Export future bright

Demand for gravure printed packaging is very strong in eastern Europe. It accounts for 60 per cent of the market in Russia. However, the long term perspectives are limited, as evidenced by the number of current and planned investments in Russia. A somewhat more difficult situation exists in the Ukraine, as this market's needs are mostly covered by local manufacturers who are comparable or even superior to major Polish manufacturers in terms of output, quality and equipment.

It is the western markets that perhaps offer better opportunities. Reasons are the much lower cost of production within Poland and the comparable quality.

What is needed is increased promotion of Polish exporters and government assistance when participating in international trade fairs, exhibitions and conferences. This is particularly the case with Polish owned companies whose chances of entering western markets are much smaller compared with foreign manufacturers with facilities within Poland.

It is difficult to estimate where flexographic technology is used for packaging in Poland as there are probably around 200 print companies in existence. Some companies have large, modern facilities while others use outdated one to four colour presses. Most use equipment that is out-of-date and are trying to modernize by either supplementing or replacing presses.

Flexo printers can be divided into two main groups - one using wide web 600-1,300mm and the second, much smaller group, using narrow web 200-600mm presses. The central players are the 30 or so companies with large modern facilities that are either part or wholly foreign owned. This group also includes companies that specialize in gravure printing.

It should also be emphasized that printing with UV flexo inks is becoming more important, especially in narrow web facilities of which there are around 15. Several companies have recently invested in the latest wide web (850mm) UV presses. They provide high print quality comparable with gravure, costs comparable to solvent based flexo and gravure technology, and the ability to provide quality not achievable using traditional flexo and not affordable using traditional gravure, due to small print runs.

The rapid development in the production of modern flexo printed packaging was caused by the growing market demand, the willingness shown by manufacturers to modify their capabilities to suit the market, and growing knowledge and experience of printers and owners. There has also been an increased ability to finance investment in new machines. This is due to structural funds made available after Poland's entry into the EU. Polish companies have been purchasing the latest flexo and laminating machines with CNC, gearless drives, sleeve technology, advanced print control systems and eight to 10 printing stations as standard.

The decisive role in gravure printed packaging within Poland is in the hands of around nine facilities equipped with modern machinery producing to a global standard. Some of them, mostly with western capital, have been successful in exporting their products to Western, Central and Eastern Europe.

They produce good quality cylinders mainly using the traditional electromechanical method, but also laser technology. They are able to cover the demand in Poland with about 28,000 cylinders/year produced. A recent change has been a fairly radical drop in the price of engraved cylinders of about 30 per cent over the last two years, which has made them comparable or even competitive price-wise with the high quality format or raster sleeves used in flexo. In addition, the most modern rotogravure machines that have recently been purchased are capable of rapid register colour presetting and automatic colour correction during printing, rapid replacement of printing assemblies and cylinders, as well as precise print quality control. This has all led to lower production costs and improved stability and quality repeatability.

The history of lamination in Poland is short. It began in the 1990s with the introduction of the first gravure machines into the country. Earlier, solvent base lamination was used to a limited degree and extrusion lamination was used in producing PE coated paper. Currently, adhesion lamination is done by all the largest flexo converters and all the gravure facilities.

Forty adhesion laminators are in use, most being solventless adhesive systems and some capable of using two adhesion systems. It is estimated that laminates account for about 20 per cent of all of the printed flexible packaging. More complex laminates such as high barrier are still imported, leaving open a possible niche for their manufacture within Poland.

One of the most significant problems currently facing Polish flexible packaging converters is the application of European Standards on emission of solvents. Since most presses used fail to meet the standard, companies are faced with the need to make the serious investment in equipment such as catalytic incineration systems. If they fail to adapt to the standards, they will find themselves facing stiff fines or be closed down. Most companies lack the financial wherewithal to make the changes and will require government or EU funds.