The integration of production processes is now one of the key drivers for increasing competitiveness in the industrial packaging sector. A representative example of this technological evolution is the recent installation of a Giugni® – Modular™ 1006 flexographic printing press at a leading European plastic film manufacturer.
Transition from roll-to-roll processing to inline printing
The project originated from the customer’s need to optimize the production of tubular polyethylene (PE) film, bubble-extruded and intended for FFS (Form-Fill-Seal) lines used to package pellets and granular products in the chemical and plastics industries.
Previously, the European partner’s workflow consisted of two separate stages: extrusion of the neutral film and a subsequent printing phase on independent roll-to-roll machines. This approach involved logistical costs for reel handling, doubled setup times, and an overall longer lead time.
With the integration of 4-color Modular™ 1006 directly into the extrusion line, the process has been unified. The film, characterized by a significant thickness (approximately 100 microns), is printed and rewound in a single pass, making the finished product immediately ready for the market.
Performance and automation: Modular™ 1006 in operation
Modular™ 1006 has been configured to manage the typical challenges of in-line printing on thick films in conjunction with extrusion, where consistent web tension and automated ink management are critical requirements.
Ink control and “Work & Wash” system
A distinctive technical feature of this installation is the advanced ink management system. The unit is equipped with automatic viscosity control, a key parameter for maintaining color consistency and print quality during long extrusion runs.
The system also manages the automatic cleaning of circuits at the end of production. This level of automation ensures maximum component cleanliness and significantly reduces downtime required for job changeovers.
A reliability path started in 2020
The choice of Modular™ 1006 is not an isolated case, but rather the consolidation of a technical partnership that began in 2020. In that year, the European customer installed its first 2-color Modular™ 978, achieving immediate results in terms of reduced operating costs.
The technical success of this first installation led the customer to reaffirm its trust in Giugni® technology in 2024, adding a new, more powerful and automated 4-color configuration alongside the existing line.
Technical presence and operational startup
The proper commissioning of systems of this complexity requires specific technical expertise and a consistent on-site presence. During the installation and startup phases at the European customer’s facility, our specialists worked to optimize the HMI interface and printing parameters in accordance with the extruder’s specifications.
The successful outcome of this project confirms the effectiveness of Giugni® technology in integrating in-line flexographic printing. The transition from a segmented process to an integrated production flow has enabled the European partner to optimize costs, reduce logistical footprint, and improve responsiveness to market demands.
These technical achievements are the direct result of the expertise and synergy of our team.
Thanks to your work, Giugni® solutions continue to represent Italian technological excellence in the international flexible packaging industry.
Team Giugni®
