HP and Karlville have introduced a complete solution for HP Indigo flexible packaging production. According to both companies, the new launch is set to break the production paradigm with a one-day pouch production process optimized for HP Indigo digital press printing.  

In the first live demonstration at Labelexpo of the HP Indigo Digital Pouch Factory concept, HP Indigo and Karlville showcased stand-up and three-side-seal pouch making, using HP Indigo printing, Pack Ready laminating and slitting, and Karlville pouch-making. Compared to traditional methods, HP based production can be accomplished in a single shift, rather than weeks, enabling converters to profitably produce short run jobs.  

“HP Indigo’s collaboration with Karlville is disrupting the production of flexible pouches, the fastest-growing packaging sector,” says Alon Bar-Shany, general manager, HP Indigo. “We have designed a Digital Pouch Factory model to facilitate simplified, consistent and affordable production, providing converters with high-value business opportunities to deliver faster turnaround and improved sustainability. With experienced business development and technical support teams, we are supporting customers in driving this disruption and helping them to quickly ramp up their digital pouch production.”

At the HP Stand (5C200), driven by HP PrintOS and web-to-pack workflow automation software, print from both the mid-web HP Indigo 20000 digital press and narrow web HP Indigo 6900 digital press are being used to produce pouches using the Karlville Pack Ready Laminator and new Karlville Swiss Stand-up Pouch making machines.

“Karlville has designed a flexible packaging finishing line specifically to work with HP Indigo digital presses to deliver immediate time to market and significantly help reduce the complexity and investment involved. Thermal lamination is by far the most economic business approach for label companies to enter flexible packaging space. Pack Ready offers the opportunity to diversify and change mentality to laminate, slit and pouch in one day,” explains John Price, Karlville president.

The Karlville Pack Ready thermal laminator, optimized for HP Indigo ElectroInks, creates a robust bond strength, allowing for slitting and pouching immediately after lamination. The solution is suitable for a wide range of packaging applications and can comply with the most stringent global food safety regulations.1

The HP Indigo Digital Pouch Factory allows converters to build a profitable flexible packaging enterprise with a pre-established supply chain of materials, enabling them to print, laminate and pack on-demand. The small footprint, reduced waste, minimal setup time with fewer required personnel, all contribute with helping to lower the total cost of ownership, making it a sustainable and economically attractive solution. 

Martin Peroutka, from the Czech Republic, was the first label converting company to establish the HP Indigo Digital Pouch Factory in Europe, while Digital Dogma was the first in the USA. Both are leveraging the turnkey concept to diversify their label businesses and open new opportunities for growth and sustainability with flexible packaging offerings.

At Labelexpo Europe, a 450 x 300mm three-side-seal pouch is being produced on the KS-DSUP-400-GS from rolls printed on the HP Indigo 6900, demonstrating to label converters with narrow web presses how to expand with HP from labels to flexible packaging.The machine can produce three-side-seal pouches from two independent webs and stand-up pouches from three independent webs.