The first cans to be printed on Orora’s high speed digital direct-to-can system, Helio, have rolled off the line at the canmaker’s Dandenong, Victoria facility, marking several first-to-market achievements.
Print21 was among the media contingent privy to seeing the new press in action for the first time. Chris Smith, executive GM Orora Cans, told Print21 that not only is the installation of this high-speed technology – The Velox NNC 500 – the first in the southern hemisphere, it also makes Orora the first can maker in the world to have this type of press integrated in a can manufacturing line.
Now fully operational and integrated into the second can line in the facility, Helio is delivering photorealistic, full-colour decoration directly onto necked aluminium beverage cans at speeds of up to 500 units per minute. The print quality and flexibility it offers positions it as a viable alternative to conventional offset lines, shrink sleeves and labels – particularly for customers seeking short-run agility or high-impact design.
Smith says the investment reflects the company’s strategy to lead with print innovation and deliver responsive, premium-quality packaging solutions for its beverage customers across Oceania.
“We’re excited to be the first in the region to bring this kind of technology to market,” Smith told Print21. “This represents powerful marketing potential for beverage brands. The system allows us to produce premium-quality decorated cans on demand, in low to mid volumes, with unprecedented speed and flexibility.”
The Helio system eliminates the need for plates, labels or sleeves, with digital artwork files sent directly to press. Setup times are virtually zero, and design changeovers are immediate. The digital process also unlocks features not feasible with traditional methods – including decoration on the chime and necked area of the can, selective opaque white, and the use of gloss and matte varnishes for visual and tactile contrast. High-build embossed finishes are also possible.
For Orora, this not only reduces complexity and material waste, but enhances speed to market. “With Helio, we can streamline production for everything from limited-edition runs to test-market campaigns, without compromising on quality or efficiency,” Smith said.
Anoop Thakur, GM Procurement and Sustainability at Orora Cans, highlighted the print system’s sustainability, stability and reliability. “What stood out to us was the robustness of the Helio platform,” Thakur said. “It’s engineered for 24/7 operation, with built-in redundancy and self-monitoring that reduces downtime and maintains high output consistency.”
Referring to how the new line complements the existing offset lines in the plant, Thakur said, “Every minute the plant is running, it consumes energy, so by reducing downtime and eliminating changeovers on long-run offset printing lines, we not only improve operational efficiency but also make meaningful progress toward our decarbonisation goals.”
Thakur also stressed the sustainability of the can itself. “Aluminium is an infinitely
recyclable material, making cans an even more compelling choice for existing and new
beverage concepts,” he said.
The press supports seamless 360° decoration, a wide colour gamut with accurate colour matching, and up to 900dpi resolution. The elimination of label application and sleeve-handling processes simplifies the workflow and reduces operating costs – an important consideration as brands demand greater customisation without inflating unit prices.
From a market perspective, the Helio system offers particular value for beverage categories with high SKU churn and promotional activity, such as RTDs, craft beer, sparkling water, and functional beverages. It also enables Orora to offer customers a more sustainable solution, avoiding additional plastics and adhesive substrates.
“This is a significant evolution in beverage can printing,” Smith said. “As demand grows for more personalised, localised and sustainable packaging, we believe digital DTS will become an increasingly important part of the print landscape.”
The Helio launch, which follows the installation of an $80m multi-size can line at the Dandenong facility completed in 2023, forms part of Orora’s multi-site investment program across Australia, which also includes recent installations of new multi-size can lines at its Revesby (NSW) and Rocklea (QLD) sites. T
For the print industry, the Dandenong deployment signals not just the arrival of new technology – but a shift in how can printing can be approached at scale.
“This is print innovation with purpose,” Smith said. “It’s about quality, speed, sustainability, and giving customers what they need, when they need it.”