Kirk Group has partnered with Xsys and Hybrid Software to deliver a new flexo plate innovation to RollsPack in Melbourne, reducing set-up times and increasing longevity on the press.
Kirk created a combination of technologies to deliver a new tailored solution for RollsPack using nyloflex plates, ThermoFlexX imaging, Velvet Screening, Woodpecker surface patterns, and Catena+ automated processing to create a tailored solution for the award-winning packaging supplier.
The new tailored solution by Kirk ticked all the boxes for RollsPack, meeting its demands for quality, sustainability and costs. A family-owned company founded in 1985, it specialises in flexible packaging production, including e-commerce, food, retail, and tamper-evident solutions.
“This solution offers a lot of potential. Set up times have been reduced significantly due to precise colour profiles, and longevity of the press is comparable to other major players on the market,” said RollsPack print manager, Thanh Huynh.
“There is a marked difference in the ink laydown on surface print; it’s one of the best I’ve seen in flexibles. Even when printing colours on a white ink base layer, where we typically experience a drop in density, the results with Woodpecker are impressive. In addition, Velvet Screening holds the dots really well, ensuring that there are minimum hard edges.”
Ben Prout, group technical manager at Kirk said, “Kirk has worked with RollsPack for 20 years, so we appreciate and understand its ambitions, requirements and workflow. For this project, we also drew on the technical expertise and experience of Xsys and Hybrid Software, with RollsPack collaborating closely to create a customised solution that exceeds the quality of competitors and offers a more competitive price point.”
To meet RollsPack´s specific criteria, the team carefully considered the combination of plate and specialised screening technologies necessary to achieve the desired outcome. They were able to leverage the versatility of the ThermoFlexX imaging system and Catena+ automated processing line to implement these solutions.
RollsPack says it is also firmly committed to sustainability, developing environmentally-friendly products for its customers. “We are dedicated to elevating the market by supplying innovations that benefit our customers and meet their sustainability goals. We successfully achieved the same high-quality print with water-based inks as with solvent-based inks. This drives a constant need to explore new avenues and Kirk Group plays a fundamental role in this endeavour. Together we are pushing the boundaries of brilliant flexo,” said Huynh.
The advanced screening technology and dedicated plate surface structures simplified the challenging task of controlling the dots and the ink behaviour on press. According to Kirk, ThermoFlexX Woodpecker and Velvet Screening proved their individual strengths, to deliver a successful outcome for RollsPack. Both software solutions are open without any extra steps needed, meaning they can be implemented into any workflow.
Brenton King, Hybrid Software’s sales manager for Australasia, expanded on the flexibility of Velvet Screening. “The beauty of Velvet is that the software doesn’t require any proprietary information or special equipment, it just slots into the existing setup. Used at any resolution or ruling, it can be imaged onto the plate of your choice on any CTP device and then processed through your existing exposure frame.
“In this collaboration, Kirk simply applied Velvet Screening and then added the Woodpecker surface patterns during imaging. It’s a clever combination.”
On the hardware side, Kirk relied on ThermoFlexX technology from Xsys, including a Catena+ automated plate processing line installed at the Melbourne site in 2021. Kirk CEO Robert Selvaggio commented, “The investment in Catena+ has been a great success story for us. We were among the first in the market to realise the potential of this high performance, one-touch technology which tripled our capacity and elevated plate quality.” He revealed the company’s future strategy, saying, “We’re now in the process of installing a Catena+ line in Brisbane and a third one is already planned for Sydney.”
“Kirk has been reaping the exceptional benefits of Catena+ for a few years, and we have witnessed the innovative solutions it enables, such as this special project for RollsPack Group,” said Roy Schoettle, VP, Xsys Asia-Pacific. “We are delighted that this partnership has been so successful, and look forward to taking the next steps with the team, as they equip all their manufacturing sites with full Catena+ lines.”
Selvaggio said, “Flexo is still the largest printing technology for packaging, both in terms of volume and value, but we must maximise the market opportunities and the potential of each technology on offer. This is why collaboration is crucial for the future of our industry and for our customers.”
Established in 1972, Kirk is known throughout the industry as an innovation leader. The reprographics company, headquartered in Sydney, works with global brands and major printing companies across the ANZ region and into Asia, supplying graphic services and image carrier solutions for packaging production. Manufacturing sites are located in Sydney, Melbourne, Brisbane, Adelaide and Auckland, and sales offices in Christchurch, New Zealand, and Mumbai, India, all focused on the company’s stated mission “to bring inspiration and innovation to marketers and brands".
The nyloflex NEF D plate is a high durometer printing plate for flexible packaging developed by Xsys for the efficient creation of flat-top dots, and reproduction of surface screenings with UV LED exposure.
Velvet Screening is a new screening type from Hybrid Software created to meet flexo requirements. As the successor to hybrid XM screening, it uses an advanced dot removal algorithm to reduce harsh edges, leading to smoother and higher-quality prints.
ThermoFlexX says Woodpecker Nano is the finest surface micro pattern available for LAMS plates, suitable for platemakers and printers who need high frequency surface screens to increase quality and efficiency while reducing costs.
