Folding cartons come to Labelexpo Europe

Labelexpo Europe 2025, to be held in Barcelona from September 16-19, will now include folding carton technology alongside labels and flexible packaging.

This looks like a big change for the show, but it is, in fact, more of a natural evolution based on in-line and digital technologies that look to disrupt the traditional folding carton industry in much the same way they did with flexible packaging.

Throughout its history, Labelexpo has constantly adapted to new package printing technologies. The early Labelexpo shows, starting in 1980 in Brussels, focused on new technology for self-adhesive labels converted in-line on narrow web presses.

As labels expanded into new formats, such as shrink sleeves, wraparound and in-mold labels, Labelexpo adapted to showcase these technologies.

The next major evolution for Labelexpo was the addition of flexible packaging, which happened around a decade ago with the launch of the 30in wide HP Indigo 20000 digital press.

Flexo press manufacturers developed wider ‘mid-web’ presses in the 26-30in (670-800mm) range, better adapted to handling these larger packaging formats.

Label converters who diversified into flexible packaging — typically stand-up pouches —found this opened up new market opportunities, strengthening their label businesses.

We are now seeing a similar convergence of print technologies between labels and folding cartons, which has the potential to open up new markets for label converters and other market disruptors.

Converging technologies

Today, folding cartons are overwhelmingly printed sheet-fed offset, followed by creasing and die-cutting, hot stamping and embossing. These multiple process steps add lead time and create a lot of work-in-progress (WIP) as pallets are moved between workstations.

“We are now seeing a similar convergence of print technologies between labels and folding cartons with the potential to open up new markets for label converters and other market disruptors”

Core Labelexpo technologies — in-line flexo, rotary offset, digital and hybrid — could revolutionize this traditional workflow.

In-line flexo, rotary offset and hybrid presses allow the processing of folding cartons in a single pass from printing and coating to cut-crease and sheeting, eliminating the work-in-progress associated with a sheet-fed offset workflow.

Of course, additional process steps can be added in-line, such as screen printing, foiling, embossing and VDP/numbering. The finished cartons are immediately ready for shipping or further processing on folder-gluer machinery.

This workflow will be demonstrated at Labelexpo Europe 2025 by Edale, now owned by Canon. The company will bring an FL5 Carton Production Line to the show, featuring in-line semi-rotary flatbed die-cutting.

In other carton-related developments, Tec-ni-Fold launches an in-line creasing module for in-line presses, and Rotatek shows a print station from its Universal 850 rotary offset press, which is specified for folding cartons.

There is also a wide range of existing exhibitors like Bobst, Omet, Sappi and more, who also supply to the folding carton market.

Digital and hybrid

Digital printing has enormous potential for short-run and personalized folding carton production. In 2013, HP Indigo demonstrated a folding carton line built around a Tresu coater and a 30000 digital press (today the 35k), with partner Kama demonstrating half-size die-cut/creasing and Highcon demonstrating laser converting.

Recently, HP announced the sale of an HP Indigo 35k digital press to label converter Altro Industries in Canada. The company can now sell PS and shrink sleeve labels, folding cartons and packaging tapes.

Interesting developments have also been made in water-based inkjet for folding cartons. Mark Andy’s executive vice president, Tom Cavalco, says the company is actively considering how to apply its hybrid UV inkjet platform to the folding carton market.

Labelexpo could speed the adoption of digital printing in the folding carton market, just as it did for labels and flexible packaging.

The addition of folding cartons to Labelexpo is also likely to galvanize developments in short-run converting systems and digital embellishment. For example, Prati showed during an open house event in 2022 a Digifast20000 carton converting line that allowed users of HP Indigo’s 20000/25k press to switch between flexible packaging and folding carton production on the same finishing machine. The Digifast20000 was fitted with a dual UV/hot air drying flexo coating station to handle UV or water-based coatings for the food industry.

We should also not forget that, by far, the biggest volumes of wet glue labels and in-mold labels are printed on sheet-fed offset presses. One result of bringing folding cartons into Labelexpo will be an increased focus on the high levels of automation on these presses and new in-line coating and foiling systems on sheet-fed offset presses.

Common themes

In addition to overlapping print technologies, wider themes unite labels, flexible packaging and folding carton converters at Labelexpo.

Sustainability is a key one, driven by the EU’s looming PPWR initiative. Labelexpo Europe 2025 will examine these trends at a feature area on the show floor, with daily presentations and interactive exhibits.

Sustainability issues are pushing many brands to consider moving from plastics to technical paper and fiberboard-based packaging formats. However, a major issue is barrier protection, which usually means non-recyclable laminations with aluminum or PE. This is addressed by Labelexpo exhibitors such as Actega, which will show samples of its barrier coating technology.

Automation is another common theme. Labelexpo exhibitors already demonstrate process automation software and robotics systems, focusing on end-of-line material handling. The addition of folding cartons will no doubt expand this area of the show.

The future

What might persuade a folding carton converter to visit Labelexpo? One would suspect the same reasons flexible packaging converters now visit the show: a general interest in visiting co-suppliers, and a general interest in new print and decorative technologies.

“At Labelexpo Europe 2023, over 25 percent of visitors registered expressed an interest in folding carton technology. This demonstrates that Labelexpo has transformed into a package printing show, albeit with labels at its core”

Also, with the entry of private equity finance into the packaging sector, we are seeing more large converting groups that include labels, flexible packaging and folding carton operations.

Minnesota-based Meyers is a recent example of this. The family-owned converter has added to its folding carton capacity with the acquisition of Mankato Packaging.

Michael Dillon, chief revenue officer and co-owner of Meyers, says: ‘We’ve built a strong partnership with Mankato Packaging in recent months, and we’re excited to take this next step together. We’ve long respected their contributions to the packaging industry and see this as a great opportunity to expand the value we deliver—especially in the folding cartons space. It’s a meaningful move in our continued commitment to sustainable, high-quality packaging and long-term client partnerships.’

This is reflected in a growing visitor interest in both flexible packaging and folding cartons. At Labelexpo Europe 2023, over 25 percent of visitors registered expressed an interest in folding carton technology and 40 percent in flexible packaging. This demonstrates that Labelexpo has transformed into a package printing show, albeit with labels at its core.

Labelexpo Europe 2025 will be a ‘soft launch’ for folding cartons. By 2027, we expect folding cartons to be fully integrated into the show.

Folding Carton Master Class at Labelexpo
The Label Academy will host a half-day Master Class at Labelexpo Europe 2025 in Barcelona. The Master Class is targeted at label converters who are looking at diversifying into folding cartons using in-line flexo/rotary offset, digital or hybrid presses.

The class covers an introduction to the folding carton market, production challenges and possibilities with the in-line flexo, digital and hybrid presses; developments in materials including barrier coatings, converting technology for cutting and creasing and folder gluers. The Master Class finishes with a case study of a label converter making the transition to folding cartons on an in-line flexo press.