setting more ambitious targets, legislators are also creating a strong driver for new product innovation across our industry.
The discussion is therefore moving beyond asking whether recycled materials, mono-material structures or thinner substrates can be used. The real question is how these materials can be converted reliably, printed at high quality and used in demanding packaging applications while still meeting the functional expectations of the final product.
This is where printing technology becomes a strategic enabler. Solutions that combine environmental benefits with process stability, productivity and strong visual results will ultimately help converters and brand owners adopt more circular packaging concepts with confidence.
At the same time, regulation alone will not deliver the transition. Success will depend on close collaboration across the key players in the value chain, including material suppliers, technology providers, converters and brand owners. Only by working together can the industry meet Circular Economy objectives, maintain product functionality and create packaging solutions that are both sustainable and commercially successful.