Customer Magazine Plastic Tubes 16 / 2017
Is there change on the horizon in the 3 global tube market? FASHION STYLING RDA 24-300: The ultra-high-speed, 300 tubes 4 per minute printing and lacquering machine A milestone in the history of tube printing: 5 The ultra offset printing process on the Linearis Print Inspection System DeCoSystem 6 Variable data a powerful brand promotion tool 7 Announcement: Get involved at 8 //polytype s «Innovation Days 2018» //polytype worldwide 9
Is there change on the horizon in the global tube market? For many years, the use of tubes as packaging has been on the rise. A study by MARKETSANDMARKETS predicts that the global tube market is set to grow by 40% by 2021 (from US$ 6.65 billion in 2016 to US$ 9.3 billion in 2021). FASHION STYLING To complete the picture, it is interesting to take a closer look at the major plastic tube manufacturers, within the framework of an ABC analysis. This analysis shows that a small number of tube manufacturers produce just under half of all of the tubes manufactured worldwide. Small manufacturers, who are responsible for a certain proportion of national tube production in China in particular, were not taken into account. In Europe and America in particular, the tube manufacturing landscape tends to be relatively stable. However, in other parts of the world, there are signs that new players are entering the market. It s worth taking a closer look at the data. Or more specifically: What does this mean for the plastic tube as a packaging solution? According to etma (the European Tube Manufacturers Association), approximately 14 billion tubes were produced TUBE PRODUCTION IN BILLLION/JAHR 12 10 8 6 4 2 Worldwide Plastic Tube Production 0 0 50 100 150 200 PLASTIC TUBE PRODUCER in Europe in 2016 (by etma members and non-members), of which 90%, or 12.5 billion, remained in Europe. Of these tubes, 3.3 billion were made from plastic. Aluminum tubes and laminate tubes each accounted for 4.6 billion. If we compare the figures from 2015 with those from 2016, it is clear that the use of both laminate tubes and plastic tubes grew over this period. We also know that just over 1/3 of all tubes worldwide end up being used in Europe (see MARKET- SANDMARKETS). From this data, we can conclude that global tube production will rise to around 38 billion tubes per year, with the market shares of each tube type remaining the same. Based on these figures, worldwide production of plastic tubes can be estimated at around 10 billion tubes per year. Global aluminum, laminate & plas1c tubes market ~38 bn/year Plas1c tubes Worldwide ~10 bn In conclusion, it is clear that there is further potential for growth in demand for plastic tubes. Irrespective of the market trends, a fundamental objective of //polytype is to promote and position the plastic tube as a preferred packaging solution above other types of tubes and the plastic bottle. 3
RDA 24-300: The ultra-high-speed, 300 tubes per minute printing and lacquering machine The RDA 24-300 by //polytype an ultra-high-speed dry offset printing and lacquering machine designed specifically for use with small tubes, prints and lacquers up to 300 plastic tubes per minute. To achieve this outstanding production rate, //polytype has produced a new machine concept that places multiple tubes on the spindle and removes them again during each individual cycle. When designing this machine, //polytype drew on its experience with cup printing machines (which now achieve speeds of 700 cups per minute as standard). The RDA 24-300 utilizes the familiar process sequence used on standard dry offset printing machines. After loading, pre treating and printing tubes with up to eight colors at a speed of 300 units per minute, the UV ink is cured and UV lacquer is applied. The tubes are transferred using a specially developed transfer mechanism, which removes the tubes from the spindle and places them in a vertical position on the chain pins. This method ensures that the tubes, some of which are very short, do not fall off the chain pins on their way to the UV lacquer drying oven. This machine was designed for maximum reliability, productivity and process stability. This results in a unique solution that represents yet another milestone in direct tube decoration for //polytype. RDA 24-300 machine specifications: Min./max. Ø: 10.0 25.0 mm Shell length: 25 110 mm Max. print area: 110 mm Max. speed: 300/min. The concept for the RDA 24-300 is based on the same principles as those applied by all other //polytype machines: Excellent access to process stations Excellent access to inking units (can be swung out individually) and plate cylinders Advanced lacquering system for optimum results Fast and simple size changes (size parts and printing unit) Exceptional reliability, even after years of service in production Logical operating console concept, simple and clear design Easy maintenance 4
A milestone in the history of tube printing: The ultra offset printing process on the Linearis In recent years, the Linearis has impressed the industry with its outstanding print quality; with its wide range of printing options, the Linearis sets the benchmark in direct tube decoration. Even considering of its excellent performance, the market was keen to find out whether this technology could be improved even further. In its search for the answer, //polytype launched a comprehensive program of research and development. The result was a resounding "YES" there is still potential to enhance the machine. The answer came in the form of an integrated offset station. In combination with dry tap process printing (print dry print), the new solution further boosts print quality and the new ultra offset printing process for tubes was born. The reasons behind the increase in quality with ultra offset printing are clear: Offset printing is known to be associated with significantly lower levels of dot gain than flexographic printing. This boosts color stability in multi-colored printing, and serves to sharpen up the edges of images by reducing the halo effect. The new solution also overcomes another limitation associated with flexographic printing the ability to deploy rainbow printing. A separating wedge can be used to achieve color transitions ranging from 100% to 0%. The advantages of this new approach are not limited to print quality. As the system uses offset printing plates, which enjoy a significantly longer service life than flexographic printing plates, the new solution boasts greater longevity too. With this technology, //polytype has reached a new milestone in the printing quality that can be achieved on directly decorated plastic tubes. Don't hesitate to contact us to find out more about the vast multitude of options offered by the Linearis machine. Email us at: info@ polytype.com with the words "Ultra offset printing process" in the subject line. 5
