Eco Flexibles doubles production capacity with Fujifilm presses

Eco Flexibles has doubled its turnover in just 18 months following its investment in two Fujifilm Jet FP790 presses, as demand for sustainable flexible packaging has soared. Known for its strong focus on sustainable packaging across the food and wellness sectors, the introduction of two Jet FP790 presses has allowed the company to capitalize on market trends and grow the business rapidly.

The first Jet FP790 press was installed in June 2023, and the results were immediate. Following the success of the first machine, Eco Flexibles installed a second press later that year to meet the soaring demand.

Eco Flexibles has already been recognized for its growth, winning an industry award with The Grocer for Flexible Plastic Pack of the Year.

Eco Flexibles made headlines back in 2023 as the first customer outside of Japan to invest in the Jet FP790 press. Simon Buswell, director at Eco Flexibles, commented: 'That was a huge moment for us. We knew we were leaping into something that hadn’t been widely proven outside of Japan, but we had complete confidence in Fujifilm and the technology. We were willing to lead the way, and it’s paid off.'

Sustainability is at the heart of everything the company does. Buswell continued: 'We’ve always focused heavily on sustainability – whether it’s through using mono-materials, recyclable pouches, compostable alternatives, or solvent-free water-wash plates. Our business is built around environmentally conscious packaging. Before investing in the Jet Press FP790, we had already been working closely with Fujifilm through our use of the company’s Flenex FW water-wash flexo plates, and the move to digital was the next logical step in our sustainability journey.

'The FP790 fitted right into our business model - no solvents, minimal waste, low energy consumption and high print quality. It has allowed us to meet all of our environmental targets. We conducted extensive testing and trials, and it became clear that this press represented the future of flexible packaging.

'We initially expected to compete against other digital platforms, but we’ve been eating into the flexo market instead. The speed, quality, and commercial viability of the press means we’re now able to take on more work and handle smaller order volumes for our customers, which has been a game-changer.

'We invested in a second machine due to a mix of necessity and planning. We were using up most of the capacity of the first machine within months. The second gave us the ability to scale while also providing valuable contingency. We’ve doubled our turnover over the last 18 months, and the bulk of that growth is thanks to digital.'

The business currently operates a 50/50 mix of digital and flexo, but Buswell anticipates that digital will continue to grow as they convert more traditional work over to their newer systems.

Customer feedback has been overwhelmingly positive, even from clients who may not fully understand the technical advantages of the Jet Press FP790. 'Most of our clients aren’t aware that it’s digital - they just see the results. But once they know, it becomes a real selling point. The print is high-quality, and the consistency is spot on.'

Eco Flexibles is also now seeing increasing interest from outside their traditional food packaging markets, particularly in the growing wellness and supplements sector. 'We’ve picked up brand new work in new markets – such as health and wellness packaging – things like collagen powders and mushroom blends. It’s a growing market, and like food, it comes with strict regulatory and quality demands, which the Jet Press FP790 helps us meet effortlessly. We are also exploring the expansion into new substrates and applications.

'There’s a lot of opportunity to introduce more paper-based packaging into our portfolio. That’s a big focus in the future. We’re also planning to grow internationally, with North America a likely next step.'

Commenting on whether they would consider adding a third Jet Press FP790, Buswell remained open: 'Never say never. The demand is there, and we know Fujifilm offers the right technology to meet it.'

'Fujifilm has been fantastic. From the early conversations to installation and support, they’ve understood what we’re trying to do as a business. We’re not just looking for faster print - we want smarter, greener, more future-focused packaging. The Jet Press FP790 gives us that and more.'

Manuel Schrutt, global business strategy packaging director at Fujifilm, commented: 'We’re incredibly proud to see the growth that Eco Flexibles has seen since partnering with Fujifilm. As the first customer outside of Japan to invest in this technology, they’ve truly led from the front – proving not just what the press can do but what is possible for the future of sustainable, flexible packaging. Their success is a testament both to their vision and ambition, the to the capability of the Jet Press FP790.'