Flexible Packaging Flexible Packaging Equipment

Vitrapack Boosts Print Efficiency with BOBST EXPERT CI Flexo Press

To keep pace with rising demand and customer expectations, Vitrapack has strengthened its capabilities with the addition of a BOBST EXPERT CI flexo press. The investment not only boosts capacity, but also enhances flexibility and sustainability, enabling the Belgian packaging producer to handle even shorter lead times, adapt to a wider range of job requirements and maintain consistent print quality, while keeping waste levels low.

Operating from a 17,000 m² facility, of which 14,500 m² is covered, Vitrapack employs a team of 100 employees, and reported an annual turnover of €32 million in 2024. Vitrapack has a long history in printing, with flexo dating back to 1952 and rotogravure since 1965. It supplies major global brands in the food sector, as well as part of the non-food market, serving customers in Belgium, the Netherlands and France.

Vitrapack’s partnership with BOBST stretches over nearly 20 years, during which time the packaging specialist has leveraged BOBST technologies to great advantage, notably the many automation and waste saving features. BOBST was also chosen for its strong technical support, which has proven invaluable throughout the years. The philosophy of Jan Laeremans – Co-owner and Delegated Administrator at Vitrapack – to carry out as much preparation as possible outside of machine production time was followed when the first BOBST 8-color CI flexo press with smartGPS system was purchased in 2009. With this fully automatic smartGPS system for registration and impression settings, productivity increased significantly since these processes were performed offline. It also minimized substrate and consumable waste during start-ups and job changes. A substantial investment program in 2017 resulted in the installation of two 10-color 20SIX CI flexo presses with a web width of 1050 mm, complemented by a CL850 laminator. Both flexo presses were also equipped with the smartGPS system.

The positive experience with smartGPS technology was one of the core reasons why Vitrapack again chose BOBST for its next flexo project. This time, the choice fell on the 10-color EXPERT CI, a press designed for process consistency and exceptional productivity. With a web width of 1300 mm and a higher print speed, output has increased significantly.

“smartGPS technology truly sets BOBST apart from the competition. It delivers the high quality our customers demand with much less unwanted downtime in production. Our first BOBST press in 2009 and the two 20SIX presses have performed exceptionally well, so we had no hesitation in choosing another BOBST press, but we needed a wider specification,” said Laeremans. “The new EXPERT CI has a capacity that is around 25% higher.”

Strategic collaboration and color innovation driving Zero Waste

Vitrapack’s recent investment in the BOBST EXPERT CI flexo press was not just about upgrading equipment; it marked further important steps to address macro trends such as sustainability and customization, while at the same time optimizing print quality. Vitrapack, Rask (the pre-press and repro sister company of Vitrapack) and Co-ëfficiënt have together, thanks to their complementary expertise, laid the foundation for the standardization of flexo printing. Today, Co-ëfficiënt continues this as a BOBST solution partner, providing data-driven consulting services to optimize production and reduce waste.

“Thanks to Co-ëfficiënt’s expertise and support, we achieved a very high improvement in OEE and a substantial reduction in the press time and waste required for ink and color adjustments. As a result, we also use much less ink and generate significantly lower volumes of residual ink,” said Laeremans. “Their expertise is crucial in refining our color matching processes to ensure precision and consistency with minimal waste.”

The focus on color accuracy and process control supports Vitrapack’s broader zero-waste ambitions. With advanced automation and smartGPS technology on all BOBST presses, job changeovers can now be completed faster than ever with minimal substrate waste - delivering both environmental and economic benefits.

Achieving long-term goals with BOBST

The new EXPERT CI now runs alongside the two older BOBST presses at Vitrapack with further increased speed and enhanced print quality. The press is equipped with Full Surface Matrix intercolor drying, which prevents substrate stretching and significantly boosts productivity.

Equipped with the AV 3.0 smartGPS system, the new EXPERT CI flexo press shortens setup time and reduces material waste, streamlining operations and minimizing environmental impact. In addition to strengthening process sustainability, this investment has significantly increased productivity, allowing Vitrapack to continue growing while delivering reliable, high-quality results.

The collaboration with Co-ëfficiënt has further amplified these benefits. By applying data-driven insights and process optimization strategies, Vitrapack has achieved substantial cost reductions and environmental improvements, including a notable decrease in CO₂ emissions. This partnership exemplifies how targeted consulting can unlock the full potential of advanced equipment and support long-term strategic goals.

Vitrapack has no plans to rest on its laurels; it is already preparing to replace one of its older flexo presses with a new BOBST machine. This decision reflects both the operational advantages demonstrated by the recently installed EXPERT CI and the team’s confidence in its performance and reliability, as well as its continued faith in the partnership with BOBST.

“Vitrapack immediately experienced a strong impact from the installation of the BOBST EXPERT CI, with a solid increase in volume and a significant reduction in time and waste,” commented Marco Carrara. “But beyond equipment efficiency, it is the close partnership between our two companies that is driving innovation, supporting Vitrapack to develop the solutions it needs to meet customer demands and achieve its long-term goals.”