Few Australian print businesses can trace their lineage through nearly a century of family craftsmanship and still be investing at the cutting edge. Platypus Print Packaging, led by general manager Aaron Lusch and operations manager Tim Lusch, stands as a rare example. What began under their father Tom Lusch in 1982 as a small trade finishing house in Brisbane has transformed into a high-performance packaging manufacturer built on precision, innovation and adaptability.
Tom’s passing in 2024 marked the close of one chapter in the Platypus story – but the spirit of progress that defined his career continues to shape the company’s trajectory. “Dad was always changing something – new equipment, new technology, new ideas,” Tim recalls. “That mindset is part of who we are. The day you stop evolving in this business, you start falling behind.”
Packaging ambitions
Originally founded as a specialist foiling and embossing finisher, Platypus Graphics (later to be renamed Platypus Print Packaging) expanded into commercial print in the late 1980s, gaining a strong reputation for high-quality work with design agencies and galleries. In 1999, the company made a pivotal move, acquiring McNiven’s Packaging along with all its machinery – the first major step towards building a dedicated packaging division.
Six years later, a major investment in a Roland 700 six-colour press with coater positioned Platypus to grow its packaging business further. At the time, packaging represented only about 10 per cent of its work, but it was a clear signal of where the future lay. “That was when we started to see packaging not just as a sideline, but as a core part of what we do,” says Aaron. “It gave us the quality, speed and versatility to take on higher-value, shelf-ready work.”
As the business expanded, operations spread across seven sites around Brisbane. In 2015, Platypus consolidated all functions into a single 10,000sqm facility in Geebung, centralising production, logistics and management. “Bringing everyone under one roof made a huge difference,” Tim explains. “We gained efficiency, consistency and team cohesion. It set the stage for the next phase of growth.”
That growth came quickly. By 2020, Platypus had become Queensland’s largest folding carton manufacturer, and packaging accounted for more than 90 per cent of its output. Today, folding carton print represents 98 per cent of total revenue, with customers spanning food, beverage, pharmaceutical and health-and-beauty sectors.
“Commercial print will always have a place in our DNA,” says Aaron. “But packaging is our future. It’s a steady, resilient market that rewards efficiency and technical capability.”
Competitive edge
Platypus’s steady investment in high-performance technology has been central to its evolution. The company’s press hall now features some of the most advanced offset packaging systems in Australia. In 2021, Platypus became the first operator in the Asia–Pacific region to adopt Kodak’s cloud-based Prinergy On Demand workflow, delivering integrated automation and live production visibility across prepress, print and finishing.
That same year, Platypus also became the first Australian company to install the new Koenig & Bauer Rapida 106 X press, a move that elevated both productivity and print quality. “It’s fast, reliable and smart,” says Tim. “The automation and real-time feedback have transformed how we manage production – it’s all about throughput and uptime.”
The investment momentum continued in 2022, when Platypus acquired Ovato’s packaging business, expanding its national footprint and customer base. “That acquisition really consolidated our position in the packaging market,” Aaron says. “We became a fully specialised packaging manufacturer, capable of meeting the stringent requirements of food and pharma clients.”
Digitalisation
While offset remains the company’s core process, Platypus is strategically embracing digitalisation. “There’s growing demand for traceability and supply chain data,” Aaron explains. “Brand owners want to know exactly where their packaging materials come from, and we can now trace that right back to the source – down to the specific forest where the fibre originated.”
Tim adds, “Digital print has made big inroads in labels and flexible packaging, but not yet in folding cartons. Offset has traditionally dominated folding carton production in Australia, but both digital and flexo have niche potential and may have growing relevance in the market.”
Sustainability by design
At Platypus, innovation doesn’t only come from machinery. It’s embedded in the design and engineering approach. “We’re constantly looking for ways to use less material without compromising performance,” says Tim. “A recent example is a four-pack beer carton concept that uses less board and fewer resources, yet still delivers strength and shelf impact. We take ideas like that to our customers and show them what’s possible.”
The company’s sustainability credentials are solid. Platypus holds ISO 14001, FSC and PEFC certifications and is a long-time APCO member. “Our sustainability story starts with what we do internally,” says Aaron. “We track and reduce our own waste every year, from pallets and shrink wrap to corrugated shippers. We measure Scope 1 and 2 emissions and will soon report Scope 3 – it’s all part of doing business responsibly.”
Sustainability, he adds, is no longer an optional extra for packaging converters. “Our customers, especially the big FMCG players, have sustainability targets they must meet. We help them by providing accurate data on packaging weight and recyclability. That level of partnership builds long-term trust.”
Culture and continuity
Behind the technology and production capacity is a loyal workforce – many of whom have been with Platypus for decades. “That loyalty says a lot about the culture,” Tim says. “We run a flat structure with open communication – it keeps us nimble and connected.”
With 125 staff, the business maintains a strong focus on training and apprenticeships. “We realised years ago that we can’t rely on the market to provide skilled operators,” Aaron says. “We have to grow our own. Around five per cent of our workforce are apprentices, and we’re building a structured pathway for new talent.”
That people-first approach echoes their father’s values. “Dad believed in investing in people as much as equipment,” Tim reflects. “He always said: the best machines in the world mean nothing if you don’t have the right team running them.”
As the business enters its next phase, the focus is squarely on efficiency, automation and controlled growth. “We’ve experienced rapid expansion in recent years,” Aaron says. “Now the goal is to build on that momentum, refine our processes, and deliver even more value to our customers.”
Acquisition opportunities remain on the radar, but for now, the emphasis is on continuous improvement. Tim says. “We’ll keep investing in new technologies, honing our systems and supporting local manufacturing. That’s what’s kept Platypus strong for four decades – and it’s what will keep us strong for the next one.”
This article was first published in the November-December 2025 edition of Print21, page 18.
