Nilpeter Interview: flexo market trends and technology

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Q: What significant trends do you observe in the Southeast Asian market?

Erik Blankenstein: When examining trends in the region—though I believe we should focus on global trends rather than solely on Asia Pacific—two main developments are currently occurring. We observe a movement toward digital printing, which Nilpeter is not heavily involved in. However, there is another trend that aligns more closely with our space, where other conventional technologies like gravure, letterpress, and offset are significantly shifting toward flexo.

We have probably changed our minds a bit over the past couple of years. We see a distinct difference between digital printing and flexo printing as the primary technologies in the conventional space. Clearly, there is a need and interest in digital print—short runs speak for themselves; it's the best method for that. However, for medium to longer runs, we observe a clear trend indicating that flexo will be the dominant printing technology.

We observe many hybrids and combinations. We don't shy away from this—we have solutions for customers with these needs. However, considering how Nilpeter positions itself and our beliefs, flexo will hold a leading role in printing technology over the next decade, and we aspire to be among the front-runners in highly automated flexo printing.

This trend aligns well with our observations: letterpress is transitioning to flexo, and gravure is also shifting to flexo. We are witnessing a movement from wide web gravure to mid-web flexo due to the decreasing run lengths on these gravure presses. They have significant setup times and generate considerable waste. Environmental concerns, often driven by government regulations, compel companies to adopt more sustainable practices. Flexo naturally emerges as a viable solution. Thus, these clear trends present an intriguing opportunity for a company like Nilpeter.

Q: From the perspective of converters currently using letterpress and gravure, what do you believe is the biggest growth opportunity when considering a shift to flexo?

Erik Blankenstein: If they have a flexo press on the floor, they can replace several letterpress machines. Initially, you'll consider productivity and production speed, but also the flexibility to run multiple jobs within a day or particular shift.

Certainly, they need to acquire some knowledge. We have several customers in the region who purchased their first flexo press from us, transitioning from letterpress. We must not only sell the machine; we must also help them understand what flexo printing involves. It's not just about the machine; there are additional aspects that need to be addressed. Our application and technical teams handle that very well.

This distinguishes us slightly from those who place less emphasis on this support. The disparities in operating speed and job configuration are clear - it's a completely different game.

Q: Flexo has experienced significant changes over the past five years, with almost everything now automated. Can you describe the advanced automation features in the FA 17 press that you will be showcasing in Bangkok, and explain how they contribute to cost savings for customers?

Erik Blankenstein: The latest model of the FA was released in 2024. While there are some differences in appearance and feel, it primarily involved fine-tuning the automation features. We made a significant leap several years ago—about five years ago, as you mentioned—achieving major advancements in automation.

This has made the FA line impactful in the market since around 2017, when we launched the new FA line at Labelexpo Europe in Brussels. Today, the press is even more automated, although there's nothing revolutionary about our methods. We have registration systems, web guidance, temperature control, and web tension control—all these features have been enhanced with each new model.

The FA is our flagship machine, representing our top model. It includes all the latest automation features that minimize setup time and waste. While everyone is advancing in automated flexo, at Nilpeter, it aligns with our philosophy of looking toward a future where even more automation will be introduced. This implies even less human interference.

The role of a printer is becoming increasingly easier. In five years, the operator will primarily observe what's happening, much like a pilot in an airplane. You want the pilot present, but they may only actively fly a little while the rest is automated. The operator will be available to take control, check, and stop the machine when something goes wrong. However, their job is evolving—perhaps they will supervise multiple machines, all linked to the existing workflow. Automation is sure to play a significant role in the printing industry over the next decade.

Martin Teilberg: I completely agree with Erik. The increase in automation and digitalization of our presses is integral to the overall Nilpeter philosophy, rooted in our vision that 'the future is flexo.' We continually push the boundaries of automation and digitalization.

When we discuss an operator potentially overseeing multiple presses, we're progressing towards a 'dark room' philosophy, where one press operator could manage perhaps 10 presses at once. That's the ultimate goal. We haven't reached that point yet, but it's what we're striving for. This approach would also help address the challenge of finding a skilled workforce in the industry.

