The corrugated packaging market has experienced considerable change in recent years with the pandemic and disrupted supply chains affecting the market and driving the rise in e-commerce. In addition, the consolidation of many of the major converters has changed the market dynamics, while the drive for increased sustainability continues to put pressure on the capabilities of production equipment. Reducing the weight of packaging (lightweighting) has long been a core demand, but logistics pricing now also takes size into account (rightsizing), meaning boxes must be optimized to avoid shipping excessive amounts of air.
To adapt to these challenges and explore growth potential while meeting strict deadlines and quality requirements, converters turn to leading equipment manufacturers for solutions. As a driving force in innovation, BOBST continues to lead the market with the introduction of the new groundbreaking MASTERFLEX-HD+ flexo press for corrugated post-print, designed to equip them with the optimal tool to address this complex market.
Setting the standard in its class, the Masterflex-HD has been a leading choice in high-definition flexo printing for the world’s largest packaging manufacturers for many years. At drupa 2024, Bobst unveiled the next-generation of this powerful, highly advanced flexo press, marking another chapter in corrugated post-print excellence.
The new Masterflex-HD+ offers excellent production speeds, more automation features, 100% quality control and connectivity capability, allowing converters to meet current market demands and emerging trends with highest definition graphics. This is the flexo alternative to offset printing when manufacturing high added-value corrugated packaging in micro-flute to double-walled board, with up to eight print colors.
“A fantastic tool for corrugated packaging producers, the new Masterflex-HD+ enables them to provide fault-free, top quality corrugated boxes to their brand owner customers. By pushing the boundaries of speed, quality, and efficiency, this highly automated, reliable and robust press ensures the longevity of flexo printing and its continued dominance in the corrugated space,” commented Denis Jahn, Technology Sales Director, Bobst.
A host of automation and digitalization components drive the exceptional productivity level of the Masterflex-HD+. As the new reference machine in the 2,100 x 1,300mm format, this impressive post-print production line is capable of printing 15,000 corrugated sheets per hour, which is equivalent to covering an area of 53 million sqm each year. As such, the press is mainly targeted at major corrugated packaging producers with a global reach, but also medium-sized converters with a large regional presence.
“This advanced flexo press offers unmatched productivity and the highest quality for the post-print corrugated market, making it the right choice for global players that serve the world’s big brand owners, such as Nestlé, Mondelez and Unilever to name a few,” explained Jahn. “But we’re also seeing smaller companies leverage the power of this technology to dominate regional markets, blowing the competition out of the water due to the staggering throughput and excellent quality.”
Tackling corrugated board in thicknesses between 0.6 and 9 mm (.024 to .35 in) and heavy solid board up to 0.75 mm (.03 in), Masterflex-HD+ can handle sheet sizes from 600 x 520 mm (23.62 x 20.47 in) to 2,100 x 1,300 mm (82.67 x 51.18 in). Enhancing operational efficiency and storage flexibility, it features a brand-new STACKER that can stack piles up to 2m high while handling sheets individually to prevent scratches. Its real direct drive feeder with sheet-edge register utilises a high-speed belt infeed system that allows correction of the front-edge position to ensure that the first colour is printed in register and to eliminate problems with crushed or marked sheets.
Offering a substantial reduction in set-up times and waste, Masterflex-HD+ features Bobst’s proven Start & Go automated register setting which can set up the job within just 10 sheets. This ultra-high precision system reads printed marks placed on the sheet, using them to automatically align each print unit in register during both start-up and throughout the production run. It does so by adjusting print length, skew, transverse and longitudinal register.
Handled via the intuitive operator interface, job changes are also highly automated with a motorised lifting and locking system helping to cut down the need for any manual intervention. The device handles up to three rollers per print unit and automatically changes the anilox in under three minutes. As well as saving time, the automatic inking and doctor blade wash-up system reduces ink and water consumption for better sustainability and lower costs. Meanwhile, job settings can be stored in the integrated MATIC system making it quick to set the parameters for repeat runs.
Finally, the press can be fitted with optional ACCUCHECK quality control system for 100% inspection of every sheet to ensure the output meets customers’ quality requirements. Non-conforming sheets are rejected automatically, saving time, reducing waste, and preventing orders from being returned. And when it comes to connectivity, the integration with Bobst Connect provides remote access to production data and real-time troubleshooting, further ensuring that maximum uptime and productivity are achieved.
Jahn concluded, “With its advanced technology and seamless automation, the Masterflex HD+ empowers businesses to increase production capacity, maintain top-tier quality, and reduce waste. Whether producing premium high-graphic packaging or meeting tight deadlines, this solution ensures converters can take on more business while maintaining efficiency and profitability.”
