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The Future Path with Hybrid Printing

The concept of hybrid printing, initially introduced in 2017, has quickly transformed the label and flexible packaging industry with new levels of flexibility in combining the best of both digital and analog printing abilities. According to a Markets and Markets report, the global hybrid printing market size was valued at USD 5.5 billion in 2023 and is estimated to reach USD 10.2 billion by 2028.

Especially appealing with hybrid printing was the introduction of a single workflow in jobs that could choose analog (typically flexo), digital, or a combination of both printing technologies with lucrative cost and time savings in a single pass.

Hybrid printing continues to revolutionize the market today. Printers specializing in luxury labels and packaging for niche sectors such as wine, beer, and spirits are embracing the shift to hybrid printing to be at the forefront of technological advancements such as traceability, anti-counterfeiting, and consumer engagemen t that can be integrated cost-effectively with their established processes.

Flexibility meets efficiency

Hybrid printing brings printers unmatched flexibility for customization, rapid prototyping, and varying run lengths with efficiency advantages of streamlined production, reduced waste, and faster time-to-market.

Variable data printing (VDP) capabilities which help printers create unique, personalized labels at high speeds brings flexibility for variable text, barcodes, unique images, and multiple SKUs. Special effects such as cold foil, metallic shades, screen printing, laminating, and varnish is where flexo printing shines.

The sweet spot for hybrid is the flexibility to print jobs with varying run lengths, typically smaller runs for digital and longer for flexo, with medium runs combining both inline finishing of flexo and variable printing with digital.

High quality for shelf appeal

Superior print quality is key for premium labels and flexible packaging in the wine, spirits, and beer sectors. These products need to be wrapped in designs that pop and win attention on the shelf.

Tactile and embossing effects typically provided by flexo printing play a key role in elevating designs, but the inks in digital printing can deliver an impressive gamut and important structural features such as resistance to heat and cold, sunlight, and abrasion.

Hybrid printing and the future path

As industry needs have evolved, Pack-Smart Inc. has risen to the challenge with leading-edge solutions for hybrid printing applications that combine speed, quality, and reliability of flexo with personalization capabilities of digital printing from our in-house designed and manufactured Drop-on-Demand (DOD) inkjet technology.

To protect brands and consumers, integrating advanced security and authentication features into labeling and packaging processes has become essential, especially with the rise in counterfeiting and new regulations.

Pack-Smart Inc. leads the future of hybrid printing with our innovative SJ Series Ink Jets and Delta-X Software applications for unmatched precision, efficiency, and data integrity in the hybrid printing process.

DOD inkjet printing with SJ Series

The Pack-Smart Inc. SJ Series inkjet printers deliver laser-quality and colour precise variable print with a high resolution of 600 DPI to print detailed images, small drop size and high nozzle density head, at speeds up to 325 fpm (99 m/min).

Authentication capabilities such as printing QR codes or holograms which is of growing interest to protect brands of premium wines and spirits are feasible with the SJ Series inkjet printers.

Seamlessly integrated into flexo lines, versatile digital printing is made possible with the SJ Series, capability of handling UV, solvent, water, or oil-based inks for a diverse range of substrate materials, including porous, semi-porous, and non-porous surfaces.

Peace of mind with Delta-X

The integration of Pack-Smart Inc.’s Delta-X global software offers label and packaging printers many benefits including robust real-time tracking, workflow optimization, and comprehensive quality assurance—ensuring the validation of complex data sets from end to end.

Delta-X provides full traceability throughout the supply chain, preventing grey market diversion by identifying unauthorized distribution channels and taking immediate action. Advanced anti-counterfeiting measures are integrated, such as serialized QR codes, microtext, and holograms, ensuring product authenticity and protecting against fraud.

Interactive QR codes fosters consumer engagement with the ability to verify product legitimacy, access detailed information, and interact with the brand in real-time. QR codes also help brands share their sustainability efforts with eco-conscious beverage consumers, and aid in compliance with stringent regulatory standards.

For example, in December 2023, a new EU regulation took effect requiring all wine sold in the EU (including imports) must have labels providing detailed information on ingredients, nutritional values, additives, and allergens, as an effort to enhance transparency and empower consumers. This detailed information can either be listed directly on the label or in the form of a QR code that consumers can scan to look up the required information.

Partner with Pack-Smart Inc.

The integration of personalization, data tracking, and sustainability practices can differentiate businesses in today’s competitive market. We help printers meet diverse and dynamic market demands and be future ready with the flexibility and efficiency of our digital hybrid printing solutions.

Pack-Smart Inc. can assist in accentuating your label and packaging applications with high print quality, customization, and also reinforce brand integrity and consumer engagement with advanced tools in personalization, security, and traceability.

Our in-house engineering and manufacturing teams collaborate with you to design cost-effective cutting-edge hybrid solutions that simplify integration into your existing workflows and help you maintain your leadership position in the market with a broadened application reach.