As part of its development work on more sustainable printing technology, film manufacturer Sudpack has made a deliberate decision to put its focus on a standardised seven-colour (7C) flexo print process.
The company believes 7C will take package printing to a new level by delivering a wide range of benefits, including brilliant colour reproduction, maximum colour consistency, greater efficiency, and stable processes; but above all, in terms of sustainability, reduced ink and film waste, lower solvent and energy consumption, less downtime, and fewer print adjustments.
As a first step, the 7C flexo print process expands the familiar CMYK colour palette (cyan, magenta, yellow, black) to include OGV (orange, green, violet), while largely moving away from Pantone and special-effect colours.
More than 85 per cent of these colours can be automatically reproduced within the expanded colour space, with colour accuracy ensured through binding references and proofs with precise Pantone simulation.
At industrial scale, however, the 7C flexo print method also requires rigorous process discipline and strict adherence to defined workflows with firmly established parameters to ensure stable, efficient, and reproducible production.
Sudpack successfully initiated this shift with the introduction of SPQ (Sustainable Print Quality) in 2019 – and has since demonstrated the process’ many advantages across numerous customer projects.
A disciplined, system-driven approach to sustainability
With SPQ, all designs are reproduced at the pre-press stage using a standardised colour palette limited to just seven colours.
Consistent colour management and the implementation of end-to-end process stability is the essential foundation for optimising efficiency, sustainability, and quality. According to Sudpack, both factors proved to be the greatest challenge – and ultimately the greatest achievement – during the development project.
This underlines the fact that 7C is not created at the printing machine, but much earlier in the upstream process.
In terms of sustainability, Sudpack’s flexo print technology is setting new standards. In essence, the company said that limiting the process to the 7C scale significantly reduced changeover time and effort, as well as ink and solvent consumption.
Alongside lower film waste, these factors have a direct impact on the carbon footprint of printed packaging films. According to a certified LCA, SPQ can reduce CO2 emissions by up to 18 per cent overall in comparison to conventional flexo print methods.
SPQ’s standardised processes, in turn, result in faster adjustments, more stable repeat orders, and tighter tolerances. In short, the real driver of sustainability is not the additional colour set, but lower process variability.
Consistent quality, creative freedom, sustainable choices
Compared with the conventional flexo print process, 7C can deliver even higher standards with regard to quality and consistency.
Print quality remains consistent across print runs, plants, and countries. In addition, almost all existing print images can be converted from standard flexo to 7C flexo print.
“We take care of everything else,” said Achim Herter, senior director competence centre converting at Sudpack “The only exception is that, when relaunching a product or creating a new print design, it absolutely makes sense to involve us from the very beginning – to achieve the best results, avoid unnecessary revision cycles, and, not least, shorten time-to-market.”
Additional benefits for customers include the fact that they no longer need to be on-site for print approvals.
The 7C-based approach also allows multiple packaging variants and short runs to be produced far more flexibly – and significantly more sustainably – than with the conventional flexo print process.
And when it comes to creativity and design freedom, the company said there are virtually no limits, as the SPQ spectrum covers everything from clean, minimalist, and large-area print images to CI-sensitive artwork and colour-intensive, complex layouts.
“Interest in 7C printing is enormous, but making the switch is not easy when design expectations, production realities, and sustainability pressures all have to be balanced. Even if it means stepping out of your comfort zone at first, switching to 7C is absolutely worth it,” Herter concluded.