Print Inspection System DeCoSystem The production of high quality tubes is a target, which is on the top of the list of every tube and can producer. The printing appearance itself determines in large part the perceived value of the tube and even its contents. This means, that in addition to excellent printing equipment, a vision control system is highly recommended to enssure that the goal of high quality printing / decorating is fulfilled. DeCoSystem develops and manufactures highly specialized print inspection systems, which can be easily integrated into various industrial applications like printing machines for plastic tubes and cans. One other feature is the optional software module SCANDIFF. This software helps to identify problems before printing the entire production job. This includes during the processing in the prepress department, setup of the printing machine and problems on the printing plate cylinders. Today, DeCoSystems is well known on the market. The Hybrid machines or the Linearis machines from //polytype are equipped with the SPECTOR System from DeCoSystem. At DeCoSystems you not only get an excellent vision control system but also worldwide service. If you would like to know more about DeCoSystems and the benefits for your tube production, please do not hesitate to contact us: info@decosystem.com The print inspection system SPECTOR is equipped with a 4K RGB-camera with a resolution of 0.05 mm. Only real errors like splotches, scratches, color lacks, wipes, color variations, material defects and mis-registrations are detected. Each of these printing errors can be provided with a separate test tolerance during the setup process of a new job. And the best is, a setup process for a new job only takes a maximum of 2 minutes for the operator. 6
Variable data a powerful brand promotion tool Unlike traditional printing technologies, digital printing offers, the flexibility to print a different graphic on each package. This offers many benefits, such as minimal pre-press and change-over costs but it also opens new horizons to use dynamic variable data management. In practice, it requires powerful and sophisticated algorithms, as well as clever design and print management systems that //polytype can now offer. One concrete use of variable data is to individualize designs to address even minute market segments, from sports events, to concerts and down to the individual consumers. Large drink and food brands have already used this very effectively in raising consumer awareness and interest for their products, leading to increased sales. Another application for variable data that is proving extremely effective is to create interactive one-to-one communication between brand owners and consumers. By asking the consumer to scan a unique QR code on the package with his smart phone, it will trigger communication with a dedicated website which will communicate a message to the consumer, for example whether he won a lottery prize. Other applications can be for example to offer a one hour free consumption of a drink within a sports event for each purchased cup. By recording at purchase point the unique QR code printed on the cup, the drink dispenser would monitor the time elapsed between the purchase and the later attempts to re-fill the cup. One could also use the same mechanism to allow a customer to claim for example a 10% discount on its next purchase of a cosmetic packaged in a tube or tub. To make this possible, the management of variable data needs to be powerful and reliable in particular from the creation to the printing stage. //polytype, through its sister company WIFAG-Polytype Technologies SA, department Digital Printing is now enabling its digital printing systems to manage such complexity. This also contributes to giving cosmetic tubes and plastic cups a flavor of high tech and trendy packaging for the benefit of its customers and the brand owners. 7
Announcement: Get involved at //polytype s «Innovation Days 2018» In autumn 2018, //polytype is opening its doors to showcase its trend-setting plastic tube decorations and achievements in tube finishing to an interested audience. At this early stage, we are already preparing this special event with the aim of showing you an abundance of innovations. What are the next steps? //polytype is working flat out to make this event happen. The scope and date of this event should be determined within the first half of next year. On this basis, an invitation will be sent to all tube producers before summer 2018. 8
//polytype worldwide Polytype America Corp. Mahwah / USA WIFAG-Polytype Holding AG Fribourg / Switzerland WIFAG-Polytype Technologies AG Fribourg / Switzerland Polytype AG Fribourg / Switzerland Mechatronica AG Gabrovo / Bulgaria 49,8% Shareholding OMV Machinery S.r.l. Parona-Verona / Italy Chachoengsao / Thailand Wifag-Polytype India Marketing Private Ltd. New Delhi / India 9
Polytype AG 26, route de la Glâne CH-1701 Fribourg/Switzerland Phone+41 26 426 11 11 Fax +41 26 426 11 12 info@polytype.com www.polytype.com SWITZERLAND WIFAG-Polytype Holding AG Fribourg/Switzerland WIFAG-Polytype Technologies AG Fribourg/Switzerland Polytype AG Fribourg/Switzerland ITALY OMV MACHINERY S.R.L Parona-Verona/Italy BULGARIA Mechatronica AG Gabrovo/Bulgaria ASIA Wifag-Polytype India Marketing Private Ltd. New Delhi/India Polytype Asia Pacific Co., Ltd. Chachoengsao/Thailand AMERICA Polytype America Corp. Mahwah, NJ/USA