For Melbourne-based Filton Packaging, print quality is no longer simply about achieving an acceptable result – it is about consistency, precision and repeatability across every production run.
That thinking is behind the company’s latest investment cycle, centred on the installation of an eight-colour Bobst flexographic press and supporting upgrades across pre-press, plate mounting, inspection and wash-up systems.
According to co-founder Ryan Worthington, customer expectations around print have shifted dramatically in recent years.
“The old term of ‘commercially acceptable’ – not anymore,” he said. “It has to be perfect. You have to supply your customer with perfect product every time.”
The investment reflects broader advances in flexographic technology, with Filton using new plate systems and automation to pursue higher-quality work while maintaining the operational consistency required by food packaging customers.
Operations manager Zoran Josic said the gap between flexo and gravure has narrowed significantly.
“Flexo has made very large steps,” he said. “We are very competitive with gravure now – in some cases, better, smoother, quicker.”
Filton is working with Esko Quartz plate technology through its pre-press partner, enabling finer dot reproduction and improved ink transfer.
“We are actually printing pretty much photo images,” Josic said.
Importantly, the improved print performance is also reducing consumables use.
“It’s actually less ink than before… stronger colour, but less ink being laid down,” he said.
The new press is also delivering production efficiencies. Automated plate mounting and microchipped sleeves allow faster registration, while integrated inspection systems monitor the web during production.
“The difference in setup efficiency has been substantial,” Worthington said. “What was once a major source of waste is now tightly controlled.”
Colour consistency is managed through digital measurement systems, helping maintain output quality across long operating hours. Filton currently runs 24/5 with around 45 employees and maintains lead times of approximately five weeks.
“That consistency is really important,” Worthington said. “Customers can plan around it.”
While the investment expands Filton’s print capability, the business remains closely tied to fresh produce and bakery packaging.
Its converting operation includes wicket bags, side-seal bags, contour sleeves and films, particularly for applications where airflow and shelf life are critical.
In contour sleeves for herbs and flowers, Filton has built a strong position in the Australian market.
“Many of the herb and hydroponic products you see on shelves rely on this style of packaging,” Worthington said, “and it’s an area where we’ve built deep experience.”
The company is also seeing increased interest from customers reassessing offshore sourcing arrangements amid continuing supply chain uncertainty.
“We’re already starting to receive enquiries from customers who have previously been sourcing offshore,” Worthington said.
Josic said local manufacturing support is becoming increasingly valuable as conditions remain volatile.
“As conditions change, customers quickly see the value of having local manufacturing support they can rely on,” he said.
Raw material pressures continue to affect polyethylene and polypropylene supply, but Filton said it is working collaboratively with customers to manage costs through specification reviews and material optimisation rather than simply passing increases through.
Further investment is already being considered, particularly around perforation capability and shelf-life enhancement technologies.
For Filton, the strategy is not rapid expansion, but measured capability growth – extending its print and converting expertise into more demanding applications while maintaining the service reliability on which its business has been built.
This article was first published in the May-June 2026 edition of Print21, page 14.