Robert Moran

Flexographic Technical Association ushered in a new era at FORUM INFOFLEX 2025, with the signature event revitalized to better serve the membership.

• Educational offerings were reinvigorated with a significantly expanded multi-track program addressing the package printing and converting industry’s most pressing challenges
• The Training and Education Services Team debuted its soon to roll-out Flexographic Image Reproduction Specifications and Tolerances (FIRST) In-Person Training certification curriculum
• Networking receptions embraced FTA’s new focus on a community platform, showcasing the success of its Women In Flexo and Leaders Inspiring Flexo’s Tomorrow (LIFT) programs
• Introduction of daily keynote addresses set the tone for what was to follow
• A pre-event kick-off drew some 100 flexographers to PNC Park where even an extensive rain delay in the Pirates vs. Padres ballgame didn’t deter camaraderie. In fact, conversations focused just as heavily on ROI (return on investment) and TCO (total cost of ownership), as they did on RBIs and ERAs

Most, if not all, of the 1,000 delegates noticed the changes with many surveyed commenting on how the subtlety introduced nuances impacted their FORUM INFOFLEX experience.

Short, Sensible  Takes
Four days, 24 technical educational sessions, 35 hours of learning opportunities, a roster of 95 speakers inclusive of session chairs, 8.5 hours of exhibit time, 142 exhibitors and a 3.5-hour banquet and reception, make it difficult to cover all that transpired at FORUM INFOFLEX 2025.

Fifty-three Excellence in Flexography Awards, three Technical Innovation Awards, two Sustainability Excellence Awards, one President’s Award and induction of the 67^th member of FTA’s Hall of Fame took place (See May/June FLEXO for full awards recap), in the customary dinner setting, marking just some major highlights of what FTA members regard as “a true family affair.”

Short, hard-hitting takes from the stage, certainly speak to the quality content shared. They follow, arranged by major subject matter, ranging from: FIRST training, the label landscape, energy cure, targets, and a press operators toolbox; to a package printing outlook, the talent gap, leveraging AI in flexographic workflow and Sunrise 2027—the advent of multi-dimension bar codes and similar media.

Also dotted throughout the agenda: flexo, digital and hybrid technologies; productivity; sustainability; women in leadership; digitalization; ink laydown; flexible packaging’s future; and, of course, what FTA is known for—printing to the numbers, from data collection and analysis to measurements and documentation and on to print tolerances and quality control techniques.

Statistically Speaking
“If technology doesn’t make money, it isn’t going to work,” Sean Smyth of Smithers cautioned listeners. Delivering the demographically oriented outlook, he said, “Packaging will be a $1.3 trillion market in 2025. …Printed packaging is a $537 billion enterprise worldwide.”

In voicing other observations relevant to challenging times, Smyth targeted the current economic climate and potential impact of tariffs. “The world went from ‘just-in-time’ to ‘just-in -case” manufacturing,” he declared. “More stockpiling in the Americas is happening as we go through uncertainty with tariffs. …There will be more pressure to make equipment and supplies in the US due to increased financial pressures from tariffs. …Net impact for flexo presses will be 8.5 percent. … Most inks are made in China… you are going to have to live with more expensive inks.”

Process Control
Bryan Ploeg, Fortis Solutions Group, while talking to a culture of productivity, insisted, “Lean management is focusing on your internal customers to increase flow. …Data doesn’t always give you the answers, but it can give you a direction.”

Carrie Aaron, Hub Labels, pointed to talent shortages and recommended that, “You need to make sure you have a well mapped-out training program for employees before you add technology.”

“Color should be a specification and not a feeling,” Ben Abray, Autum Graphic, noted in campaigning for measurements and documentation. Dave Ruckman, Berry Global, maintained, “FIRST is paramount for consistent color.”  Bob Coomes, PPC Flex, shared the vision. “Not running to the numbers is like going back to the 1900s.”

Days later, Moe Ramah, Sun Chemical, speaking to ink laydown, decreed, “Optimization is critical for efficiency! “Elaborating on the point, he stated, “The relationship between resin and solute in an ink affects how fast the press can print it. -…With high-speed printing, you have a very narrow window of tolerance in the ink.”  Supportive of the claim, Rick Dear, Intercraft, asserted that, “Focusing on net speed goals will give you better results.”   

AI, Automation Digitization
“Advanced register and color control systems reduce reliance on visual inspection. Digital sensors and inline cameras ensure consistent print quality without manual monitoring. Centralized touchscreens and remote diagnostics allow efficient operation with minimal lighting needs. “That message was delivered by Carsten Clemensen, Nilpeter in a talk dubbed “Digitalization Nation.”   

“Going forward, we need to make sure decisions are made on data coming from the presses.,” Clemensen, contended. “Highly skilled engineers are working to get it done.” Of note, he pointed to the importance of “Modular upgradability and circular design,” then claimed, “It supports longer machine life, easy retrofits, and end-of-life recyclability.”

Nilpeter’s CTO cited an overarching objective relative to flexo presses. “Make them live in the field for decades!” Strategies he alluded to as necessary to make it happen were built around his capital equipment check list:

• AI driven quality control
• Intelligent subsystem synchronization
• Robotic automation for mechanical tasks
• Predictive maintenance through sensor analytics
• Cloud based job management
• Press synchronization

His colleague, John Crammer put the plan succinctly: “Deliver a perfect job with minimum waste at maximum speed!” He added, “Things are changing dynamically month to month. Watch all developments very carefully. Act at the optimal time.”

