Innovations

Flexowrap

A new partnership between Flexowrap and National Flexible is making major packaging reduction targets achievable for brand owners and manufacturers with the launch of the world's first in-line automated ultrasonic film sleeve technology for the ready meal market.

The patented system substitutes a traditional cardboard sleeve for a low-cost, lightweight film equivalent and is set to change the face of ready meal packaging by cutting costs, reducing packaging weight and minimising waste.

Suitable for use on a wide variety of trays, the film sleeves are durable and offer improved aesthetics, with high quality flexographic or gravure print options to create eye-catching shelf-appeal.

• 90% lighter than cardboard sleeves
• 3x lower carbon footprint
• Savings on transport/logistics costs
• Savings on energy costs
• Up to 15x less storage space required
• Savings on waste taxes
• 100% recyclable

Kodak Flexcel NX - gravure quality flexo

National Flexible have become the very first in the UK packaging industry to take advantage of a ground breaking advance in printing technology for Dr. Organic's range of soap bars. Three flow-wrap designs were printed using Kodak's innovative Flexcel NX technology which, when used alongside their Digicap screening process, enhances the quality of image reproduction to such an extent that it allows flexo plates to reproduce detail to the same standard as that of gravure cylinders.

Dr Organics' highly detailed packaging artwork required the very best quality print to ensure that their flow-wrap packs had strong stand-out shelf appeal, as well as matching exactly to the existing colour palette of other packaging formats in the range.

National Flexible worked on the project in conjunction with partners Kodak and Reproflex3.

Chalk-based film for thermoforming

National Flexible has introduced a new generation of sustainable films which are set to open up a whole new avenue for the food packaging industry. Chalk-based films are an environmentally friendly, sustainable alternative to conventional oil polymer based films.

Already in use in a number of commercial applications in the UK it is being hailed as a major breakthrough in the industry. The materials strengths are in its composition which is based on calcium carbonate (common chalk) which is found in abundance worldwide. The co-extruded film can be tailored to any food-related application in terms of moisture, oxygen and light barriers.

It can be used as a laminate replacement for flow-wrap, form-fill-seal or thermoform applications. As a mono-layer material it eliminates problems associated with conventional laminates, its unique surface is ideal for printing and it will run on existing packaging machinery without modification.

First oxy-degradable laminate film

A well-known supplier of foods for the natural and organic market has been able to re-launch their pre-packed product lines in a brand new 'greener' packaging material thanks to the help of National Flexible's technical team. SuperEco film has all the same characteristics as standard films but with the added advantage of being able to break down into water, C02 and organic biomass after disposal - effectively addressing the problem of plastic packaging waste lying inert in landfill or as litter in the streets.

This is the first time that SuperEco has been used in a laminate application. A specialist blend of the film was used to give the pack a sturdy sealing layer capable of holding products as varied as nuts, beans, lentils, dried fruit, rice, etc.