Written by Alexandra Blanck
Content Manager, Esko
When sustainability comes up in packaging conversations, the focus is usually on materials: recyclable substrates, mono-material structures, and the growing use of recycled content.
But these material changes don’t just affect packaging design. They also change how packaging must be printed.
Regulations such as Europe’s Packaging and Packaging Waste Regulation (PPWR) are accelerating the shift toward recyclable mono-material packaging and increased use of post-consumer recycled content.
Yet sustainability discussions rarely address another critical factor: printing technology.
As packaging materials evolve, so do the challenges of printing on them. Recyclable films, thinner structures, and substrates containing post-consumer recycled (PCR) material can behave differently during printing. Surface variability, impurities, and structural differences can affect ink transfer on press.
In other words, sustainability is changing not only what packaging is made from, but also how it must be printed.
These challenges were explored during Esko’s Unboxing Live session, “Sustainable Flexo Printing Without Compromising Gravure Quality”, where Thomas Klein, CTO of Flexo at Esko, discussed how the shift toward recyclable substrates is changing packaging production.
So, what does this mean for converters going forward?
The Packaging Industry is Facing Rapid Change
Converters today are operating in an environment defined by rapid technological advancement, supply chain disruption, and increasing regulatory pressure.
Industry experts note that converters are adapting to these changes while maintaining quality, efficiency, and scalability in their operations.
Nathan Plavnick, Sr. FIQ Specialist at Esko, stated that the industry is navigating multiple shifts simultaneously, from new material requirements to evolving production technologies.
The pace of change has never been faster or more consequential.
These pressures are forcing converters to rethink not only what they print on, but also how they manage production.
Sustainability Regulations Are Changing Packaging Materials
Sustainability regulations around the world are pushing packaging toward designs that are easier to recycle and better aligned with circular economy goals.
Many of these initiatives are driving increased use of mono-material packaging structures and substrates that include post-consumer recycled (PCR) content.
As Thomas Klein explained, these changes are influencing the types of materials converters must work with on press.
All those legislations will bring us a shift to 100% recyclable substrates and substrates containing PCR material.
While these materials support sustainability goals, they also introduce new complexities into the printing process.
Recyclable substrates are often thinner and more stretchable and require greater precision in material handling on the press as well as advanced plate imaging technologies to maintain a sufficient ink transfer.
PCR substrates often contain microscopic impurities and surface inconsistencies from the recycling process, which can disrupt uniform ink transfer on press.
Converters often see inconsistent ink laydown, reduced registration stability, and more variability between print runs when working with PCR materials.
Why Flexo is Well Positioned for Sustainable Packaging
Despite these challenges, flexo printing is increasingly well suited for many sustainable packaging designs.
According to Klein, “Flexo printing capability is very good for all the new recyclable substrates.”
Flexo’s ability to handle thin films and flexible materials makes it particularly well suited for packaging designed for recyclability.
Central impression (CI) flexo presses, for example, help stabilize thin and stretchable substrates during printing, reducing the risk of registration issues.
When paired with modern workflow and plate technologies, it can deliver both efficiency and sustainability benefits.
Historically, however, converters often faced a difficult trade-off.
For many years, gravure printing set the benchmark for premium packaging graphics, particularly when it came to fine detail and tonal reproduction.
Flexo offered advantages in flexibility and substrate compatibility, but matching gravure-level print quality remained a challenge.
As sustainability regulations push converters toward recyclable and PCR substrates, that equation is shifting, and new flexo technologies are helping close the gap.
Innovation Across the Flexo Workflow
The progress being made in flexo printing is not limited to screening technology alone.
Across the flexo workflow, technologies such as UV LED exposure systems are enabling converters to achieve consistent plate production across multiple facilities.
These systems make it possible to reproduce plates with the same characteristics even years after the original job was produced.
Automation is also becoming more important as converters deal with labor shortages and more complex production demands.
Automated workflows and smarter production processes allow teams to maintain quality standards while reducing manual intervention.
Flexo’s Role in Sustainable Packaging Production
As sustainability expectations continue to evolve packaging design decisions, converters must adapt not only to new materials but also to new production realities.
Recyclable substrates and PCR materials are introducing additional complexity into the printing process. At the same time, brands still expect packaging to deliver the same level of visual impact on store shelves.
Meeting both requirements demands printing technologies capable of handling evolving substrates while maintaining consistent graphic quality.
Advances in flexo screening and plate imaging are helping make this possible.
During the session, Klein demonstrated packaging printed on fully recyclable substrates using Esko CDI Quartz technology.
The results showed gravure-like image detail while also improving ink efficiency and supporting high-speed production.
Advanced screening and plate imaging also improve ink transfer control, helping printers maintain smooth gradients and highlight detail on challenging recyclable substrates.
As sustainability continues to influence every aspect of the packaging supply chain, innovations in printing technology will play an important role in helping converters deliver both environmental performance and high-quality graphics.
Curious how converters are tackling these challenges today? Watch the Unboxing Live session: Sustainable Flexo Printing Without Compromising Gravure Quality.