Eric Ferguson of Avery Dennison and Gary Peterson, Domino, also had the future of flexo on their minds. Addressing the pending implementation of 2-D barcodes and other augmented reality tools, associated with deployment of the Sunrise 2027 expanded package data requirements.

Ferguson explained, “The purpose of a QR code is to enhance the barcode function by adding a web link.” Peterson stated bluntly, “The future of flexo is to adapt to the need for unique artwork (QR codes) on every design.” 

Flexo, Digital, Hybrid
Brian Cleary, hp, set the stage for a thorough discussion, “Flexo, Digital, Hybrid—Each has its Place,” by rattling off statistics. “Label market share stands at 39.6 percent flexo; digital and hybrid, 6.7 percent. …Flexo controls 40 percent of dollars; digital and hybrid, 21.6 percent. …Forty-eight percent of capital expenditure minded printers intend to buy a flexo press, 41 percent look to hybrid.”

Acknowledging that, “We should be thrilled we’re working in a growing industry,” Cleary urged audience members to “Capture your fair share of this huge opportunity.”

Tommy Haas, Fortis Solutions Group, lamented, “Our press is our money. We want to keep it running.” He keenly observed, “Flexo requires more of a mechanical operator; digital is computer oriented. …At the end of the day, it would take six months for a flexo press operator to be trained, but for digital press operators, indoctrination is measured in days.”

He also maintained, “Certain pieces of art drive the decision to go flexo vs. digital. …Determination is rooted in what becomes tribal knowledge—a production director instinctively comes to know ‘This is definitely a fit for digital. This runs flexo.”

Thomas Dahbura, Hub Labels, remembered, “I started my digital journey with Indigo in 2003.” He further recollected, “When I saw a hybrid press for the first time, I said ‘Oh my God, this is the Holy Grail!’”

Ben Luly, Mark Andy, in a follow-up session devoted to hybrid technology, offered, “Compared to flexo, hybrid provides a 45 percent cost savings. Compared to digital, hybrid provides a 20 percent cost savings.”

He insinuated, “Having multiple press technologies allows jobs to be produced in the most competitive way possible. …As run lengths continue to fall, hybrid presses will play a key role to maintain converter profitability.”

Windell McGill, bw converting, decreed, “Wider and faster hybrid presses are closing the gap between digital and conventional flexo. …We need resolution and we need speed!”

Digital ‘s Potential
Greg Horney and Michael Whelpley, FujiFilm charted the history of digital, admitting everything began with, as Horney said, “Variable data short runs, special editions, contests, campaigns personalization—a name on a package–lot numbers, date codes, QR codes, and bar codes.” The philosophy he claimed was embraced: “Get it. Run it. Go!” The objective: “Reduce inventory and lead time for customers.“

Whelpley talked to introducing digital into the current environment, urging printers to, “Support cross platform consistency.” His message held, “Preparation starts before you acquire any digital equipment and before you make any promises to customers.”

Other observations he voiced included, “Process printing requires better intel on the condition of your printing deck. …Modern pressrooms move away from a philosophy of how it has always been done, instead targeting print production to print standards and print specifications that allow you to get control of production and have targets that you can then use to align and set up new digital projects.”

Flexible Packaging
“We’re moving on from dependence on deep individual expertise to systems that make expertise accessible,” declared Rory Marsoun, Esko. “Focus on things that help in multiple areas to get the best bang for your buck.”

He adamantly held, “Leadership means looking ahead, understanding what is coming and doing something about it. New things are coming. We better be ready!” In Marsoun’s view, “The prepress department of tomorrow will shift from repetitive tasks to strategic oversight.”

Jason Cagle, Windmoeller & Hoelscher, argued, “Efficiencies your customers are demanding are going to require more and more automation. …Speed and quality must get faster and better with no tradeoffs. …Quick changeovers are no longer optional. Downtime is going to continue to be a killer. Decreasing changeover time by even 5 or 10 minutes will have high impact on the bottom line.”

Cagle affirmed his belief, “Assets are only going to become tighter and tighter. …Automation is going to be the future of running a press. Adaptability of substrates coming into press, mean you need a machine to handle unknown challenges ahead. Presses are getting faster, runs are getting shorter, skilled labor is harder and harder to come by. Smarter presses make for smarter workflows.”

He recommended converters, “Push the limits on what we can do with film. …Talk about sustainability now.! Films of the future will interact with the press differently.” His closing charge: “Embrace change–don’t just react to it.”

Roberto Santos, Accredo Packaging, told fellow flexible packaging printers that they had two options: “Change or die.” He indicated several developments are imminent:

• Recyclable becomes obsolete. Only fully compostable, regenerative materials will be accepted
• AI and robotic logistics take over

“Survive and dominate! …Burn current models. Invest aggressively. Design for machines. Establish cross disciplinary teams,” Santos proclaimed.

“Destroy your operating paradigms before they’re rendered obsolete. Start today, not tomorrow. …Pour resources into AI, next-gen print, and compostable R&D immediately! …The packaging industry stands at the edge of total reset. By 2032, everything we know will vanish.”

Editor’s Note: Save the date! FTA’s 68^th annual meeting is set for Milwaukee, WI, and the Baird Center. Plan to be there! Calendar it for April 26-29, 2026.

As Stacey Ebben, tc Transcontinental asserts, “Milwaukee, as a venue, will be a great opportunity for printers to bring their press operators, prepress technicians, etc to FTA to experience and LEARN! Pittsburgh presenters emphasized leaning on the OEMs for training…let’s put the rubber to the road and make that happen in 2026!”