Established in 1972, Kirk Group, a reprographics company headquartered in Sydney, Australia, works with global brands and major printing companies across the ANZ region and into Asia, supplying graphic services and image carrier solutions for packaging production. Manufacturing sites are located in Sydney, Melbourne, Brisbane, Adelaide and Auckland, and sales offices in Christchurch, New Zealand, and Mumbai, India, all focused on the company’s stated mission “to bring inspiration and innovation to marketers and brands.”

With decades of experience in delivering flexo excellence, Kirk Group understands that close collaboration with technology suppliers and customers is key to success. When long-term customer RollsPack Group challenged the team to find a more cost-effective and sustainable way to print high value flexible packaging, they knew where to turn.

Ben Prout, Group technical manager, says, “Kirk Group has worked with RollsPack for over 20 years, so we appreciate and understand their ambitions, requirements and workflow. For this project, we also drew on the technical expertise and experience of XSYS and Hybrid Software, as well as RollsPack collaborating closely to create a customized solution that not only meets or exceeds the quality of competitors but also offers a more competitive price point.”

To meet RollsPack´s specific criteria, the team carefully considered the combination of plate and specialized screening technologies necessary to achieve the desired outcome. They were able to leverage the versatility of the ThermoFlexX imaging system and Catena+ automated processing line to implement these solutions:

ThermoFlexX Woodpecker Nano – the finest surface micro pattern available for LAMS plates, suitable for platemakers and printers who need high frequency surface screens to increase quality and efficiency while reducing costs.

nyloflex NEF D – a high durometer printing plate for flexible packaging developed by XSYS for the efficient creation of flat-top dots and reproduction of surface screenings with UV LED exposure.

Velvet Screening – a new screening type from Hybrid Software created to meet flexo requirements. As the successor to hybrid XM screening, it uses an advanced dot removal algorithm to reduce harsh edges, leading to smoother and higher-quality prints.

Pushing the boundaries of flexo printing

The nyloflex plates with Velvet Screening and Woodpecker micro surface patterns provided by Kirk Group ticks all the boxes for RollsPack Group, meeting its demands for quality, sustainability and costs. A family-owned company founded in 1985, it specializes in flexible packaging production, including e-commerce, food, retail, and tamper-evident solutions.

“This solution offers a lot of potential. Set up times have been reduced significantly due to precise color profiles, and longevity on press is comparable to other major players on the market,” says print manager Thanh Huynh.

Commenting on the print quality, he adds, “There’s a marked difference in the ink laydown on surface print; it’s one of the best I’ve seen in flexibles. Even when printing colors on a white ink base layer, where we typically experience a drop in density – the results with Woodpecker are impressive. In addition, Velvet Screening holds the dots really well, ensuring that there are minimum hard edges.”  

As well as delivering top quality at great cost, RollsPack is also firmly committed to sustainability, developing environmentally friendly products for its customers. “We are dedicated to elevating the market by supplying innovations that benefit our customers and meet their sustainability goals. We successfully achieved the same high-quality print with water-based inks as with solvent-based inks. This drives a constant need to explore new avenues and Kirk Group plays a fundamental role in this endeavor. Together we are pushing the boundaries of brilliant flexo,” states Thanh Huynh.

Easy implementation in any workflow

In this scenario, advanced screening technology and dedicated plate surface structures simplified the challenging task of controlling the dots and the ink behavior on press. ThermoFlexX Woodpecker and Velvet Screening proved their individual strengths, to deliver a successful outcome for RollsPack. Both software solutions are truly open without any extra steps needed, meaning they can be implemented into any workflow.

Brenton King, Hybrid Software’s sales manager for Australasia, expands on the flexibility of Velvet Screening. He says, “The beauty of Velvet is that the software doesn’t require any proprietary information or special equipment, it just slots into the existing setup. Used at any resolution or ruling, it can be imaged onto the plate of your choice on any CTP device and then processed through your existing exposure frame.”

King adds, “In this collaboration, Kirk Group simply applied Velvet Screening and then added the Woodpecker surface patterns during imaging. It’s a very clever combination.”

Maximizing opportunities and potential

On the hardware side, Kirk Group relies on ThermoFlexX technology from XSYS, including a Catena+ automated plate processing line installed at the Melbourne site in 2021. Kirk’s chief operating officer Robert Selvaggio comments, “The investment in Catena+ has been a great success story for us. We were among the first in the market to realize the potential of this high performance, one-touch technology which tripled our capacity and elevated plate quality.”

Selvaggio reveals the company’s’ future strategy, saying, “We’re now in the process of installing a Catena+ line in Brisbane and a third one is already planned for Sydney.”

Roy Schoettle, VP, XSYS Asia Pacific, comments, “Kirk Group has been reaping the exceptional benefits of Catena+ for a few years, and we have witnessed the innovative solutions it enables, such as this special project for RollsPack Group. We are delighted that this partnership has been so successful and look forward to taking the next steps with the team, as they equip all their manufacturing sites with full Catena+ lines.”

Concludes Selvaggio, “Flexo is still the largest printing technology for packaging, both in terms of volume and value, but we must maximize the market opportunities and the potential of each technology on offer. This is why collaboration is crucial for the future of our industry and for our customers.”