Q: The ease of use has become a major selling point. In terms of your support in the region, what do you offer to help machine operators maximize their efficiency?

Erik Blankenstein: We provide training. If you're a Nilpeter Asia Pacific customer, a significant service component is included when purchasing the machine. We're not offering the cheapest machinery; we're providing high-quality equipment with all the features you'd expect from a premium-priced product.

Our service is crucial. We have a large service department here, and we ensure everything functions properly. It doesn't end with installing the press and training the staff to operate it. We also prioritize application training. We have dedicated personnel for application support, so whatever requests or questions customers have—perhaps for a new project—we'll fly out to assist them. This is part of the territory with the press sale.

Our team helps optimize their projects, which is crucial for return on investment. Customers may pay more for our machines, but they understand the value of their spending. It pays off later when they learn to optimize their machinery, generate revenue, and take on new jobs and projects they might not have pursued before—potentially projects with much higher margins.

This is part of our discussions with customers and partners to ensure these relationships thrive. This approach isn't limited to Asia; it's how Nilpeter operates globally. Training and maintenance are crucial aspects of our work across all regions.

Q: You mentioned sustainability earlier. Can you elaborate on how the FA 17 press can help reduce the carbon footprint, particularly for converters transitioning from gravure or letterpress to flexo?

Martin Teilberg: The FA 17 is a fully automated press that accelerates job setup. It reduces both press running time and waste during setup, enhancing efficiency. The press adapts to various materials and substrates, continually improving processes. These advantages are not unique to Nilpeter presses; they are general benefits that come with modern presses.

Erik Blankenstein: When discussing sustainability, you immediately consider inks, substrates, recycling, and more environmentally friendly materials. You also consider energy savings, such as the UV lamps you use—there's a significant shift towards LED technology. Like that of other manufacturers, our machinery acts more like a carrier—we enable the implementation of sustainability-focused products or alternatives. Specifically looking at Nilpeter, having a highly automated flexo press reduces your setup times and waste, contributing to sustainability.

Another aspect is the lifespan of our machinery. When you purchase a Nilpeter press, you're investing in a machine that will remain on your floor for 20 to 25 years without problems. We sell second-hand machinery that's over 20 years old to customers who are just starting out, and those machines operate smoothly. It's like buying a car that retains good value even after 200,000 miles. This durability is also a part of sustainability.

We can also discuss in-line finishing. Many customers still use gravure or other technologies that require two or even three processes to produce a finished label. With flexo technology, you can achieve much in-line and obtain an almost finished or fully finished product at the end of the machine. This is another advantage, as it makes other processes unnecessary and contributes to sustainability by requiring less equipment to complete the job.

Automation plays a crucial role in sustainability, alongside advancements in materials, inks, and other areas that collectively facilitate a truly sustainable concept. We certainly do our part.

Q: What are Nilpeter's main goals for attending Labelexpo in Bangkok? Is there a particular message or proposition you wish to share with attendees?

Martin Teilberg: For many years, Nilpeter has played a significant role in the development of flexo printing within the industry. About three or four years ago, we made a conscious decision to emphasize that flexo is Nilpeter's core business. This isn't a reaction to digital trends in the industry; rather, it has been essential for us to communicate clearly that flexo is our main focus.

We want to be very clear about this wherever we go, so that no one is uncertain about what our core business is. We communicated this message at Labelexpo Americas last year, in Brussels two years ago, and in Mexico just last month. This will also be our message at Labelexpo in Bangkok, addressing all the topics Erik mentioned: automation, sustainability, digitalization, return on investment, and production efficiency.

Showcasing our flexo flagship, the FA line, effectively communicates Nilpeter's position in the market. This is our primary goal, and naturally, we also aim to sell some presses. We want to demonstrate to our partners and customers that we play a vital role in the market. Our message is that we stand as market leaders, we are strong, and we are here to support you.

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